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UNDER SEAT STORAGE BIN COVERING
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 81UNDER SEAT STORAGE BIN LATCH
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 81HEADREST
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 82HEADREST SLEEVE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
CENTER SEAT REMOVAL
NOTE: Do not reuse the seat replace with new ones.
fasteners, always
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 82
SEAT - FRONT
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 82SEAT BACK CUSHION / COVER - FRONT
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 83SEAT CUSHION / COVER - FRONT
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 83SEAT TRACK
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 83SEAT - REAR
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 84SEAT BACK - REAR
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 84SEAT BACK CUSHION / COVER - REAR
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 85SEAT CUSHION / COVER - REAR
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 85SEAT CUSHION FRAME - REAR
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 85SEAT BACK REAR - FOOTMANS LOOP
BRACKETS REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 85(4) Fold the seat backs forward and roll the seat
assembly back in the vehicle.
(5) Remove the nuts attaching the center seat to the drivers seat and the passenger seat and discard. (Fig. 3)
(6) Roll the seat assembly forward and remove the
center seat portion.
(1) Remove and discard the front bolts. (Fig. 1) (2) Position the seats forward, remove the rear
bolts and discard.
(3) Disconnect the 12v power supply electrical con-
nector, if equipped. (Fig. 2)
DR CENTER SEAT (Continued)
SEATS
23 - 77
Fig.1FRONTSEATASSEMBLY
Fig.3REARATTACHMENTS
1 - FRONT SEAT ASSEMBLY 2 - REAR BOLTS (4) 3 - ELECTRICAL CONNECTOR 4 - FRONT BOLTS (4)
1 - 12V POWER SUPPLY HARNESS 2 - CENTER SEAT STORAGE BIN 3 - FRONT SEAT TRACKS 4 - REAR NUTS (4)
INSTALLATION
NOTE: Do not reuse the seat replace with new ones.
fasteners, always
(1) Install the center seat and roll the seat assem-
bly back in the vehicle.
(2) Install new nuts attaching the center seat to
the drivers and passenger seat.
(3) Tighten the nuts to 25 N·m (18 ft. lbs.). (4) Roll the seat assembly forward and install new
rear bolts.
nector, if equipped.
(5) Connect the 12v power supply electrical con-
(6) Tighten the rear bolts to 40 N·m (30 ft. lbs.). (7) Fold the seat backs up and slide the seats to
(8) Install new front bolts and tighten to 28 N·m
the rear.
(21 ft. lbs.).
Fig.2CENTERSEATATTACHMENTS
1 - CENTER SEAT ASSEMBLY 2 - FRONT NUTS (2) 3 - POWER SUPPLY ELECTRICAL CONNECTOR 4 - REAR NUTS (4) 5 - 12V POWER SUPPLY HARNESS
CENTER ARMREST / SEAT BACK REMOVAL
NOTE: Do not reuse the seat replace with new ones.
fasteners, always
(1) Remove the center seat. (Refer to 23 - BODY/
SEATS/SEAT - CENTER - REMOVAL)
(2) Disconnect the storage bin cover j-straps and
position aside.
(3) Remove and discard the hinge bolts and sepa-
rate the seat back from the storage bin. (Fig. 4)
SEATS
23 - 78
CENTER ARMREST / SEAT BACK (Continued)DR
Fig.4CENTERSEATBACKHINGES
1 - STORAGE BIN COVERING 2 - SEAT BACK HINGE BOLTS (4) 3 - STORAGE BIN FRAME
INSTALLATION
NOTE: Do not reuse the seat replace with new ones.
fasteners, always
(1) Install the seat back onto the storage bin and
install new hinge bolts.
N·m (18 ft. lbs.).
(2) Tighten the hinge to storage bin bolts to 25
(3) Connect the storage bin cover j-straps. (4) Install the center seat. (Refer to 23 - BODY/
SEATS/SEAT - CENTER - INSTALLATION)
CENTER SEAT BACK INERTIA HINGE COVER REMOVAL
NOTE: Free pivot hinge cover is removed with the free pivot hinge. (Refer to 23 - BODY/SEATS/CEN- TER SEAT BACK HINGE - REMOVAL)
Fig.5HINGECOVER
1 - SEAT BACK COVER ZIP STRIP 2 - CENTER SEAT BACK 3 - HINGE COVER 4 - STORAGE BIN COVER 5 - PIVOT BOLT
INSTALLATION
NOTE: Free pivot hinge cover is installed with the free pivot hinge. (Refer to 23 - BODY/SEATS/CEN- TER SEAT BACK HINGE - INSTALLATION)
(1) Position the hinge cover over the hinge and
close over the lock tabs.
(2) Install the pivot bolt and tighten to 10 N·m (89
in. lbs.).
(3) Reposition the storage bin cover. (4) Connect the zip strip.
(1) For the inertia hinge cover disconnect the zip
strip. (Fig. 5)
(2) Position aside the storage bin cover. (3) Remove the pivot bolt. (4) Open the hinge cover at the bottom and remove
the hinge cover. (Fig. 6)
DR CENTER SEAT BACK INERTIA HINGE COVER (Continued)
SEATS
23 - 79
Fig.6HINGECOVERREMOVAL
Fig.7PIVOTHINGE/COVER
1 - PIVOT BOLT 2 - HINGE COVER 3 - STORAGE BIN COVER 4 - 12V POWER SUPPLY HARNESS 5 - HINGE BOLTS (2) 6 - HINGE
1 - HINGE COVER 2 - HINGE 3 - HINGE COVER TABS 4 - CENTER SEAT BACK 5 - STORAGE BIN
CENTER SEAT BACK HINGE REMOVAL
NOTE: Do not reuse the seat replace with new ones.
fasteners, always
(1) Remove the seat back. (Refer to 23 - BODY/ SEATS/CENTER ARMREST / SEAT BACK - REMOVAL)
Free Pivot Hinge/Cover
(1) Disconnect the storage bin cover j-strap and
position aside.
(2) Remove and discard the pivot bolt. (Fig. 7) (3) Remove the hinge spacer. (Fig. 8) (4) Open the hinge cover flap and remove the wire
harness. (Fig. 9)
(5) Remove the cover from the hinge.
Inertia Hinge
(1) Remove the seat back inertia hinge cover. (Refer to 23 - BODY/SEATS/CENTER SEAT BACK INERTIA HINGE COVER - REMOVAL)
(2) Remove and discard the inertia hinge bolts and
remove the hinge. (Fig. 10)
Fig.8PIVOTHINGESPACER
1 - HINGE COVER 2 - SPACER 3 - STOP PIN
SEATS
23 - 80
CENTER SEAT BACK HINGE (Continued)DR
Free Pivot Hinge/Cover
(1) Position the pivot hinge cover over the pivot hinge and install the 12v power supply harness into the channel.
(2) Close the hinge cover flat and position the
spacer into place.
(3) Align the stop pin with the spacer and hinge
and install the assembly onto the seat back.
(4) Install a new pivot bolt and tighten to 25 N·m
(18 ft. lbs.)
Inertia Hinge
(1) Install the inertia hinge onto the center seat
back and install new bolts.
(2) Tighten the bolts to 25 N·m (18 ft. lbs.). (3) Install
the seat back inertia hinge covers. (Refer to 23 - BODY/SEATS/CENTER SEAT BACK INERTIA HINGE COVER - INSTALLATION)
(1) Install the center seat back.
(Refer to 23 - BODY/SEATS/CENTER ARMREST / SEAT BACK - INSTALLATION)
Fig.9PIVOTHINGECOVER
1 - HINGE COVER FLAP 2 - STOP PIN 3 - HINGE COVER 4 - HINGE 5 - 12V POWER SUPPLY HARNESS
CENTER SEAT BACK LID REMOVAL
(1) Open the center armrest/seat back. (2) Remove the four screws attaching the hinge to
the storage bin and remove the lid.
INSTALLATION
(1) Position the center seat back lid onto the stor-
age bin and install the screws.
CENTER SEAT CUSHION REMOVAL
NOTE: Do not reuse the seat replace with new ones.
fasteners, always
Fig.10INERTIAHINGEBOLTS
1 - SEAT BACK BOLTS 2 - CENTER SEAT BACK 3 - INERTIA HINGE
INSTALLATION
NOTE: Do not reuse the seat replace with new ones.
fasteners, always
(1) Open the center seat cushion storage bin. (2) Position the seat cushion cover aside, remove
the hinge bolts and discard. (Fig. 11)
(3) Remove the seat cushion.
INSTALLATION
NOTE: Do not reuse the seat replace with new ones.
fasteners, always
(1) Position the center seat cushion the hinges and
install new bolts.
(2) Tighten the bolts to 20 N·m (15 ft. lbs.). (3) Position the cushion cover back over
the
hinges.
DR CENTER SEAT CUSHION (Continued)
SEATS
23 - 81
UNDER SEAT STORAGE BIN REMOVAL
(1) Remove the center seat cushion. (Refer to 23 -
CUSHION
SEAT
BODY/SEATS/CENTER REMOVAL)
(2) Remove the six screws and remove the bin.
INSTALLATION
(1) Install the bin over the seat cushion hinges and
install the six screws.
(2) Install the center seat cushion. (Refer to 23 - BODY/SEATS/CENTER SEAT CUSHION - INSTAL- LATION)
Fig.11CENTERSEATCUSHIONHINGE
1 - CENTER SEAT CUSHION 2 - HINGE BOLTS 3 - SEAT CUSHION HINGE 4 - STORAGE BIN
CENTER SEAT CUSHION COVER REMOVAL
(1) Remove the center seat cushion. (Refer to 23 -
CUSHION
SEAT
BODY/SEATS/CENTER REMOVAL)
(2) Disconnect the zip strips and remove the cover
from the cushion.
INSTALLATION
(1) Install the cover over the center seat cushion
and connect the zip strips.
(2) Install the center seat. (Refer to 23 - BODY/
SEATS/CENTER SEAT - INSTALLATION)
UNDER SEAT STORAGE BIN COVERING REMOVAL
(1) Remove the under seat storage bin. (Refer to 23 - BODY/SEATS/UNDER SEAT STORAGE BIN - REMOVAL)
(2) Disconnect the j-straps and remove the cover.
INSTALLATION
(1) Install the storage bin cover and connect the
j-straps.
(2) Install the under seat storage bin. (Refer to 23
- BODY/SEATS/UNDER SEAT STORAGE BIN - INSTALLATION)UNDER SEAT STORAGE BIN LATCH REMOVAL
(1) Open the under seat storage bin. (2) Remove the two screws and remove the latch
assembly.
INSTALLATION
(1) Install
screws.
the latch assembly and install
the
23 - 82
SEATS
HEADREST REMOVAL
(1) Raise the headrest. (2) Press the headrest release button and remove
the headrest.
INSTALLATION
(1) Position the headrest. (2) Press the release button and install the head-
rest.
HEADREST SLEEVE REMOVAL
(1) Remove the headrest. (Refer to 23 - BODY/
SEATS/HEADREST - REMOVAL)
(2) Grasp the sleeves and pull up and out of the
seat back to remove.
INSTALLATION
(1) Position each headrest sleeve into correct seat
back hole and press into place fully.
(2) Install the headrest.
(Refer to 23 - BODY/
SEATS/HEADREST - INSTALLATION)
SEAT - FRONT REMOVAL
NOTE: Do not reuse the seat replace with new ones.
fasteners, always
(1) Remove and discard the front bolts. (Fig. 12) (2) Position the seats forward, remove the rear
bolts and discard.
(3) Disconnect the 12v power supply electrical con-
nector, if equipped. (Fig. 13)
(4) Fold the seat backs forward and roll the seat
assembly back in the vehicle.
(5) Separate the seat assembly by removing and discarding the three nuts on either the drivers or passengers seat. (Fig. 14)
(6) Remove each section of the seat assembly from
the vehicle.
INSTALLATION
NOTE: Do not reuse the seat replace with new ones.
fasteners, always
(1) Position each seat section into the vehicle and
tip back.
DR
Fig.12FRONTSEATASSEMBLY
1 - FRONT SEAT ASSEMBLY 2 - REAR BOLTS (4) 3 - ELECTRICAL CONNECTOR 4 - FRONT BOLTS (4)
Fig.13CENTERSEATATTACHMENTS
1 - CENTER SEAT ASSEMBLY 2 - FRONT NUTS (2) 3 - POWER SUPPLY ELECTRICAL CONNECTOR 4 - REAR NUTS (4) 5 - 12V POWER SUPPLY HARNESS
(2) Install the three nuts attaching the center seat section to the other seat, and tighten to 25 N·m (18
ft. lbs.).(3) Roll the seat assembly forward and install new
(4) Connect the 12v power supply electrical con-
rear bolts.
nector.
DR SEAT - FRONT (Continued)
SEATS
23 - 83
SEAT CUSHION / COVER - FRONT REMOVAL
(1) Remove the front seat. (Refer to 23 - BODY/
SEATS/SEAT - FRONT - REMOVAL)
(2) Remove the screw and remove the recliner han-
dle.
(3) Remove the two screws and remove the power seat controls, if equipped, and disconnect the electri- cal connector.
(4) Remove the seat track. (Refer to 23 - BODY/
SEATS/SEAT TRACK - REMOVAL)
(5) Disconnect the j-straps and remove the seat
cushion and cover.
INSTALLATION
(1) Position the seat cushion and cover onto the
frame assembly and connect the j-straps.
(2) Install the seat track. (Refer to 23 - BODY/
SEATS/SEAT TRACK - INSTALLATION)
(3) Connect the power seat control switch electrical
connector, if equipped.
(4) Install
the power seat control switch and
install the two screws, if equipped.
(5) Install
the recliner handle and install
the
screw.
(6) Install the front seat. (Refer to 23 - BODY/
SEATS/SEAT - FRONT - INSTALLATION)
SEAT TRACK REMOVAL
(1) Remove the front seat. (Refer to 23 - BODY/
SEATS/SEAT - FRONT - REMOVAL)
(2) Disconnect the power lumbar and/or the heated
seat electrical connectors, if equipped.
(3) Remove the four nuts attaching the seat track
to the seat and remove the track.
INSTALLATION
(1) Position the seat track onto the seat and install
the four nuts.
(2) Tighten the four nuts to 25 N·m (18 ft. lbs.). (3) Connect the power lumbar and/or heated seat
electrical connectors, if equipped.
(4) Install the seat. (Refer to 23 - BODY/SEATS/
SEAT - FRONT - INSTALLATION)
Fig.14REARATTACHMENTS
1 - 12V POWER SUPPLY HARNESS 2 - CENTER SEAT STORAGE BIN 3 - FRONT SEAT TRACKS 4 - REAR NUTS (4)
(5) Tighten the rear bolts to 40 N·m (30 ft. lbs.). (6) Fold the seat backs up and slide the seats to
(7) Install new front bolts and tighten to 28 N·m
the rear.
(21 ft. lbs.).
SEAT BACK CUSHION / COVER - FRONT REMOVAL
(1) Remove the front seat. (Refer to 23 - BODY/
SEATS/SEAT - FRONT - REMOVAL)
(2) Remove the headrest sleeves. (Refer to 23 -
BODY/SEATS/HEADREST SLEEVE - REMOVAL)
(3) Unzip the zip strip at the lower end of the seat
back and remove the seat back cover and cushion.
INSTALLATION
(1) Install the seat back cushion and cover onto
the seat frame assembly.
(2) Connect the zip strip at the bottom of the seat
back.
(3) Install the headrest sleeves.
BODY/SEATS/HEADREST SLEEVE - TION)
(Refer to 23 - INSTALLA-
(4) Install the seat. (Refer to 23 - BODY/SEATS/
SEAT - FRONT - INSTALLATION)
23 - 84
SEATS
SEAT - REAR REMOVAL
DR
(1) Remove the load floor. (Refer to 23 - BODY/IN-
TERIOR/LOAD FLOOR - REMOVAL)
(2) Fold the rear seat cushions up and remove the
rear bolts. (Fig. 15)
(3) Lift each seat assembly up and disengage the seat back frame hooks from the footmans loops bolted to the rear cab back. (Fig. 16)
(4) Remove the seats from the vehicle.
Fig.16SEATBACKATTACHMENT
1 - OUTER SEAT BACK FRAME HOOKS (2) 2 - OUTER FOOTMANS LOOP (2) 3 - INNER SEAT BACK FRAME HOOKS (2) 4 - INNER FOOTMANS LOOP (2) 5 - SEAT BACK
Fig.15SEATATTACHMENT
1 - OUTER BOLTS (2) 2 - REAR SEAT ASSEMBLY 3 - INNER BOLTS (4) 4 - REAR SEAT BACK 5 - OUTER BOLTS (2)
INSTALLATION
(1) Install the seats into the vehicle and engage the seat back frame hooks with the footmans loops in the cab back panel.
(2) Install the rear seat bolts and tighten to 40
N·m (30 ft. lbs.).
(3) Install the load floor. (Refer to 23 - BODY/IN-
TERIOR/LOAD FLOOR - INSTALLATION)
SEAT BACK - REAR REMOVAL
(1) Remove the rear seat. (Refer to 23 - BODY/
SEATS/SEAT - REAR - REMOVAL)
(2) Remove the seat back bolts and remove the
seat back. (Fig. 17)
Fig.17REARSEATHINGE
1 - SEAT BACK BOLT (2) 2 - SEAT CUSHION 3 - SEAT BACK/CUSHION HINGE 4 - SEAT BACK
INSTALLATION
(1) Install the seat back and install the bolts. (2) Tighten the bolts to 25 N·m (18 ft. lbs.). (3) Install the rear seat. (Refer to 23 - BODY/
SEATS/SEAT - REAR - INSTALLATION)
DR
SEATS
23 - 85
SEAT BACK CUSHION / COVER - REAR REMOVAL
(1) Remove the rear seat back.
(Refer to 23 -
BODY/SEATS/SEAT BACK - REAR - REMOVAL)
(2) Unzip the zip strip at the bottom of the seat
back and remove the cover and cushion.
INSTALLATION
(1) Install the seat back cushion and cover and
connect the zip strip.
(2) Install the seat back. (Refer to 23 - BODY/
SEATS/SEAT BACK - REAR - INSTALLATION)
SEAT CUSHION / COVER - REAR REMOVAL
(1) Remove the rear seat. (Refer to 23 - BODY/
SEATS/SEAT - REAR - REMOVAL)
(2) Remove the screws and remove the grocery bag
hooks, if equipped.
(3) Separate the zip strip at the rear of the seat
cushion and remove the cushion and cover.
INSTALLATION
(1) Install the seat cushion and cover over the
cushion frame assembly and connect the zip strip.
(2) Install the grocery bag hooks and screws, if
equipped.
(3) Install the seat. (Refer to 23 - BODY/SEATS/
SEAT - REAR - INSTALLATION)
SEAT CUSHION FRAME - REAR REMOVAL
(1) Remove the seat cushion/cover. (Refer to 23 - BODY/SEATS/SEAT CUSHION / COVER - REAR - REMOVAL)
(2) Remove the bolts and remove the seat cushion
frame. (Fig. 18)
INSTALLATION
(1) Install the seat cushion frame onto the rear
seat hinges.
lbs.).
(2) Install the bolts and tighten to 32 N·m (24 ft.
(3) Install the seat cushion/cover. (Refer to 23 - BODY/SEATS/SEAT CUSHION / COVER - REAR - INSTALLATION)
Fig.18SEATCUSHIONFRAMEATTACHMENT
1 - REAR SEAT BACK 2 - REAR SEAT CUSHION FRAME 3 - SEAT CUSHION FRAME BOLTS (4) 4 - SEAT CUSHION HINGE
SEAT BACK REAR - FOOTMANS LOOP BRACKETS REMOVAL
(1) Remove the rear seat. (Refer to 23 - BODY/
SEATS/SEAT - REAR - REMOVAL)
(2) Remove bolts and remove the loop. (Fig. 19)
Fig.19FOOTMANSLOOPBRACKET
1 - FOOTMANS LOOP (4) 2 - BOLTS (2 PER LOOP) 3 - CAB BACK PANEL
INSTALLATION
(1) Install the loop and install the bolts. (2) Tighten the bolts to 12 N·m (9 ft. lbs.). (3) Install the seat. (Refer to 23 - BODY/SEATS/
SEAT - REAR - INSTALLATION)
23 - 86
STATIONARY GLASS
STATIONARY GLASS
TABLE OF CONTENTS
page
DR
page
BACKLITE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 86BACKLITE VENT GLASS
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 87WINDSHIELD
WARNING
WINDSHIELD SAFETY PRECAUTIONS . . . . . 88
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 88BACKLITE REMOVAL
It is difficult to salvage the backlite during the removal operation. The backlite is part of the struc- tural support for the roof. The urethane bonding used to secure the glass to the fence is difficult to cut or clean from any surface. Since the molding is set in urethane, it is unlikely it would be salvaged. Before removing the backlite, check the availability from the parts supplier.
The backlite 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 ure- thane adhesive to the backlite.
(1) Roll down door glass. (2) Remove headliner. (Refer to 23 - BODY/INTE-
RIOR/HEADLINER - REMOVAL).
(3) On standard cab models remove the upper b-pillar trim. (Refer to 23 - BODY/INTERIOR/B-PIL- LAR UPPER TRIM - REMOVAL)
(4) On quad cab models remove the upper c-pillar (Refer to 23 - BODY/INTERIOR/C-PILLAR
trim. UPPER TRIM - REMOVAL)
(5) Bend backlite retaining tabs (Fig. 1) inward
against glass.
(6) Disconnect the rear window defogger electrical
connector, if equipped.
(7) Using a suitable pneumatic knife from inside the vehicle, cut urethane holding backlite frame to opening fence.
(8) Separate glass from vehicle.
Fig.1BackliteTabs
1 - BACKLITE 2 - TAB
(3) If black-out primer was pre-applied on backlite, clean bonding surface with Isopropyl alcohol and clean lint free cloth. Allow 3 minutes for drying time. (4) Apply black-out primer to backlite opening
fence.
(5) Apply a 13 mm (0.5 in.) bead of urethane around the perimeter of the window frame bonding surface (Fig. 2).
(6) Set glass on lower fence and move glass for-
ward into opening (Fig. 3).
(7) Firmly push glass against rear window glass
opening fence.
fence to retain glass.
(8) Bend tabs around edges of backlite opening
(9) Clean excess urethane from exterior with
MOPARt, Super Clean or equivalent.
INSTALLATION
opening fence.
(1) Clean urethane adhesive from around backlite
(10) Allow urethane to cure at least 24 hours (full
(2) If necessary, apply black-out primer to outer
(11) Water test to verify repair before returning
edge of replacement backlite frame.
cure is 72 hours).
vehicle to service.
(12) Connect the rear window defogger electrical
connector, if equipped.
DR BACKLITE (Continued)
(13) On standard cab models,
install the upper b-pillar trim. (Refer to 23 - BODY/INTERIOR/B-PIL- LAR UPPER TRIM - INSTALLATION)
(14) On quad cab models, install the upper c-pillar (Refer to 23 - BODY/INTERIOR/C-PILLAR
trim. UPPER TRIM - INSTALLATION)
(15) Install the headliner. (Refer to 23 - BODY/IN-
TERIOR/HEADLINER - INSTALLATION).
STATIONARY GLASS
23 - 87
BACKLITE VENT GLASS REMOVAL
(1) Slide the upper run channel out of the window
frame. (Fig. 4)
lower window frame.
and remove.
(2) Slide the vent glass upward to remove from the
(3) Lower the glass out of the upper window frame
Fig.2UrethaneAdhesiveApplication
1 - WINDOW FRAME 2 - GLASS 3 - RETAINER TAB 4 - URETHANE ADHESIVE
Fig.4UPPERGLASSRUNCHANNEL
1 - GLASS RUN CHANNEL 2 - VENT GLASS FRAME 3 - VENT GLASS
INSTALLATION
(1) Slide the vent glass upper edge into window frame and insert the lower edge into the lower mold- ing.
(2) Position the upper run channel into the win-
dow frame and slide it into place. (3) Verify vent glass operation.
Fig.3BackliteInstallation
1 - BACKLITE
23 - 88
STATIONARY GLASS
DR
WINDSHIELD
WARNING
WINDSHIELD SAFETY PRECAUTIONS
WARNING: DO NOT OPERATE THE VEHICLE WITHIN 24 HOURS OF WINDSHIELD INSTALLATION. IT TAKES AT LEAST 24 HOURS FOR URETHANE ADHESIVE TO CURE. IF IT IS NOT CURED, THE WINDSHIELD MAY NOT PERFORM PROPERLY IN AN ACCIDENT. † URETHANE ADHESIVES ARE APPLIED AS A SYSTEM. USE GLASS CLEANER, GLASS PREP SOLVENT, GLASS PRIMER, PVC (VINYL) PRIMER AND PINCH WELD (FENCE) PRIMER PROVIDED BY THE ADHESIVE MANUFACTURER. IF NOT, STRUC- TURAL INTEGRITY COULD BE COMPROMISED. † DAIMLERCHRYSLER DOES NOT RECOMMEND GLASS ADHESIVE BY BRAND. TECHNICIANS SHOULD REVIEW PRODUCT LABELS AND TECHNI- CAL DATA SHEETS, AND USE ONLY ADHESIVES THAT THEIR MANUFACTURES WARRANT WILL RESTORE A VEHICLE TO THE REQUIREMENTS OF FMVSS 212. TECHNICIANS SHOULD ALSO INSURE THAT PRIMERS AND CLEANERS ARE COMPATIBLE WITH THE PARTICULAR ADHESIVE USED. † BE SURE TO REFER TO THE URETHANE MAN- UFACTURER’S DIRECTIONS FOR CURING TIME SPECIFICATIONS, AND DO NOT USE ADHESIVE AFTER ITS EXPIRATION DATE. † VAPORS THAT ARE EMITTED FROM THE URE- THANE ADHESIVE OR PRIMER COULD CAUSE PERSONAL INJURY. USE THEM IN A WELL-VENTI- LATED AREA. † SKIN CONTACT WITH URETHANE ADHESIVE SHOULD BE AVOIDED. PERSONAL INJURY MAY RESULT. † ALWAYS WEAR EYE AND HAND PROTECTION WHEN WORKING WITH GLASS.
CAUTION: Protect all painted and trimmed surfaces from coming in contact with urethane or primers. Be careful not to damage painted surfaces when removing moldings or cutting urethane around windshield.
REMOVAL
(1) Remove inside rear view mirror. (Refer to 23 - BODY/INTERIOR/REAR VIEW MIRROR - REMOV- AL).
(2) Remove cowl grill. (Refer to 23 - BODY/EXTE-
RIOR/COWL GRILLE - REMOVAL).
(3) Remove the a-pillar weatherstrip retainer. (Refer to 23 - BODY/WEATHERSTRIP/SEALS/A- PILLAR WEATHERSTRIP RETAINER - REMOVAL) (4) Remove the a-pillar trim panels. (Refer to 23 -
BODY/INTERIOR/A-PILLAR TRIM - REMOVAL)
(5) Remove the headliner and from the inside of the vehicle, cut the upper urethane bonding from around windshield upper edge using a suitable sharp cold knife (C-4849). A pneumatic cutting device can be used but is not recommended. (Refer to 23 - BODY/INTERIOR/HEADLINER - REMOVAL)
(6) From the outside of the vehicle, cut urethane bonding from the remaining sides of the windshield using a suitable sharp cold knife (C-4849). A pneu- matic cutting device can be used but is not recom- mended.
(7) Separate windshield from vehicle.
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, should remain on the fence. Do not grind off or com- pletely 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. 5).
(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. 6).
(3) Clean inside of windshield with MOPAR Glass
Cleaner and lint-free cloth.
DR WINDSHIELD (Continued)
STATIONARY GLASS
23 - 89
(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 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.
(6) Locate new support spacers on support brack-
ets and adjust to lowest height. (Fig. 5)
(7) Position seven new foam spacers on the inside surface of the windshield, flush with the lower and side edges. (Fig. 7)
(8) Position three new foam spacers on the inside surface of the windshield, at a minimum distance of 3 mm (0.12 in.) from the top edge of the windshield. (Fig. 7)
(9) Apply a 13 mm (1/2 in.) high and 10 mm (3/8
in.) wide bead of urethane around the perimeter of windshield. At the top, apply the bead 7 mm (1/4 in.) inboard from the glass edge. On the other three sides apply the bead 14 mm (0.55 in.) inboard from the glass edge. The urethane bead should be shaped in a triangular cross-section, this can be achieved by notching the tip of the applicator (Fig. 8).(10) Install the a-pillar trim. (Refer to 23 - BODY/
INTERIOR/A-PILLAR TRIM - INSTALLATION)
(11) 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.
(12) Slowly lower windshield glass to the fence opening guiding the lower corners into proper posi- tion. 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. 9).
(13) Push windshield upward, setting the wind- shield to roof gap to 1.5 mm (0.06 in.) to 3 mm (0.12
in.) and ratchet up the adjustable support brackets. (14) Using clean water, lightly mist the supportspacers.
(15) Clean excess urethane from exterior with
MOPARt Super Clean or equivalent.
(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/ INSTALLA-
INTERIOR/REAR VIEW MIRROR - TION).
(19) Install
the a-pillar weatherstrip retainer. (Refer to 23 - BODY/WEATHERSTRIP/SEALS/A- PILLAR WEATHERSTRIP RETAINER - INSTALLA- TION)
(20) After urethane has cured, remove tape strips
and water test windshield to verify repair.
Fig.5CENTERWINDSHIELDANDMARKAT
SUPPORT
1 - WINDSHIELD 2 - INDEX MARKS 3 - SUPPORT SPACERS
Fig.6WORKSURFACESETUP
1 - WINDSHIELD AND MOLDINGS 2 - URETHANE BEAD AROUND GLASS 7mm (0.3 in.) FROM EDGE 3 - BLOCKS
23 - 90
STATIONARY GLASS WINDSHIELD (Continued)DR
Fig.7WINDSHIELDFOAMSUPPORTSPACERS
Fig.9LOWERWINDSHIELDINTOPOSITION
1 - UPPER FOAM SPACERS (3) 2 - SPACER LOCATION 75 MM (2.95 IN) 3 - LOWER FOAM SPACERS (3) 4 - SIDE FOAM SPACERS (4)
1 - COMPRESSION SPACER 2 - WINDSHIELD 3 - ADJUSTABLE SUPPORT SPACERS
Fig.8APPLICATORTIP
1 - APPLICATOR TIP
DR
WEATHERSTRIP/SEALS
23 - 91
WEATHERSTRIP/SEALS
TABLE OF CONTENTS
page
page
A-PILLAR WEATHERSTRIP RETAINER
FRONT DOOR OUTER BELT MOLDING
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 91REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 93DRIP RAIL WEATHERSTRIP
FRONT DOOR INNER BELT MOLDING
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 91REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 93DOOR OPENING SEAL
REAR DOOR GLASS RUN WEATHERSTRIP
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 92REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 93DRIP RAIL WEATHERSTRIP RETAINER
REAR DOOR OUTER BELT MOLDING
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 92REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 94FRONT DOOR GLASS RUN WEATHERSTRIP
REAR DOOR INNER BELT MOLDING
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 92REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 94A-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.1DOOROPENINGWEATHERSTRIPS/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
23 - 92 WEATHERSTRIP/SEALS
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 - TRIM -
LOWER
BODY/INTERIOR/B-PILLAR 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 - INSTALLA-
BODY/INTERIOR/C-PILLAR TRIM - TION)
DR
(3) Install the lower b-pillar trim. (Refer to 23 - TRIM -
LOWER
BODY/INTERIOR/B-PILLAR 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
the seven screws.
(1) Install the weatherstrip retainer and install
(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)
DR FRONT DOOR GLASS RUN WEATHERSTRIP (Continued)
WEATHERSTRIP/SEALS
23 - 93
Fig.3INNERBELTMOLDING
1 - BELT MOLDING 2 - CORNER SEAL 3 - FRONT DOOR
INSTALLATION
Fig.2FRONTDOORGLASSSEALS
1 - OUTER BELT MOLDING 2 - FRONT DOOR GLASS RUN WEATHERSTRIP 3 - LOWER DOOR SEAL 4 - SCREW 5 - FRONT DOOR
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 door flange
and seat fully.
(2) Install the screw.
FRONT DOOR INNER BELT MOLDING REMOVAL
(1) Remove the door trim panel. (Refer to 23 - BODY/DOOR - FRONT/TRIM PANEL - REMOVAL) (2) Separate the belt molding from the mounting
flange from the back to the front. (Fig. 3)
(1) Position the belt molding and seat onto the
mounting flange fully.
(2) Install the door trim panel.
(Refer to 23 - BODY/DOOR - FRONT/TRIM PANEL - INSTALLA- TION)
REAR DOOR GLASS RUN WEATHERSTRIP REMOVAL
(1) Lower the glass. (2) Separate the weatherstrip out of
the door frame and remove through the window opening. (Fig. 4)
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.
23 - 94 WEATHERSTRIP/SEALS REAR DOOR GLASS RUN WEATHERSTRIP (Continued)
DR
REAR DOOR INNER BELT MOLDING REMOVAL
(1) Remove the door trim panel. (Refer to 23 - BODY/DOORS - REAR/TRIM PANEL - REMOVAL)
(2) Separate the belt molding from the mounting
flange from the back to the front. (Fig. 5)
Fig.4REARDOORGLASSSEALS
1 - OUTER BELT MOLDING 2 - REAR DOOR 3 - SCREW 4 - LOWER DOOR SEAL 5 - GLASS RUN WEATHERSTRIP
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 door flange
and seat fully.
(2) Install the screw.
Fig.5REARDOORINNERSEALS
1 - REAR SECONDARY SEAL 2 - INNER BELT MOLDING 3 - FRONT SECONDARY SEAL 4 - SCREWS
INSTALLATION
(1) Position the belt molding and seat onto the
mounting flange fully.
(2) Install the door trim panel.
(Refer to 23 - BODY/DOORS - REAR/TRIM PANEL - INSTALLA- TION)
DR
BODY STRUCTURE
23 - 95
BODY STRUCTURE
TABLE OF CONTENTS
page
page
GAP AND FLUSH
STRUCTURAL ADHESIVE LOCATIONS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . 95
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . 113
WELD LOCATIONS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . 122
OPENING DIMENSIONS
SPECIFICATIONS - BODY OPENING
DIMENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . 99
SEALER LOCATIONS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . 103
GAP AND FLUSH SPECIFICATIONS
GAP & FLUSH DIMENSIONS INDEX
DESCRIPTION STANDARD CAB
QUAD CAB PICKUP BOX
FIGURE
BODY STRUCTURE
23 - 96
GAP AND FLUSH (Continued)DR
Fig.1GAP&FLUSH-STANDARDCAB
NOTE:
All measurements are in mm.
DESCRIPTION Bumper to grille Hood to grille
Fender to hood
Fender to hood
(Up/Down surface only) Front door to windshield
Roof to front door
Quarter to front door
Front door to quarter character
line alignment
Front door to fender character
line alignment
Front door to fender
Bumper to fender
Bumper to headlamp
GAP
19.0 ± 3.0
1.5 ± 1.0Parallel within 2.0
6.0 ± 2.0
Parallel within 1.0
6.0 ± 1.5
Parallel within 1.0
—
—
5.0 ± 1.5
Parallel within 1.0
—
—
5.0 ± 1.5
Parallel within 1.0
19.0 ± 3.0
Parallel within 3.0
19.0 ± 4.0
FLUSH
—
U/F 0.75 ± 1.75
U/F 3.2 ± 1.5
(Underflush from front of hood to start of hockey stick area only)
0.0 ± 1.5
O/F 20.5 ± 1.5
(Base of windshield)
O/F 9.0 ± 1.5
(Top of windshield)
U/F 6.0 ± 1.5
Parallel within 1.5
0.0 ± 1.5
Up/Down 0.0 ± 1.5
Up/Down 0.0 ± 1.5
0.0 ± 1.5
O/F 5.0 ± 5.0 (SLT)
O/F 14.0 ± 5.0 (SPORT)
—
O/F = Over Flush U/F = Under Flush
DIMENSION
*1
*2*3
*4
*5
*6
*9
*10
*11
*12
* ALL MODELS
DR GAP AND FLUSH (Continued)
BODY STRUCTURE
23 - 97
Fig.2GAP&FLUSH-QUADCAB
NOTE:
All measurements are in mm.
O/F = Over Flush
U/F = Under Flush
DIMENSION
DESCRIPTION Roof to rear door
Quarter to rear door
Rear door to quarter character line
alignment
Rear door to front door character line
alignment
Rear door to front door
GAP —
5.0 ± 1.5
Parallel within 2.0
—
—
5.0 ± 1.5
Parallel within 2.0
FLUSH
U/F 6.0 ± 1.5
Parallel within 1.5
0.0 ± 1.5
Up/Down 0.0 ± 1.5
Up/Down 0.0 ± 1.5
0.0 ± 1.5
BODY STRUCTURE
23 - 98
GAP AND FLUSH (Continued)DR
Fig.3GAP&FLUSH-PICKUPBOX
NOTE:
All measurements are in mm.
O/F = Over Flush
U/F = Under Flush
DIMENSION
DESCRIPTION
Tailgate to outer box
(Up/Down surface only) Cab Back to box front
Fuel door to outer box
Cab to box side
GAP —
31.0 ± 5.0
Parallel within 3.0
5.0 ± 1.5
Parallel within 1.0
31.0 ± 5.0
Parallel within 3.0
FLUSH 0.0 ± 1.5
Parallel within 1.0
—
0.0 ± 1.5
4.0 ± 2.5 (Standard Cab) O/F 5.0 ± 2.5 (Quad Cab)
Up/Down 0.0 ± 3.0
U/F 1.5 ± 1.5
—
Cab to box character line alignment
—
Tailgate to outer box
Bumper to outer box
5.0 ± 2.0
Parallel within 1.0
24.75 ± 5.0 (F/A) 23.75 ± 5.0 (C/C) Parallel within 5.0Tailgate to outer box character line
—
Up/Down 0.0 ± 1.5
adjustment
Bumper to tailgate
30.25 ± 3.0
Parallel within 4.0
—
DR
BODY STRUCTURE
23 - 99
OPENING DIMENSIONS SPECIFICATIONS - BODY OPENING DIMENSIONS
INDEX
DESCRIPTION
FIGURE
WINDSHIELD OPENING
DOOR OPENING - STANDARD
CAB
DOOR OPENINGS - QUAD CAB
REAR WINDOW OPENING
ENGINE COMPARTMENT/FRONT
STRUCTURE
Fig.4WINDSHIELDOPENING
23 - 100
OPENING DIMENSIONS (Continued)BODY STRUCTURE
DR
Fig.5DOOROPENING-STANDARDCAB
Fig.6DOOROPENINGS-QUADCAB
DR OPENING DIMENSIONS (Continued)
BODY STRUCTURE
23 - 101
Fig.7REARWINDOWOPENING
23 - 102
OPENING DIMENSIONS (Continued)BODY STRUCTURE
DR
Fig.8ENGINECOMPARTMENT/FRONTSTRUCTURE
DR
BODY STRUCTURE
23 - 103
SEALER LOCATIONS SPECIFICATIONS
INDEX
DESCRIPTION
FIGURE
LOWER WINDSHIELD PILLAR, LOWER PLENUM AND COWL BAR
DASH PANEL, LOWER PLENUM AND COWL SIDE PANEL
LOWER DASH PANEL, LOWER COWL SIDE AND FLOOR PAN SUPPORT
ROOF PANEL, OUTER BODY SIDE APERTURE AND BACKLITE
CAB BACK, BODY SIDE APERTURE - REAR AND BACKLITE LOWER CORNER
LOWER DASH PANEL AND FLOOR PAN FLOOR PAN AND BODY SIDE APERTURE
FRONT FLOOR PAN AND REAR PAN
FLOOR PAN TO CAB BACK
PICKUP BOX
10
11
12
13
14
15
16
17
18Fig.9LOWERWINDSHIELDPILLAR
23 - 104
SEALER LOCATIONS (Continued)BODY STRUCTURE
DR
Fig.10DASHPANEL
DR SEALER LOCATIONS (Continued)
BODY STRUCTURE
23 - 105
Fig.11LOWERDASHPANEL
23 - 106
SEALER LOCATIONS (Continued)BODY STRUCTURE
DR
Fig.12ROOFPANEL
DR SEALER LOCATIONS (Continued)
BODY STRUCTURE
23 - 107
Fig.13CABBACKPANEL
23 - 108
SEALER LOCATIONS (Continued)BODY STRUCTURE
DR
Fig.14LOWERDASHPANEL
DR SEALER LOCATIONS (Continued)
BODY STRUCTURE
23 - 109
Fig.15FLOORPAN
23 - 110
SEALER LOCATIONS (Continued)BODY STRUCTURE
DR
Fig.16FRONTFLOORPAN
DR SEALER LOCATIONS (Continued)
BODY STRUCTURE
23 - 111
Fig.17FLOORPAN
23 - 112
SEALER LOCATIONS (Continued)BODY STRUCTURE
DR
Fig.18PICKUPBOX
DR
BODY STRUCTURE
23 - 113
STRUCTURAL ADHESIVE LOCATIONS SPECIFICATIONS
INDEX
DESCRIPTION
FIGURE
FLOOR PAN AND SEAT MOUNTING FRONT CROSSMEMBER
FRONT FENDER
FLOOR PAN
INNER WHEELHOUSE TO INNER BOX SIDE PANEL
INNER BOX SIDE PANEL TO OUTER BOX SIDE PANEL
INNER WHEELHOUSE, CROSSMEMBERS AND CROSSMEMBER END SUPPORT
BRACKET TO INNER BOX SIDE PANEL
INNER BOX SIDE PANEL TO OUTER BOX SIDE PANEL
INNER DOOR PANEL TO OUTER DOOR PANEL - FRONT DOOR (QUAD CAB)
INNER DOOR PANEL TO OUTER DOOR PANEL - FRONT DOOR (STANDARD CAB)
INNER DOOR PANEL TO OUTER DOOR PANEL - REAR DOOR (QUAD CAB)
SILL RAIL - STD CAB SILL RAIL - QUAD CAB
19
20
21
22
23
2425
26
27
28
29
30Fig.19FLOORPAN
