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Frame and Bumpers: Other RAM Cab & Chassis 3500 HD

Frames, Subframes & Crossmembers 7 illustrations ~1137 words

SPORT BUMPER

  1. Position the bumper (3) onto the frame tip brackets (1) and install the nuts (2).
  2. Check and adjust the bumper alignment as necessary. Refer to «GAP AND FLUSH, SPECIFICATIONS»(ref-476497-S31212473422012060400000) .
  3. Tighten the nuts (2) to 95 N.m (70 ft. lbs.).

NON SPORT BUMPER

  1. Position the bumper (3) onto the frame tip brackets (1) and install the nuts (2).
  2. Check and adjust the bumper alignment as necessary. Refer to «GAP AND FLUSH, SPECIFICATIONS»(ref-476497-S31212473422012060400000) .
  3. Tighten the nuts (2) to 95 N.m (70 ft. lbs.).

Scheme 20

Scheme 20
Scheme 20
  1. Install the bumper brackets (2) and install the bolts (3) and nuts (1). Do not tighten the nuts at this time.
  2. If equipped, install the tow hooks (3) and install the bolts (2) and nuts (1).
  3. Tighten the nuts to 275 N.m (203 ft. lbs.).
  4. Position the bumper onto the frame tip brackets and install the eight nuts (2).
  5. Connect the electrical connectors (1), if equipped.
  6. Tighten the eight bumper nuts using the sequence shown in illustration, to 95 N.m (70 ft. lbs.).
  7. Check and adjust the bumper alignment as necessary. Refer to «GAP AND FLUSH, SPECIFICATIONS»(ref-476497-S31212473422012060400000) .
  8. Tighten the nuts (1) to 95 N.m (70 ft. lbs.).
  9. Install the charge air cooler, if necessary. Refer to «COOLER AND HOSES, CHARGE AIR, INSTALLATION, 6.7L»(ref-476519-S25874048602012060400000) .
  10. Install the grille. Refer to «GRILLE, INSTALLATION»(ref-476497-S16177228722012060400000) .

Scheme 21

Scheme 21: REMOVAL
Scheme 21: REMOVAL

Scheme 22

Scheme 22
Scheme 22
  1. Disconnect the electrical connectors (2).
  2. Raise and support the vehicle. Refer to «HOISTING, STANDARD PROCEDURE»(ref-476495-S23938607452012060400000) .
  3. Remove the license plate.
  4. Remove the bolts behind the plate (3).
  5. Support the bumper with a suitable lifting device.
  6. Remove the bolts attaching the bumper support brackets (4) to the trailer hitch (2).

UPPER

  1. Locate the end wings under the headlamp (3) and roll down into position.
  2. Position the center locator pin in the center of the fascia to the retainer hole and seat fully.
  3. Working from the center out, seat all the clips fully.
  4. Install the grille. Refer to «GRILLE, INSTALLATION»(ref-476497-S16177228722012060400000) . NOTE: Sport fascia shown in illustration, upper fascia similar.
  5. Install the screws (1) attaching the fascia (3) to the fender (2).
  6. Position the wheelhouse splash shield back and install the push pins (3).

SPORT

  1. Locate the fascia (1) over the upper surface of the bumper beam (2).
  2. Position the center locator pin in the center of the fascia to the retainer hole and seat fully.
  3. Pry or bend the outer ears of the fascia (1) around the headlamps and align to the fender (3).
  4. Confirm that the fascia (1) and the bumper (2) are lined up correctly and seat the upper clips fully.
  5. Install the grille. Refer to «GRILLE, INSTALLATION»(ref-476497-S16177228722012060400000) .
  6. Install the four lower fasteners (2).
  7. Install the screws (1) attaching the fascia (3) to the fender (2).
  8. Position the wheelhouse splash shield back and install the push pins (3).

USE OF HEAT DURING REPAIR

WARNINGChrysler Group LLC 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 LLC 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. This statement supersedes any previously released information by the Chrysler Group LLC. Failure to follow these instructions may result in serious or fatal injury.

WARNINGS

WARNINGUse an Occupational Safety and Health Administration (OSHA) approved breathing filter, when spraying paint or solvents in a confined area. Failure to follow these instructions may result in possible serious or fatal injury. avoid prolonged skin contact with petroleum or alcohol based cleaning solvents. do not stand under a hoisted vehicle that is not properly supported on safety stands. Failure to follow these instructions may result in possible serious or fatal injury.
CAUTIONWhen holes are drilled or punched in an inner body panel, verify the depth of space to the outer body panel, electrical wiring or other components. Damage to the vehicle can result. do not weld exterior panels unless combustible material on the interior of vehicle is removed from the repair area. Fire or hazardous conditions, can result. always have a fire extinguisher ready for use when welding. disconnect the negative (-) cable clamp from the battery when servicing electrical components that are live when the ignition is off. Damage to electrical system can result. do not use abrasive chemicals or compounds on painted surfaces. Damage to finish can result. do not use harsh alkaline based cleaning solvents on painted or upholstered surfaces. Damage to finish or color can result. do not hammer or pound on plastic trim panel when servicing interior trim. Plastic panels can break.

RESTRAINT WARNINGS

WARNINGTo avoid potential physical injury, or damage to sensitive electronic circuits and systems, always disconnect and isolate the battery negative (ground) cable and the positive cable, then ground the positive cable to discharge the ORC capacitor before performing any welding operations on the vehicle. Failure to take the proper precautions could result in accidental airbag deployment, possible damage to the Supplemental Restraint System (SRS) circuits and components, and possible damage to other electronic circuits and components. Whenever a welding process is being performed within 30 cm (12 in) of an electronic module/harness, then that module/harness should be relocated out of the way, or disconnected. Always protect against component or vehicle damage from weld spatter by using weld blankets and screens. Failure to follow these instructions may result in serious or fatal injury.
WARNINGTo avoid serious or fatal injury on vehicles equipped with the Supplemental Restraint System (SRS), never attempt to repair the electrically conductive circuits or wiring components related to the SRS for which there is no MOPAR wiring repair kit. It is important to use ONLY the recommended splicing kit and procedure. For applicable and available MOPAR wiring repair kits, please visit the MOPAR Connector Web Site at the following address on the Internet: (http://dto.vftis.com/mopar/disclaimer.asp). Inappropriate repairs can compromise the conductivity and current carrying capacity of those critical electrical circuits, which may cause SRS components not to deploy when required, or to deploy when not required. Only minor cuts or abrasions of wire and terminal insulation where the conductive material has not been damaged, or connector insulators where the integrity of the latching and locking mechanisms have not been compromised may be repaired using appropriate methods.
WARNINGTo avoid serious or fatal injury during and following any seat belt or child restraint anchor service, carefully inspect all seat belts, buckles, mounting hardware, retractors, tether straps, and anchors for proper installation, operation, or damage. Replace any belt that is cut, frayed, or torn. Straighten any belt that is twisted. Tighten any loose fasteners. Replace any belt that has a damaged or ineffective buckle or retractor. Replace any belt that has a bent or damaged latch plate or anchor plate. Replace any child restraint anchor or the unit to which the anchor is integral that has been bent or damaged. Never attempt to repair a seat belt or child restraint component. Always replace damaged or ineffective seat belt and child restraint components with the correct, new and unused replacement parts listed in the Chrysler Mopar® Parts Catalog. Failure to follow these instructions may result in possible serious or fatal injury.
WARNINGTo avoid serious or fatal injury on vehicles equipped with side curtain airbags, disable the Supplemental Restraint System (SRS) before attempting any Occupant Restraint Controller (ORC) diagnosis or service. The ORC contains a rollover sensor, which enables the system to deploy the side curtain airbags in the event of a vehicle rollover event. If an ORC is accidentally rolled during service while still connected to battery power, the side curtain airbags will deploy. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment.
WARNINGTo avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, Occupant Classification System (OCS), seat belt tensioner, impact sensor or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to follow these instructions may result in accidental airbag deployment.
WARNINGTo avoid potential physical injury or damage to sensitive electronic circuits and systems, always disconnect and isolate the battery negative (ground) cable and the positive cable, then ground the positive cable to discharge the Occupant Restraint Controller (ORC) capacitor before performing any welding operations on the vehicle. Failure to take the proper precautions could result in accidental airbag deployment, possible damage to the Supplemental Restraint System (SRS) circuits and components, and possible damage to other electronic circuits and components. Whenever a welding process is being performed within 12 inches (30 centimeters) of an electronic module or wiring harness, then that module or harness should be relocated out of the way, or disconnected. Always protect against component or vehicle damage from weld spatter by using weld blankets and screens.
WARNINGTo avoid serious or fatal injury, do not attempt to dismantle an airbag unit or tamper with its inflator. Do not puncture, incinerate or bring into contact with electricity. Do not store at temperatures exceeding 93° C (200° F). An airbag inflator unit may contain sodium azide and potassium nitrate. These materials are poisonous and extremely flammable. Contact with acid, water, or heavy metals may produce harmful and irritating gases (sodium hydroxide is formed in the presence of moisture) or combustible compounds. An airbag inflator unit may also contain a gas canister pressurized to over 17.24 kPa (2500 psi). Failure to follow these instructions may result in possible serious or fatal injury.
WARNINGTo avoid serious or fatal injury when handling a seat belt tensioner retractor. Exercise proper care to keep fingers out from under the retractor cover and away from the seat belt webbing where it exits from the retractor cover. Failure to follow these instructions may result in possible serious or fatal injury.
WARNINGTo avoid serious or fatal injury, replace all Supplemental Restraint System (SRS) components only with parts specified in the Chrysler Mopar® Parts Catalog. Substitute parts may appear interchangeable, but internal differences may result in inferior occupant protection.
WARNINGTo avoid serious or fatal injury, the fasteners, screws, and bolts originally used for the Supplemental Restraint System (SRS) components must never be replaced with any substitutes. These fasteners have special coatings and are specifically designed for the SRS. Anytime a new fastener is needed, replace it with the correct fasteners provided in the service package or specified in the Chrysler Mopar® Parts Catalog.
WARNINGTo avoid serious or fatal injury when a steering column has an airbag unit attached, never place the column on the floor or any other surface with the steering wheel or airbag unit face down. Failure to follow these instructions may result in possible serious or fatal injury.
  1. Install the transmission crossmember (2), the bolts (1) and nuts (3). Tighten the bolts to 122 N.m (90 ft. lbs.).
  2. Remove the transmission support and install the transmission mount nuts (3).
  3. Tighten the nuts (3) to 61 N.m (45 ft. lbs.).
  4. Install the transfer case skid plate (4) and crossmember (2), if equipped. Refer to «PLATE, SKID, TRANSFER CASE, INSTALLATION»(ref-476503-S23326338662012060400000) .

2500 - 3500 HEAVY DUTY STANDARD CAB

  1. Install the crossmember (2), the bolts (1) and the nuts (3). Tighten the nuts to 122 N.m (90 ft. lbs.).
  2. Remove the transmission support and install the transmission mount nuts (3).
  3. Tighten the nuts (3) to 61 N.m (45 ft. lbs.).
  4. Install the transfer case skid plate (2), if equipped. Refer to «PLATE, SKID, TRANSFER CASE, INSTALLATION»(ref-476503-S23326338662012060400000) .

3500 - 5500 CAB CHASSIS

  1. Install the crossmember (2), the bolts (1) and the nuts (3). Tighten the nuts to 127 N.m (94 ft. lbs.).
  2. Remove the transmission support and install the transmission mount nuts (3).
  3. Tighten the nuts (3) to 61 N.m (45 ft. lbs.).
  4. Install the transfer case skid plate (2), if equipped. Refer to «PLATE, SKID, TRANSFER CASE, INSTALLATION»(ref-476503-S23326338662012060400000) .

Scheme 23

Scheme 23: 1500 LIGHT DUTY
Scheme 23: 1500 LIGHT DUTY
  1. Remove the rear bumper. Refer to «BUMPER, REAR, REMOVAL»(ref-476503-S11518570522012060400000) .
  2. Remove the hitch bolts (1).
  3. Support the hitch (3) with a suitable lifting device and remove the remaining hitch bolts (2).

Scheme 24

Scheme 24: 2500 - 3500 HEAVY DUTY
Scheme 24: 2500 - 3500 HEAVY DUTY

Scheme 25

Scheme 25
Scheme 25
  1. Remove the rear bumper. Refer to «BUMPER, REAR, REMOVAL»(ref-476503-S11518570522012060400000) .
  2. Remove the hitch bolts (1).
  3. Support the hitch (2) with a suitable lifting device and remove the hitch from the frame (1).
  1. Install the hitch (3) and install the four bolts (2).
  2. Install the four bolts (1).
  3. Tighten the bolts (2) to 190 N.m (140 ft. lbs.).
  4. Tighten the bolts (1) to 190 N.m (140 ft. lbs.).
  5. Install the rear bumper. Refer to «BUMPER, REAR, INSTALLATION»(ref-476503-S19747796432012060400000) .

2500 - 3500 HEAVY DUTY

  1. Install the hitch (2) onto the frame (1).
  2. Install the six bolts (1).
  3. Tighten the bolts (1) to 169 N.m (125 ft. lbs.).
  4. Install the rear bumper. Refer to «BUMPER, REAR, INSTALLATION»(ref-476503-S19747796432012060400000) .

Scheme 26

Scheme 26: 1500 LIGHT DUTY
Scheme 26: 1500 LIGHT DUTY
  1. Remove the front bumper. Refer to «BUMPER, FRONT, REMOVAL»(ref-476503-S20073422232012060400000) .
  2. Remove the bolts (3) and remove the tow hook assembly (2).

2500 - 5500 HEAVY DUTY

  1. Remove the front bumper. Refer to «BUMPER, FRONT, REMOVAL»(ref-476503-S20073422232012060400000) .
  2. Remove the nuts (1) and bolts (2) and remove the tow hooks (3), if equipped.
  1. Install the tow hook (2) onto the frame tip (1) and install the bolt (3).
  2. Make sure the hook is positioned fully against the bumper mount and tighten the bolt (3) to 85 N.m (63 ft. lbs.)
  3. Install the front bumper. Refer to «BUMPER, FRONT, INSTALLATION»(ref-476503-S34261189492012060400000) .
  1. If equipped, install the tow hooks (3) and install the bolts (2) and nuts (1).
  2. Tighten the bolts to 275 N.m (203 ft. lbs.).
  3. Install the front bumper. Refer to «BUMPER, FRONT, INSTALLATION»(ref-476503-S34261189492012060400000) .

1500 - 3500 STANDARD CHASSIS

  1. Raise and support the vehicle. Refer to «HOISTING, STANDARD PROCEDURE»(ref-476495-S23938607452012060400000) .
  2. Support the skid plate (4) and remove the bolts (3).
  3. Remove the skid plate (4).
  4. Support the skid plate crossmember (2) and remove the bolts (1).
  5. Remove the skid plate crossmember (2).

3500 - 5500 HEAVY DUTY - CAB CHASSIS

  1. Raise and support the vehicle. Refer to «HOISTING, STANDARD PROCEDURE»(ref-476495-S23938607452012060400000) .
  2. Support the skid plate (2) and remove the bolts (1).
  3. Remove the skid plate (3).
  1. Install the skid plate crossmember (2) and bolts (1).
  2. Tighten the bolts (1) to 18 N.m (13 ft. lbs.).
  3. Install the skid plate (4) and bolts (3).
  4. Tighten the bolts (3) to 18 N.m (13 ft. lbs.).

2500/3500 STANDARD CHASSIS

Note. 1500 Standard Chassis shown in illustration, 2500/3500 similar

  1. Install the skid plate crossmember (2) and bolts (1).
  2. Tighten the bolts (1) to 24 N.m (18 ft. lbs.).
  3. Install the skid plate (4) and bolts (3).
  4. Tighten the bolts (3) to 24 N.m (18 ft. lbs.).
  1. Install the skid plate (2) and bolts (1).
  2. Tighten the bolts (1) to 37 N.m (27 ft. lbs.).

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