Doors - Front: Removal & Installation Dodge Pickup R2500

INSTALLATION

1. Support the door with a suitable lifting device and install the door onto the hinges.
2. Install the washers, if there were removed previously, nuts and tighten to 28 N.m (21 ft. lbs.).
3. Connect the electrical connectors.
4. Adjust the door as necessary. (Refer to «ADJUSTMENTS»(ref-189710-S15545620582005091100000) )

1. Position the glass into the window opening.
2. Engage the glass into the glass run weatherstrip.
3. Raise the glass within the door opening and connect the window regulator to the lift plate.
4. Install the nuts and tighten to 10 N.m (89 in. lbs.).
5. Install the inner belt molding. (Refer to «WEATHERSTRIP/SEALS»(ref-189719) )
6. Position the front run channel and install the screws. (Refer to «GLASS RUN CHANNEL - INSTALLATION»(ref-189710-S23947138742005091100000) )
7. Remove the window switch from the wire harness, if equipped.
8. Remove the window handle, if equipped.
9. Install the waterdam. (Refer to «WATERDAM - INSTALLATION»(ref-189710-S38170340292005091100000) )

REMOVAL

1. Remove the door glass. (Refer to «DOOR GLASS - REMOVAL»(ref-189710-S09628277612005091100000) )
2. Disconnect the lock switch electrical connector, if equipped. (Scheme 3)
3. Disconnect the actuator rods at the handle.
4. Remove the nuts and remove the handle.

Scheme 3

1. Install the exterior handle and install the nuts.
2. Connect the actuator rods at the handle
3. Connect the lock switch electrical connector, if equipped.
4. Install the door glass. (Refer to «DOOR GLASS - INSTALLATION»(ref-189710-S21518583942005091100000) )

1. Raise glass into the full up position.
2. Remove the waterdam. (Refer to «WATERDAM - REMOVAL»(ref-189710-S06960809142005091100000) )

1. Remove the door. (Refer to «DOOR - REMOVAL»(ref-189710-S25589466752005091100000) )
2. Using a grease pencil or equivalent, mark the hinge location and remove the bolts.

1. Install the hinges and bolts.
2. Tighten bolts to 28 N.m (21 ft. lbs.).
3. Install the door. (Refer to «DOOR - INSTALLATION»(ref-189710-S35304328042005091100000) )

Scheme 4

1. Remove the screw and remove the inside handle. (Scheme 4)
2. Remove the door trim panel. (Refer to «TRIM PANEL - REMOVAL»(ref-189710-S34086271272005091100000) )
3. Disconnect the latch actuator rod. (Scheme 5)
4. Remove the nuts and remove the remote handle actuator.

Scheme 5

1. Install the remote handle actuator and install the nuts.
2. Tighten the nuts to 10 N.m (89 in. lbs.).
3. Connect the latch actuator rod.
4. Install the door trim panel. (Refer to «TRIM PANEL - INSTALLATION»(ref-189710-S34006502962005091100000) )
5. Install the inside handle and install the bolt.
6. Tighten the bolt to 9 N.m (80 in. lbs.).

1. Raise the window to the full up position.
2. Remove the waterdam. (Refer to «WATERDAM - REMOVAL»(ref-189710-S06960809142005091100000) )
3. Disconnect the actuator rods.
4. Remove the bolts. (Scheme 6)
5. Disconnect the electrical connector and remove the latch.

1. Connect the electrical connector and install the latch assembly.
2. Install the bolts and tighten to 10 N.m (89 in. lbs.).
3. Connect the actuator rods.
4. Adjust the latch as needed. (Refer to «LATCH - ADJUSTMENT»(ref-189710-S31937064182005091100000) )
5. Install the waterdam. (Refer to «WATERDAM - INSTALLATION»(ref-189710-S38170340292005091100000) )

Scheme 6

Scheme 7

1. Locate access hole and remove the mylar tape covering it. (Scheme 7)
2. Insert a 5/32-inch hex-wrench through hole and into adjustment screw. Loosen screw.
3. Operate outside handle several times to release any restriction because of mis-alignment.
4. Tighten adjustment screw to 3 N.m (30 in. lbs.).
5. Test handle for proper operation.

1. Using a grease pencil or equivalent, mark the position of the striker.
2. Remove the bolts and remove the striker.

1. Install the striker and install the bolts.
2. Tighten the bolts to 28 N.m (21 ft. lbs.).
3. Adjust the striker if needed. (Refer to «ADJUSTMENT»(ref-189710-S33532403672005091100000) )

1. Remove the exterior handle. (Refer to «EXTERIOR HANDLE - REMOVAL»(ref-189710-S12027692532005091100000) )
2. Remove the clip and remove the lock cylinder lever and switch, if equipped.
3. Remove the screw and remove the lock cylinder. (Scheme 8)

Scheme 8

1. Install the lock cylinder and install the screw.
2. Install the lock cylinder switch, if equipped, lever and retaining clip.
3. Install the exterior handle. (Refer to «EXTERIOR HANDLE - INSTALLATION»(ref-189710-S23204984442005091100000) )

1. Remove the window crank, if equipped. (Scheme 10)
2. Remove the interior handle. (Refer to «INSIDE HANDLE ACTUATOR - REMOVAL»(ref-189710-S28725089852005091100000) )
3. Remove the screws at the mirror flag and near the inside handle. (Scheme 9) CAUTION: Trim panel is attached to the door using hooks molded into the panel. Do not pull the trim panel straight off or damage to the panel and/or power switch assembly may occur
4. Lift the trim panel up off the belt seal and attachment hooks and separate the panel from the door slightly.
5. Disconnect the power window switch electrical connector, if equipped, and remove the trim panel.

Scheme 9

Scheme 10

1. Install the window switch into the trim panel, if equipped.
2. Position the trim panel onto the lower hooks and connect the power window switch electrical connector, if equipped.
3. Position the remaining trim panel attachment hooks into the door panel and seat the trim panel into the belt seal fully.
4. Install the screws near the inside handle and at the mirror flag.
5. Install the interior handle. (Refer to «INSIDE HANDLE ACTUATOR - INSTALLATION»(ref-189710-S27509481302005091100000) )
6. Install the window crank, if equipped.

1. Remove the inside handle actuator. (Refer to «INSIDE HANDLE ACTUATOR - REMOVAL»(ref-189710-S28725089852005091100000) )
2. Remove the speaker. (Refer to «AUDIO»(ref-189658) )
3. Separate the waterdam from the inner door panel and off of the latch linkages.

1. Position the wire harness and actuator rods through the holes in the waterdam.
2. Secure the waterdam to the inner door panel.
3. Install the speaker. (Refer to «AUDIO»(ref-189658) )
4. Install the inside handle actuator. (Refer to «INSIDE HANDLE ACTUATOR - INSTALLATION»(ref-189710-S27509481302005091100000) )

1. Remove the waterdam. (Refer to «WATERDAM - REMOVAL»(ref-189710-S06960809142005091100000) )
2. Remove the window switch from the door trim panel and reconnect it to the door harness.
3. Raise the window to the position shown and remove the nuts. (Scheme 11)
4. Disengage the door glass from the regulator lift plate and position into the full up position.
5. Secure the glass in the up position using a wood wedge or equivalent.
6. Lower the regulator.
7. Remove the stabilizer nuts.
8. Remove the forward regulator bolt and loosen the other two. (Scheme 12)
9. Slide the regulator up and out of the keyhole slots in the door panel.
10. Disconnect the electrical connector and remove the regulator.

Scheme 11

Scheme 12

1. Install the regulator through the door panel opening and connect the electrical connector.
2. Position the regulator bolts into the keyhole slots and slide into place.
3. Install the forward bolt and tighten all three to 10 N.m (89 in. lbs.).
4. Position the stabilizer, install the nuts and tighten to 10 N.m (89 in. lbs.).
5. Raise the regulator to the position shown in (Scheme 11)
6. Remove the glass support and connect to the regulator lift plate.
7. Install the glass nuts and tighten to 10 N.m (89 in. lbs.).
8. Disconnect the window switch and install into the door trim panel.
9. Install the waterdam. (Refer to «WATERDAM - INSTALLATION»(ref-189710-S38170340292005091100000) )

1. Remove the waterdam. (Refer to «WATERDAM - REMOVAL»(ref-189710-S06960809142005091100000) )
2. Reinstall the window handle and raise the window to the position shown and remove the nuts. (Scheme 11)
3. Disengage the door glass from the regulator lift plate and position into the full up position.
4. Secure the glass in the up position using a wood wedge or equivalent.
5. Lower the regulator.
6. Remove the stabilizer nuts.
7. Remove the two lower and loosen the two upper bolts. (Scheme 13)
8. Slide the regulator up and out of the keyhole slot.
9. Remove the regulator from the door panel opening.

Scheme 13

1. Install the regulator through the hole in the inner door panel.
2. Position the regulator and slide the upper bolts into the keyhole slots.
3. Install the lower two bolts.
4. Tighten the regulator bolts to 10 N.m (89 in. lbs.).
5. Position the stabilizer, install the nuts and tighten to 10 N.m (89 in. lbs.).
6. Using the window handle raise the regulator to the position shown in (Scheme 11)
7. Remove the glass support and connect to the regulator lift plate.
8. Install the glass nuts and tighten to 10 N.m (89 in. lbs.).
9. Remove the window handle and install the waterdam.

1. Remove the door trim panel. (Refer to «TRIM PANEL - REMOVAL»(ref-189710-S34086271272005091100000) ) CAUTION: Do not use a drill to remove the heat stakes
2. Remove the heat stakes using a razor knife or equivalent.
3. Release the tabs and remove the mirror flag.

Note. Clean the excess heat staking off of the studs to aid installation.

1. Install the new mirror flag over the tabs and install the screws into the heat stake studs.
2. Install the door trim panel. (Refer to «TRIM PANEL - INSTALLATION»(ref-189710-S34006502962005091100000) )