Dodge Fe Bumpers SRM 2006 Service Manual
DR FRAME & BUMPERS 13 - 1
FRAME & BUMPERS
TABLE OF CONTENTS
page page
FRAMES & BUMPERS
SPECIFICATIONS
TORQUE ....................................2
FRONT AIR DAM
REMOVAL .....................................3
INSTALLATION ................................3
FRONT BUMPER
REMOVAL .....................................4
INSTALLATION ................................4
FRONT FASCIA
REMOVAL .....................................5
INSTALLATION ................................6
REAR BUMPER
REMOVAL .....................................7
INSTALLATION ................................8
FASCIA-FRONT SRT-10
REMOVAL .....................................9
INSTALLATION ................................11
FASCIA-REAR SRT-10
REMOVAL ....................................14
INSTALLATION ...............................15
FRAME
WARNING
WARNINGS ................................17
STANDARD PROCEDURE
HYDROFORM FENDER RAIL REPAIR ........18
REAR FRAME H-SECTION REPLACEMENT .. . 27
SPECIFICATIONS
WELD PROCESS ...........................33
FRAME DIMENSIONS .......................34
TORQUE ...................................45
FRONT CROSSMEMBER
REMOVAL ....................................46
INSTALLATION ...............................48
FRONT SKID PLATE
REMOVAL ....................................50
INSTALLATION ...............................51
FRONT TOW HOOK ASSEMBLY
REMOVAL ....................................52
INSTALLATION ...............................53
TRANSMISSION CROSSMEMBER
REMOVAL ....................................54
INSTALLATION ...............................56
TRAILER HITCH
REMOVAL ....................................58
INSTALLATION ...............................60
TRANSFER CASE SKID PLATE
REMOVAL ....................................62
INSTALLATION ...............................63
13 - 2 FRAME & BUMPERS DR
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
DR FRAME & BUMPERS 13 - 3
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.
13 - 4 FRAME & BUMPERS DR
FRONT BUMPER
REMOVAL
1. Using a grease pencil or equivalent, mark the position of the bumper support bracket (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 bumper support 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 FRAME & BUMPERS 13 - 5
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 - 6 FRAME & BUMPERS DR
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 FRAME & BUMPERS 13 - 7
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 - 8 FRAME & BUMPERS DR
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.
DR FRAME & BUMPERS 13 - 9
FASCIA-FRONT SRT-10
REMOVAL
1. Remove the belly pan screws (1).
2. Remove the screws (1 & 2) from the wheel well.
13 - 10 FRAME & BUMPERS DR
3. Remove the push pin fasteners attaching the upper
fascia to the fascia retainer.
4. Lift the fascia off of the support brackets (1 & 2)
and remove the fascia.
DR FRAME & BUMPERS 13 - 11
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).
13 - 12 FRAME & BUMPERS DR
3. Position the belly pan (2) over the lip of the fascia
(1).
4. Install the push pin fasteners into the fascia
retainer.
DR FRAME & BUMPERS 13 - 13
5. Install the screws (1 & 2) into the wheel well.
6. Install the screws (1) into the belly pan.
13 - 14 FRAME & BUMPERS DR
FASCIA-REAR SRT-10
REMOVAL
1. Remove the screws (1, 3 and 5).
2. Separate end cap (4) and lift off of the support brackets (2).
DR FRAME & BUMPERS 13 - 15
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.
INSTALLATION
13 - 16 FRAME & BUMPERS DR
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).
4. Position the end caps (4) over the support brackets (2) and install.
5. Install the screws (1, 3 and 5).
DR FRAME & BUMPERS 13 - 17
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.
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.
13 - 18 FRAME & BUMPERS DR
STANDARD PROCEDURE
HYDROFORM FENDER RAIL REPAIR
CAUTION: This 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 23 - BODY/BODY STRUCTURE/
WELD LOCATIONS - SPECIFICATIONS, when replacing the entire hydroform.
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.
1. Before proceeding with this repair procedure review the required service warnings and precautions (Refer to 13
- FRAME & BUMPERS/FRAME - WARNING).
DR FRAME & BUMPERS 13 - 19
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 fender (Refer to 23 - BODY/EXTERIOR/FRONT FENDER - REMOVAL).
5. Remove the A/C condenser, if required (Refer to 24
- HEATING & AIR CONDITIONING/PLUMBING/A/C
CONDENSER - REMOVAL).
6. Remove the A/C lines, if required. Refer to the
Heating and Air Conditioning section of the manual
for recommended procedures.
7. Remove the radiator assembly (4) (Refer to 7 COOLING/ENGINE/RADIATOR - REMOVAL).
13 - 20 FRAME & BUMPERS DR
8. Remove the air cleaner and support bracket (1 - if
required) (Refer to 9 - ENGINE/AIR INTAKE SYSTEM/AIR CLEANER ELEMENT - REMOVAL).
9. Remove the integrated power module (Refer to 8 ELECTRICAL/POWER DISTRIBUTION/INTEGRATED POWER MODULE - REMOVAL).
10. Remove the bolts and position aside the wire har-
ness and grounds, if required.
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