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Frames & Bumpers: Other Dodge Cab & Chassis R3500 HD

Frames, Subframes & Crossmembers 34 illustrations ~2498 words

FRONT AIR DAM

  1. Remove the two outboard screws.
  2. Remove the three middle screws and remove the air dam.
  1. Position the air dam onto the bumper and seat the carrot type fasteners fully.
  2. Starting at the center screw install the three middle screws.
  3. Install the two outboard screws.

Scheme 11

Scheme 11: FRONT BUMPER
Scheme 11: FRONT BUMPER
  1. If necessary, remove the charge air cooler, refer to «REMOVAL»(ref-303808-S33831638072008103100000) .
  2. Using a grease pencil or equivalent, mark the position of the bumper support bracket (5) on the frame rail tip (7) to aid installation.
  3. Disconnect the fog lamp electrical connector at the left frame rail.
  4. Support the bumper with a suitable lifting device.
  5. Remove the bumper support bracket (5) nuts and bolts (8 and 9) and remove bumper.

FRONT BUMPER

  1. Install the bumper onto the frame rails (7) and position the wheelhouse splash shield into the support brackets (4).
  2. Install the bolts and nuts (8 and 9).
  3. Line up the bumper with the marks made previously and tighten the bolts and nuts to 95 N.m (70 ft. lbs.).
  4. Check and adjust the bumper alignment as necessary. Refer to «SPECIFICATIONS»(ref-303774-S05050900492008103100000) .
  5. If necessary, install the charge air cooler, refer to «INSTALLATION»(ref-303808-S33760780322008103100000) .

Scheme 12

Scheme 12: ST/SLT/SLT+
Scheme 12: ST/SLT/SLT+
  1. Remove the two screws (4) at each trailing edge of the fascia.
  2. Remove the four push pin fasteners (5) from the upper edge of the close out panel.
  3. Using a trim stick (special tool #C-4755) or equivalent, carefully release the six lower clips and remove the close out panel.
  4. Using a trim stick or equivalent, carefully remove the step pad (1).
  5. Remove and discard the four push pin fasteners (5) and remove the fascia.

Scheme 13

Scheme 13: SPORT
Scheme 13: SPORT

Scheme 14

Scheme 14
Scheme 14
  1. Raise and support the vehicle. Refer to «STANDARD PROCEDURE»(ref-303775-S36253149762008103100000) .
  2. Remove the three screws (3) at each trailing edge of the fascia.
  3. Remove the five lower screws (8).
  4. Remove and discard the four upper push pins (7).
  5. Using a trim stick (special tool #C-4755) or equivalent, carefully release the six lower clips and remove the close out panel.
  6. Using a trim stick or equivalent, carefully remove the step pad (1).
  7. Spread the fascia (2) out at the wheels and remove from the vehicle.

ST/SLT/SLT+

Note. The left and right inboard bumper to bracket attachments must be secured before installing the fascia and step pad.

  1. Install the fascia.
  2. Position the close out panel and seat the 6 lower clips fully.
  3. Install four new upper push pin fasteners (5).
  4. Position the step pad (1) onto the fascia (2) and fully seat the attachment clips.
  5. Align the fascia to the fender with a 19 mm (0.75 inch) gap and install the two screws at each trailing edge of the fascia.

SPORT

Note. The left and right inboard bumper to bracket attachments must be secured before installing the fascia and step pad.

  1. Position the fascia (2) onto the bumper.
  2. Position the step pad (1) onto the fascia (2) and fully seat the attachment clips.
  3. Install four new upper push pin fasteners (7).
  4. Install the five lower screws (8).
  5. Install the three screws (3) at each trailing edge of the fascia.

Scheme 15

Scheme 15
Scheme 15
  1. Raise and support the vehicle. Refer to «STANDARD PROCEDURE»(ref-303775-S36253149762008103100000) .
  2. Remove the license plate.
  3. Remove the bolts behind the plate.
  4. Disconnect the license plate light electrical connectors.
  5. Disconnect the trailer light connector electrical connection (if equipped).
  6. Remove the two bolts along the front upper edge of the bumper near the frame tips.
  7. Support the bumper with a suitable lifting device.
  8. Remove the bolts attaching the bumper support brackets (4) to the trailer hitch (1).

REAR BUMPER

  1. Align the holes in the bumpers to the trailer hitch pins and install the bumper.
  2. Loosely install the hitch bolts (2) in the support bracket (4).
  3. Install the front upper edge to the trailer hitch bolts (2) and tighten to 54 N.m (40 ft. lbs.).
  4. Install the license plate reinforcement to hitch bolts (2) and tighten to 54 N.m (40 ft. lbs.).
  5. Tighten the left bumper bracket bolts (3) to 54 N.m (40 ft. lbs.).
  6. Tighten the right bumper bracket bolts (3) to 54 N.m (40 ft. lbs.).
  7. Connect the trailer light connector electrical connection (if equipped).
  8. Connect the license plate light electrical connectors.
  9. Install the license plate.

WARNING - FRAME REPAIR

Use eye protection when grinding or welding metal. Failure to do this could result in serious personal injury or death.

Before proceeding with frame repair involving grinding or welding, verify that the vehicle fuel system is not leaking or in contact with the repair area. Failure to do this could result in serious personal injury or death.

Do not allow an open flame or heat and metal spatter from arc welding to contact plastic body panels. Fire, explosion can result causing serious personal injury or death.

When welded frame components are replaced, ensure that a complete penetration weld is achieved during installation. If not, dangerous operating conditions can result.

Stand clear of cables or chains on pulling equipment during frame straightening operations. Failure to do this can result in serious personal injury or death.

Do not venture under a hoisted vehicle that is not supported on safety stands. Walking under an unsupported vehicle can result in serious personal injury or death.

1500 series Dodge Ram Trucks (2002 and later) are not designed for snow plow equipment. The front collision repair tips must not be installed on any truck equipped with a snow plow, or even intended to be equipped with a snow plow.

Do not reuse damaged fasteners. The quality of repair would be suspect. Failure to use only production fasteners or fasteners of equivalent hardness can result in loosening or failure of the part. Do not drill any holes in the frame that are not specifically outlined in this, or in other DaimlerChrysler procedures as frame rail failure can result causing serious personal injury or death. When using heat to straighten frame components, do not exceed 566°C (1050°F). If temperature is exceeded, metal fatigue can happen and result in serious personal injury or death.

WARNING - USE OF HEAT DURING REPAIR

WARNINGChrysler Group engineering's position on the use of heat during collision repair is as follows: Any body panel or frame component damaged which is to be repaired and reused, must be repaired using the "cold straightening" method. No heat may be used during the straightening process. During rough straightening prior to panel replacement, damaged panels or frame components may be heated to assist in body/frame realignment. The application of heat must be constrained to the parts which will be replaced and not allowed to affect any other components. This "no heat" recommendation is due to the extensive use of high strength and advanced high strength steels in Chrysler Group products. High-strength materials can be substantially and negatively affected from heat input which will not be obviously known to the repairer or consumer. Ignoring these recommendations may lead to serious compromises in the ability to protect occupants in a future collision event, reduce the engineered qualities and attributes, or decrease the durability and reliability of the vehicle. Failure to follow these instructions may result in serious or fatal injury. This statement supersedes any previously released information by the Chrysler Group.

Scheme 16

Scheme 16: HYDROFORM FENDER RAIL REPAIR
Scheme 16: HYDROFORM FENDER RAIL REPAIR
CAUTIONThis repair procedure assumes damage to the right or left hydroform fender rail (1). Prior to any repairs, the vehicle must be mounted on the appropriate frame repair equipment ("frame rack"), checked with three dimensional measuring equipment, and necessary pull corrections made. If damage exists in the hydroform fender rail, or cab beyond the area covered by this service procedure after dimensional corrections are made, the hydroform must be replaced in its entirety. Refer to SPECIFICATIONS .
CAUTIONInspect the tire winch assembly for damage. If any one or more of the following are evident, replace the winch assembly. Indications of cracked or bulging plastic. Housing flanges are bent or cracked. If winch was loose before repair. If the rivet heads are separated from the housing in any way.

Scheme 17

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Scheme 17

Scheme 18

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Scheme 18

Scheme 19

Scheme 19
Scheme 19

Scheme 20

Scheme 20
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Scheme 21

Scheme 21
Scheme 21

Scheme 22

Scheme 22
Scheme 22

Scheme 23

Scheme 23
Scheme 23
  1. Before proceeding with this repair procedure review the required service warnings and precautions. See «WARNING»(ref-303885-S27407660032008103100000) .
  2. Disconnect and isolate the battery negative cable.
  3. Remove the front wheelhouse splash shield. Refer to «REMOVAL»(ref-303774-S09297323782008103100000) .
  4. Remove the fender. Refer to «REMOVAL»(ref-303774-S08576092582008103100000) .
  5. Remove the A/C condenser, if required. Refer to «REMOVAL»(ref-303776-S24423809302008103100000) .
  6. Remove the A/C lines, if required. Refer to «HEATING & AIR CONDITIONING - SERVICE INFORMATION»(ref-303776) for recommended procedures.
  7. Remove the radiator assembly (4). Refer to «REMOVAL»(ref-303804-S19187681662008103100000) . 1 - AIR CLEANER HOUSING ASSEMBLY 2 - LOCATING PINS (4)
  8. Remove the air cleaner and support bracket (1 - if required). Refer to «REMOVAL»(ref-303789-S36688760202008103100000) for 3.7L, «REMOVAL»(ref-303790-S35123859352008103100000) for 4.7L, «REMOVAL»(ref-303791-S30944562112008103100000) for 5.7L, «REMOVAL»(ref-303792-S30126614112008103100000) for 5.9L, or «REMOVAL»(ref-303793-S29872466332008103100000) for 6.7L.
  9. Remove the integrated power module. Refer to «REMOVAL»(ref-303814-S37418555882008103100000) .
  10. Remove the bolts and position aside the wire harness and grounds, if required.
  11. Remove the upper radiator crossmember (4). Refer to «REMOVAL»(ref-303774-S21106616262008103100000) .
  12. Remove the front lamp unit (5). Refer to «REMOVAL»(ref-303795-S10710512572008103100000) .
  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 not use any flame or plasma cutting equipment to cut the frame in this procedure. The inaccurate and high temperatures achieved during flame or plasma cutting will change the metal characteristics and may weaken the frame and/or repair location.
  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 the rail 25 mm (1.0 in.) from the butt joint of the tube. On the lower rail, cut two 13 mm (0.5 in.) holes on the inner and outer sides of the rail 25 mm (1.0 in.) 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 with a weld. See «SPECIFICATIONS»(ref-303885-S26237721962008103100000) .
  22. Insert the service part into place and using the appropriate measuring equipment, 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. 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. Apply a durable top coat to the outside of the repair area.
  27. Install the front cab mount bolt (2) if previously removed and tighten to 81 N.m (60 ft. lbs.).
  28. Install the lower radiator crossmember (6) bolts (5) and tighten to 28 N.m (21 ft. lbs.).
  29. Install the front lamp unit, refer to «INSTALLATION»(ref-303795-S15714733822008103100000) .
  30. Install the upper radiator crossmember (4). Refer to «INSTALLATION»(ref-303774-S21210958442008103100000) .
  31. Install the wire harness and ground if previously removed and install the bolts.
  32. Install the integrated power module, if previously removed. Refer to «INSTALLATION»(ref-303814-S21353612102008103100000) . 1 - AIR CLEANER HOUSING ASSEMBLY 2 - LOCATING PINS (4)
  33. Install the air cleaner bracket and air cleaner (1), if previously removed. Refer to «INSTALLATION»(ref-303789-S29971672092008103100000) for 3.7L, «INSTALLATION»(ref-303790-S33008755512008103100000) for 4.7L, «INSTALLATION»(ref-303791-S39516497992008103100000) for 5.7L, «INSTALLATION»(ref-303792-S06626918342008103100000) for 5.9L, or «INSTALLATION»(ref-303793-S18370901502008103100000) for 6.7L.
  34. Install the radiator assembly (4). Refer to «INSTALLATION»(ref-303804-S16749352232008103100000) .
  35. Install the A/C lines, if previously removed. Refer to «HEATING & AIR CONDITIONING - SERVICE INFORMATION»(ref-303776) for the recommended procedures.
  36. Install the A/C condenser, if previously removed. Refer to «INSTALLATION»(ref-303776-S21511157632008103100000) .
  37. Install the fender. Refer to «INSTALLATION»(ref-303774-S27894086022008103100000) .
  38. Install the front wheelhouse splash shield. Refer to «INSTALLATION»(ref-303774-S26376404672008103100000) .
  39. Reconnect the battery negative cable.

VEHICLE PREPARATION

Position the vehicle on a level work surface. Using screw or bottle jacks, adjust the vehicle PLP heights to the specified dimension above a level work surface. Vertical dimensions can be taken from the work surface to the locations indicated were applicable.

DESCRIPTIONFIGURE
1500 STANDARD CAB - 2 WHEEL DRIVE(Scheme 24).
1500 STANDARD CAB - 4 WHEEL DRIVE(Scheme 25).
1500 QUAD CAB - 2 WHEEL DRIVE(Scheme 26).
1500 QUAD CAB - 4 WHEEL DRIVE(Scheme 27).
140.5 IN WHEELBASE - HEAVY DUTY - 2 WHEEL DRIVE(Scheme 28).
140.5 IN WHEELBASE - HEAVY DUTY - 4 WHEEL DRIVE(Scheme 29).
160.5 IN WHEELBASE - 2500 - 2 WHEEL DRIVE(Scheme 30).
160.5 IN WHEELBASE - 2500 - 4 WHEEL DRIVE(Scheme 31).
160.5 IN WHEELBASE - 3500 - 2 WHEEL DRIVE(Scheme 32).
160.5 IN WHEELBASE - 3500 - 2 WHEEL DRIVE(Scheme 33).
FRONT FRAME (COMMON) - 4500/5500(Scheme 34).
144.5" WHEELBASE - 4500/5500(Scheme 35).
164.5" WHEELBASE - 4500/5500(Scheme 36).
168.5" WHEELBASE - 4500/5500(Scheme 37).
192.5" WHEELBASE - 4500/5500(Scheme 38).
204.5" WHEELBASE - 4500/5500(Scheme 39).

INDEX

Scheme 24

Scheme 24
Scheme 24

Scheme 25

Scheme 25
Scheme 25

Scheme 26

Scheme 26
Scheme 26

Scheme 27

Scheme 27
Scheme 27

Scheme 28

Scheme 28
Scheme 28

Scheme 29

Scheme 29
Scheme 29

Scheme 30

Scheme 30
Scheme 30

Scheme 31

Scheme 31
Scheme 31

Scheme 32

Scheme 32
Scheme 32

Scheme 33

Scheme 33
Scheme 33

Scheme 34

Scheme 34
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Scheme 35

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Scheme 39

Scheme 39
Scheme 39

FRONT CROSSMEMBER

  1. Install the crossmember (1).
  2. Install the bolts (2); On light duty 2WD vehicles, tighten the bolts to 61 N.m (45 ft. lbs.). On heavy duty 2WD vehicles, tighten the bolts to 75 N.m (55 ft. lbs.).
  3. On 4WD models, install the crossmember (2).
  4. Install the bolts (1) and tighten to 102 N.m (75 ft. lbs.).
  5. Install the front skid plate, if equipped (2). See «INSTALLATION»(ref-303885-S10639704502008103100000) .

FRONT SKID PLATE

  1. Raise and support the vehicle. Refer to «STANDARD PROCEDURE»(ref-303775-S36253149762008103100000) .
  2. Remove the bolts (3).
  3. Slide skid plate (2) back off of the crossmember (1) and remove.
  1. Snap the rear tabs over the front crossmember (1) and install the skid plate (2).
  2. Install the bolts (3) and tighten to 34 N.m (25 ft. lbs.).

Scheme 40

Scheme 40
Scheme 40

Scheme 41

Scheme 41
Scheme 41
  1. Remove front bumper. See «REMOVAL»(ref-303885-S00822757802008103100000) .
  2. Remove the bolts (2) and remove the tow hook assembly (3).
  3. If the vehicle is a Heavy Duty , then remove the bolts (1) and remove the tow hook (2).

TRANSMISSION CROSSMEMBER

  1. On Light Duty Vehicles , install the crossmember (2) and the bolts (4). Tighten the bolts to 102 N.m (75 ft. lbs.).
  2. Install the transmission mount nuts and tighten to 54 N.m (40 ft. lbs.).
  3. On Heavy Duty Vehicles , install the crossmember (4) and the bolts (3). Tighten the bolts to 115 N.m (85 ft. lbs.).
  4. Install the transmission mount nuts and tighten to 54 N.m (40 ft. lbs.).
  5. Remove the transmission support (2).
  6. Install the transfer case skid plate (3 - if equipped). See «INSTALLATION»(ref-303885-S40188835332008103100000) .

Scheme 42

Scheme 42: TRAILER HITCH
Scheme 42: TRAILER HITCH

Scheme 43

Scheme 43
Scheme 43

Scheme 44

Scheme 44
Scheme 44
  1. Remove the rear bumper. See «REMOVAL»(ref-303885-S20638265272008103100000) .
  2. On Light Duty Vehicles , remove the hitch bolts (7)
  3. On Heavy Duty Vehicles , remove the hitch bolts (8)
  4. Disconnect all wire harness support push pins.
  5. Remove the rear two cargo box bolts (3) and loosen the remaining bolts. Refer to «REMOVAL»(ref-303774-S14242521352008103100000) .
  6. Using a suitable lifting device, lift and support the rear of the cargo box and remove the hitch.

TRAILER HITCH

  1. On Light Duty Vehicles , install the hitch (5) onto the frame rails and make sure the locators (1 and 2) on the inside of the hitch brackets are engaged with the holes in the top of the frame rails properly.
  2. Install the hitch bolts (7) and tighten to 170 N.m (125 ft. lbs.).
  3. Connect all wire harness support push pins.
  4. On Heavy Duty Vehicles , install the hitch (5) onto the frame rails and make sure the locators (1 and 2) on the inside of the hitch brackets are engaged with the holes in the top of the frame rails properly.
  5. Install the hitch bolts (8) and tighten to 170 N.m (125 ft. lbs.).
  6. Connect all wire harness support push pins.
  7. Lower the cargo box and install the rear bolts (3). Refer to «INSTALLATION»(ref-303774-S20939916162008103100000) .
  8. Install the rear bumper. See «INSTALLATION»(ref-303885-S35771044872008103100000) .

TRANSFER CASE SKID PLATE

  1. Raise and support the vehicle. Refer to «STANDARD PROCEDURE»(ref-303775-S36253149762008103100000) .
  2. Support the skid plate (3) and remove the bolts (4).
  3. Remove the skid plate (3).
  4. Support the skid plate crossmember (2) and remove the bolts (1).
  5. Remove the skid plate crossmember (2).
  1. Install the skid plate crossmember (2) and bolts (1).
  2. Tighten the bolts (1) to 34 N.m (25 ft. lbs.).
  3. Install the skid plate (3) and bolts (4).
  4. Tighten the bolts (4) to 34 N.m (25 ft. lbs.).

More articles — Frames & Bumpers