Exterior: Removal & Installation Dodge Pickup R2500

REMOVAL

Note. Body side moldings are attached to the body panels with adhesive tape.

1. Apply a length of masking tape on the body panel, parallel to the top edge of the molding and to one end to use as a guide for installation, if necessary.
2. If temperature is below 21°C (70°F) warm molding with a heat lamp or gun. Do not exceed 52°C (120°F) when heating molding.
3. Using a trim stick C-4755 or equivalent, remove and discard the molding from the outside of the body panel.

INSTALLATION

1. Thoroughly clean all residue from the body side molding attachment area of the body panel.
2. Wipe area with a clean lint free cloth moistened with a 50% solution of water and alcohol and wipe dry immediately with a dry lint free cloth.
3. Apply new body side molding using the guide tape on the body panel and apply consistent and uniform pressure of approximately 40 p.s.i. over the entire surface of the molding.

Scheme 4

1. Loosen all cab to frame mounting bolts (six standard cab, eight quad cab). (Scheme 4)
2. Remove the mounting bolts and rebound cushions
3. Using a floor jack and block of wood under the cab sill, lift the body to gain access to the isolators.
4. Remove the isolators.
5. Install new isolators and repeat steps 1 through 4, for the opposite side.

1. For the rear isolators install the rebound cushions, washers, reinforcement plates and bolts. (Scheme 4)
2. Install the remaining rebound cushions and bolts.
3. Tighten the bolts to 81 N.m (60 ft. lbs.).

Scheme 5

Scheme 6

1. Disconnect the fuel fill hose and vent hose. (Refer to «FUEL TANK»(ref-158737-S27744512662003101600000) )
2. Disconnect the tail lamp wire harness.
3. Remove the cargo box bolts. (Scheme 5) or (Scheme 6)
4. Remove the cargo box.

1. Install the cargo box and install the bolts.
2. Tighten the bolts to 108 N.m (80 ft. lbs.).
3. Connect the fuel fill and vent hoses. (Refer to «FUEL TANK»(ref-158737-S27744512662003101600000) )
4. Connect the tail lamp wire harness.

1. Remove the bolts and remove the tie down cleat. (Scheme 7)

1. Install the tie down cleat and install the bolts.
2. Tighten the bolts to 34 N.m (25 ft. lbs.).

1. Remove the wiper arms. (Refer to «WIPER ARM»(ref-189677-S02519511372005091200000) )
2. Disconnect the washer hose.
3. Remove the hood seal.
4. Remove the six push pin fasteners from the front of the grille. (Scheme 8)
5. Remove the two rear corner screws and remove the grilles.

1. Install the grill and install the two rear corner screws.
2. Install the six push pin fasteners along the front of the grille.
3. Install the hood seal.
4. Connect the washer hose.
5. Install the wiper arms. (Refer to «WIPER ARM»(ref-189677-S02519511372005091200000) )

Note. Exterior name plates are attached to body panels with adhesive tape.

1. Apply a length of masking tape on the body, parallel to the top edge and one end of the name plate to use as a guide for installation, if necessary.
2. If temperature is below 21°C (70°F) warm emblem with a heat lamp or gun. Do not exceed 52°C (120°F) when heating name plate.
3. Using a trim stick C-4755 or equivalent, remove and discard the name plate.

1. Thoroughly clean all residue from the name plate attachment area of the body panel.
2. Wipe area with a clean lint free cloth moistened with a 50% solution of water and alcohol and wipe dry immediately with a dry lint free cloth.
3. Remove protective cover from adhesive tape on back of name plate.
4. Position name plate properly on the body panel.
5. Apply consistent and uniform pressure over the entire surface of the name plate, with palm of hand.
6. If temperature is below 21°C (70°F) warm emblem with a heat lamp or gun to assure adhesion. Do not exceed 52°C (120°F) when heating name plate.

Scheme 7

1. Remove the antenna, if equipped. (Refer to «ANTENNA BODY & CABLE»(ref-189658-S05361455832005091200000) )
2. Remove the battery tray, if required.
3. Remove the cowl grille. (Refer to «COWL GRILLE - REMOVAL»(ref-189712-S22873599922005091100000) )
4. Remove the headlamp unit. (Refer to «HEADLAMP»(ref-189664-S27881971662005091200000) )
5. Remove the wheelhouse splash shield. (Refer to «FRONT WHEELHOUSE SPLASH SHIELD - REMOVAL»(ref-189712-S10251240732005091100000) )
6. Remove the inside and lower bolts. (Scheme 9)
7. Remove the two bolts below the headlamp.
8. Remove the hinge support bolt at the cowl.
9. Remove the three bolts along the fender rail.

1. Install the three bolts along the upper fender rail and tighten to 9 N.m (80 in. lbs.).
2. Install the upper hinge support bolt at the cowl and tighten to 17 N.m (13 ft. lbs.).
3. Install the two bolts below the headlamp and tighten to 9 N.m (80 in. lbs.).
4. Install the inside and lower bolts and tighten to 17 N.m (13 ft. lbs.).
5. Check the fender positioning and adjust as required by adding shims. (Refer to «GAP AND FLUSH»(/dodge/pickup-r2500/1996-2010/remont/exterior-body-panels/#body-structure) )
6. Install the wheelhouse splash shield. (Refer to «FRONT WHEELHOUSE SPLASH SHIELD - INSTALLATION»(ref-189712-S19795639172005091100000) )
7. Install the headlamp unit. (Refer to «HEADLAMP»(ref-189664-S27881971662005091200000) )
8. Install the cowl grille. (Refer to «COWL GRILLE - INSTALLATION»(ref-189712-S26000127272005091100000) )
9. Install the battery tray, if required.
10. Install the antenna, if required. (Refer to «ANTENNA BODY & CABLE»(ref-189658-S05361455832005091200000) )

Scheme 8

1. Open fill door and remove the bolts. (Scheme 10)
2. Remove the door.

1. Install the fuel fill door.
2. Install the bolts and tighten to 9 N.m (80 in. lbs.).

Scheme 9

1. Open the hood.
2. Remove the six lower screws. (Scheme 11)
3. Remove the six upper nuts and separate the grille from the grille frame.

1. Position the grille onto the grille frame.
2. Install the six upper nuts.
3. Install the six lower screws.

1. Remove the grille. (Refer to «GRILLE - REMOVAL»(ref-189712-S06907610562005091100000) )
2. Remove the screws and remove the grille frame. (Scheme 12)

1. Install the grille frame and install the six screws.
2. Install the grille. (Refer to «GRILLE - INSTALLATION»(ref-189712-S07277816692005091100000) )

Scheme 10

1. Remove the three screws at the fender. (Scheme 13)
2. Remove the electrical connector push pin fastener.
3. Remove the five inside screws and remove the splash shield.

1. Install the splash shield and position the front edge into the support bracket on the bumper.
2. Install the five inner screws.
3. Install the three screws at the fender.
4. Install the electrical connector push pin fastener.

Scheme 11

1. Remove the screws and remove the shield. (Scheme 14)

1. Install the splash shield and install the screws.

1. Remove the door trim panel. (Refer to «TRIM PANEL»(ref-189710-S35319048732005091100000) )
2. Disconnect the electrical connector and remove the nuts. (Scheme 15)
3. Squeeze the electrical connector tabs and remove the mirror. (Scheme 16)

1. Install the mirror onto the door and engage the electrical connector tabs. (Scheme 16)
2. Install the nuts and tighten to 7 N.m (60 in. lbs.).
3. Install the door trim panel. (Refer to «TRIM PANEL»(ref-189710-S35319048732005091100000) )

Scheme 12

Scheme 13

1. Remove the hood latch. (Refer to «LATCH»(/dodge/pickup-r2500/1996-2010/remont/exterior-body-panels/#hood) )
2. Remove the radiator and condenser bolts. (Scheme 17)
3. Remove the bolts and remove the crossmember. (Scheme 18)

1. Install the crossmember and install the bolts.
2. Tighten the bolts to 28 N.m (21 ft. lbs.).
3. Install the radiator and condenser bolts and tighten to 8 N.m (75 in. lbs.).
4. Install the hood latch. (Refer to «LATCH»(/dodge/pickup-r2500/1996-2010/remont/exterior-body-panels/#hood) )

Scheme 14

Scheme 15

Scheme 16

1. Position the mirror glass so that it's facing in toward the vehicle as far as possible. (Scheme 19)
2. Disengage the rear housing cover retaining tabs and remove the cover. (Scheme 20)
3. Disengage the lower glass retaining tab to motor. see scheme 18
4. Slide glass up and remove from motor.
5. Disconnect the two heated mirror electrical connectors, if equipped.

Scheme 17

Scheme 18

1. Position the mirror in the out position. see scheme 19
2. Release the retaining clip and separate the glass.
3. Disconnect the four heated glass electrical connectors, if equipped. see scheme 20

Scheme 19

Scheme 20

1. Connect the two heated mirror electrical connectors, if equipped. see scheme 21
2. Position the mirror glass mounting holes over the four feet of the mirror motor and slide down. see scheme 22
3. Engage the lower glass retaining tab to the motor. see scheme 18
4. Position the rear housing cover and seat the retaining tabs fully. (Scheme 20)

1. Remove the wheel house splash shield. (Refer to «REAR WHEELHOUSE SPLASH SHIELD - REMOVAL»(ref-189712-S27884193372005091100000) )
2. Disconnect the marker lamps electrical connectors.
3. Remove the tail lamp units. (Refer to «TAIL LAMP UNIT»(ref-189664-S24854071442005091200000) )
4. Remove the two fender nuts. see scheme 23
5. Remove the rear inner nuts below the tail lamp. see scheme 24
6. Remove the two bolts at the rear bottom edge.
7. Remove the two bolts at the front bottom edge.
8. Remove the four inner nuts front edge. see scheme 25
9. Loosen bolts and loosen the two fender support brackets. see scheme 26 CAUTION: Mask off the surrounding box area to avoid damage to the painted surfaces.
10. Lift the fender up off the support brackets and remove the fender.

1. Carefully position the fender over the support brackets.
2. Install the four inner nuts along the front edge of the fender and tighten to 7 N.m (60 in. lbs.).
3. Install the two inner nuts along the rear edge of the fender below the tail lamp unit and tighten to 7 N.m (60 in. lbs.).
4. Tighten the six support bracket bolts and tighten to 11 N.m (8 ft. lbs.).
5. Install the bolts along lower edge of the fender and tighten to 7 N.m (60 in. lbs.).
6. Connect the marker lamps electrical connectors.
7. Install the wheelhouse splash shield. (Refer to «REAR WHEELHOUSE SPLASH SHIELD - INSTALLATION»(ref-189712-S24695628272005091100000) )
8. Install the two nuts from within the tail lamp opening and tighten to 7 N.m (60 in. lbs.).
9. Install the tail lamp unit. (Refer to «TAIL LAMP UNIT»(ref-189664-S24854071442005091200000) )

See also:
• GAP AND FLUSH
• LATCH