Dodge Fe Bumpers 3500 2005, Fe Bumpers 2500 2005, Fe Bumpers 1500 2005 Service Manual
DR/DH FRAME & BUMPERS 13 - 1
FRAME & BUMPERS
TABLE OF CONTENTS
page page
FRAMES & BUMPERS
SPECIFICATIONS
TORQUE .............................1
FRONT AIR DAM
REMOVAL ..............................2
INSTALLATION ..........................2
FRONT BUMPER
REMOVAL ..............................2
INSTALLATION ..........................2
FRONT FASCIA
REMOVAL ..............................3
INSTALLATION ..........................4
REAR BUMPER
REMOVAL ..............................5
INSTALLATION ..........................6
FASCIA-FRONT SRT-10
REMOVAL ..............................6
INSTALLATION ..........................8
FASCIA-REAR SRT-10
REMOVAL .............................11
INSTALLATION .........................13
FRAME
WARNING
WARNINGS ..........................14
STANDARD PROCEDURE
LIGHT DUTY FRONT FRAME RAIL TIP
REPLACEMENT.......................15
HYDROFORM FENDER RAIL REPAIR ......23
REAR FRAME H-SECTION REPLACEMENT . 32
SPECIFICATIONS
WELD PROCESS .....................38
FRAME DIMENSIONS ..................39
TORQUE ............................45
FRONT CROSSMEMBER
REMOVAL .............................46
INSTALLATION .........................48
FRONT SKID PLATE
REMOVAL .............................49
INSTALLATION .........................50
FRONT TOW HOOK ASSEMBLY
REMOVAL .............................51
INSTALLATION .........................52
TRANSMISSION CROSSMEMBER
REMOVAL .............................53
INSTALLATION .........................55
TRAILER HITCH
REMOVAL .............................56
INSTALLATION .........................58
TRANSFER CASE SKID PLATE
REMOVAL .............................60
INSTALLATION .........................61
FRAMES & BUMPERS
SPECIFICATIONS
TORQUE
TORQUE SPECIFICATIONS
DESCRIPTION N·m Ft. Lbs.
Front bumper center bracket nuts 95 70
Front bumper stud plate nuts 95 70
License plate hitch reinforcement bolts 54 40
Rear bumper support bracket stud plate nuts 54 40
Rear bumper support bracket to hitch bolts 54 40
Rear bumper to hitch bolts 54 40
13 - 2 FRAME & BUMPERS DR/DH
FRONT AIR DAM
REMOVAL
1. Remove the two outboard screws.
2. Remove the three middle screws and remove the air dam.
INSTALLATION
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.
FRONT BUMPER
REMOVAL
1. Using a grease pencil or equivalent, mark the position of the bumper (5) on the frame rail tip (7) to
aid installation.
2. Disconnect the fog lamp electrical connector at the
left frame rail.
3. Support the bumper with a suitable lifting device.
4. Remove the center bracket (5) nuts and bolts (8
and 9) and remove bumper.
INSTALLATION
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 23 - BODY/BODY STRUCTURE/
GAP AND FLUSH - SPECIFICATIONS).
DR/DH FRAME & BUMPERS 13 - 3
FRONT FASCIA
REMOVAL
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.
SPORT
1. Raise and support the vehicle (Refer to LUBRICATION & MAINTENANCE/HOISTING - STANDARD
PROCEDURE).
13 - 4 FRAME & BUMPERS DR/DH
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.
INSTALLATION
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.
DR/DH FRAME & BUMPERS 13 - 5
REAR BUMPER
REMOVAL
1. Raise and support the vehicle (Refer to LUBRICATION & MAINTENANCE/HOISTING - STANDARD
PROCEDURE).
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).
13 - 6 FRAME & BUMPERS DR/DH
INSTALLATION
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.
FASCIA-FRONT SRT-10
REMOVAL
1. Remove the belly pan screws (1).
DR/DH FRAME & BUMPERS 13 - 7
2. Remove the screws (1 & 2) from the wheel well.
3. Remove the push pin fasteners attaching the upper
fascia to the fascia retainer (1).
13 - 8 FRAME & BUMPERS DR/DH
4. Lift the fascia off of the support brackets (1 & 2)
and remove the fascia.
INSTALLATION
1. Position the fascia onto the vehicle.
2. Position the fascia (2) over the side support
bracket (1) on one side then around and over the
other side support bracket (1).
DR/DH FRAME & BUMPERS 13 - 9
3. Position the belly pan (2) over the lip of the fascia
(1).
4. Install the push pin fasteners into the fascia
retainer.
13 - 10 FRAME & BUMPERS DR/DH
5. Install the screws (1 & 2) into the wheel well.
6. Install the screws (1) into the belly pan.
DR/DH FRAME & BUMPERS 13 - 11
FASCIA-REAR SRT-10
REMOVAL
1. Remove the screws (2 and 4).
2. Separate end cap (3) and lift off of the support brackets (1).
13 - 12 FRAME & BUMPERS DR/DH
3. Remove the license plate lamp clips (2).
4. Remove the license plate lamps (4) and disconnect the electrical connectors.
5. Remove the push pin fasteners (3) and remove the fascia.
DR/DH FRAME & BUMPERS 13 - 13
INSTALLATION
1. Install the fascia (5) and install the push pin fasteners (3).
2. Connect the electrical connectors and install the license plate lamps (4).
3. Install the lamp clips (2).
13 - 14 FRAME & BUMPERS DR/DH
4. Position the end caps (3) over the support brackets (1) and install.
5. Install the screws (2 and 4).
FRAME
WARNING
WARNINGS
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.
DR/DH FRAME & BUMPERS 13 - 15
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.
STANDARD PROCEDURE
LIGHT DUTY FRONT FRAME RAIL TIP REPLACEMENT
CAUTION: This procedure is designed to replace the front frame rail tips that have been damaged in the
crush initiator zones. Prior to any cutting, the vehicle must be mounted on the appropriate frame repair
equipment (“frame rack”), checked with three dimensional measuring equipment, and the necessary pull
corrections made. If damage remains in the frame beyond the area covered by this service part after the
pull, the frame must be replaced in its entirety.
CAUTION: Inspect 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.
NOTE: Procedures for 4X2 and 4X4 are common except as noted in this procedure.
1. Before proceeding with this repair procedure review
the required service warnings and precautions.
(Refer to 13 - FRAME & BUMPERS/FRAME WARNING)
2. Disconnect and isolate the battery negative cable.
3. Remove the front wheelhouse splash shield. (Refer
to 23 - BODY/EXTERIOR/FRONT WHEELHOUSE
SPLASH SHIELD - REMOVAL)
4. Remove the bolts and position aside the wire harness and grounds, if required.
5. Remove the front bumper. (Refer to 13 - FRAME &
BUMPERS/BUMPERS/FRONT BUMPER REMOVAL)
6. Loosen and lower the stabilizer bar mount and bar.
(Refer to 2 - SUSPENSION/FRONT/STABILIZER
BAR - REMOVAL)
7. Remove the front cab mount bolt (6) to the Front End Sheet Metal (FESM) bracket.
13 - 16 FRAME & BUMPERS DR/DH
8. Make a vertical mark (6) on the inside and outside
face of the frame rail 112 mm (4.5 in.) from the forward edge of the PLP hole (3) in the sides of the
rail.
9. Using a straightedge, connect the two lines on the
top and bottom of the rail.
10. Using the service tip as a guide, recheck your cut
lines to ensure the service tip will fit when the cut
is made.
CAUTION: Do not use any flame or plasma cutting
equipment to cut the frame in this procedure. This
is due to the inaccurate nature of the cut-line and
the fact that the high temperatures achieved during flame or plasma cutting will change the metal
characteristics and may weaken the frame and/or
repair location.
11. Using a reciprocating saw or equivalent, carefully cut and remove the damaged frame rail tip (7).
12. Assemble the service sleeve. Refer to SERVICE
SLEEVE ASSEMBLY at the end of this procedure.
NOTE: Any burned surface coatings will need to
be removed from the sleeve prior to installation
and application of corrosion preventative coatings.
13. Smooth and square the cut edges of the original
frame.
14. Dress the cut edge of the existing frame in prep-
aration for the new rail tip.
15. Drill four 13 mm (0.5 in.) diameter holes (9) in the
new tip (1) and four more in the existing frame (2)
to accommodate ring-fillet welds. Center these
holes (8) 19 mm (0.75 in.) from the cut face of the
rail and (6) 38 mm (1.5 in.) from the top and bottom of the rail.
DR/DH FRAME & BUMPERS 13 - 17
16. Bevel the edges of the new tip, existing frame,
and ring-fillet holes 25° - 30° (3). Scribing a line 2
mm from the cut edge and then grinding back to
the mark will simplify the bevel creation process
and accuracy.
17. Remove any burrs at the holes and beveled
edges.
18. Dry fit the new rail to ensure alignment and fit and
make any adjustments as necessary.
19. Remove all internal and external OEM e-coat
within 51 mm (2.0 in.) of the weld joint on the
replacement tip and the existing frame rail.
NOTE: Any burned surface coatings will need to
be removed prior to application of corrosion preventative coatings.
CAUTION: Shield the surrounding area and components from exposure to the welding spatter and
heat.
20. On 4X4 models use the service sleeve (3) as a
template to drill a hole in the frame tip (1) to
accommodate the sway bar mounting bolt (6).
13 - 18 FRAME & BUMPERS DR/DH
21. Slide the service sleeve (3) into the replacement
frame tip (1) and align to the 2 mm (0.08 in.) off
center line made previously during the sleeve
assembly and tack the ring fillet welds to hold
them in place.
22. On 4X4 models, install the sway bar tapping plate
(5) and secure with tack welds.
DR/DH FRAME & BUMPERS 13 - 19
23. Apply ring-fillet welds (3) into the ring-fillet weld
holes on the replacement frame tip. (Refer to 13 FRAME & BUMPERS/FRAME - SPECIFICATIONS - WELDING)
24. Start the ring-fillet welds at location (1) and follow
around the circumference of the ring-fillet weld
hole and end weld overlapping start point (2).
25. Install the upper FESM insulator onto the replace-
ment tip and position the service sleeve/replacement tip into the existing frame rail.
26. Loosely install the lower FESM insulator and cab
mounting bolt.
27. Using the appropriate measuring equipment, ver-
ify the front end sheet metal bracket’s location in
all three (X,Y, and Z) planes of space, and adjust
if required.
Loading...