Repair Procedure

REPAIR PROCEDURE:

This bulletin involves the addition of 4 cab reinforcements on 1994 & 1995 model year vehicles and replacement of the cab isolators on 1994 model year vehicles.

NOTE:
THE 1995 RAM TRUCK SERVICE MANUAL (PUBLICATION NO. 81-370-5108) WILL BE REFERENCED THROUGHOUT THIS TSB.

BOX REMOVAL AND CAB ISOLATOR REPLACEMENT:

1. Open fuel fill door and remove screws holding fuel fill neck adapter to cargo box side wall. Separate from cargo box.

2. Remove rear wheel splash shields by referring to 1995 Ram Truck Service Manual, Page 23-14.

3. Remove tailgate referencing the Ram Truck Service Manual, Page 23-15.

4. Remove the rear bumper assembly referring to page 13-3 of the Ram Truck Service Manual.

5. Remove spare tire crank bezel.

6. Disengage tail lamp wire connector from main body harness at left rear frame rail.

7. Remove the bolts (6 for 6'5" box - 8 for 8' box) holding the cargo box to frame rails and discard.

8. Using four helpers or a suitable lifting device, separate the cargo box from the vehicle. Set box aside and complete repair procedure.

CAB ISOLATOR REPLACEMENT (1994 ONLY):

9. Remove all cab isolator bolts, lift cab as necessary. Replace each isolator (P/N 55234693) and bolt (P/N 6501557), torque to 60 ft. lbs. before proceeding to the next cab isolator. Refer to Page 13-22 of the Ram Truck Service Manual for further information.

CAUTION:
NEW CAB CHASSIS BOLTS (P/N 6501557) MUST BE USED WHEN REPLACING THE ISOLATORS. SUPPORT WITH SAFETY STANDS WHILE CAB ISOLATOR BOLTS ARE REMOVED AND CAB IS BEING LIFTED.

CRACK REPAIR:

1. Drill a 1/8 in. hole at the end(s) of each crack.

2. Using a MIG type welder, weld the cracks together.

3. Finish the surface of the welded areas. Grind and smooth as needed.

UNDERSIDE REINFORCEMENT:

1. Sand and clean the underside of the cab and reinforcement.





2. Apply a 3/8 (10 mm) dia. bead of 2 part adhesive to the under floor reinforcement along bend reinforcement as shown in Figure 1. (Follow instructions provided with adhesive).

3. Fit the under floor reinforcement in place as shown in Figure 1. Hold the under floor reinforcement in place with clamps at the down standing flange. Make sure that the under floor reinforcement fits tightly to the cab underside.

4. Drill the first (of four) 1/4" hole in the under floor reinforcement and cab floor at the pilot hole location. Apply the sealant to the hole and install a 1/4" rivet (P/N 6033688). Complete the procedure by installing one rivet at a time to the other 3 positions (See Figure 1).

5. Center punch the four rivet hole locations in the cab back panel between the existing spot welds as shown in Figure 1. Due to the small size of the down standing flange, use caution to position the rivet locations in the center of the flange so as to obtain complete contact of the rivet head to the sheetmetal.

6. Drill the first (of four) 1/4" holes in the down standing flange and under floor reinforcement. Apply the sealant to the hole and install a 1/4" rivet (P/N 6033688 or P/N 6033864) as called out in Figure 1. Complete the procedure by installing one rivet at a time (See Figure 1).

7. Repeat steps 1 through 6 for the other side of cab.

INSIDE REINFORCEMENT:
1. Remove the bolts holding the seats to the floor and pull seats forward in cab. Reference page 23-32 of the Ram Truck Service Manual.

2. Remove the stowage box. Refer to Page 23-39.

3. Remove the "B" pillar trim. Refer to Page 23-36.

4. Remove cab back trim panel. Refer to Page 23-36.

5. Pull carpet away to expose cab floor.

6. Sand and clean the cab back and cab back reinforcement.





7. Mark the inside reinforcement to cab back rivet locations through the inside reinforcement as shown in Figure 2. Center punch these five rivet locations.

NOTE:
TWO PEOPLE WILL BE NEEDED FOR STEP EIGHT. ONE TO HOLD THE INSIDE REINFORCEMENT IN PLACE, AND ONE TO INSTALL THE RIVETS.

8. Apply 3/8 (10 mm) dia beads of 2-part adhesive to the cab back (at interface to inside reinforcement) and inside reinforcement (at interface to cab floor) as shown in Figure 2. Follow instructions included for 2-part adhesive. Fit the inside reinforcement in place as shown in Figure 2. Make sure that the inside reinforcement fits tightly to the cab floor and cab back panel.

9. From inside the vehicle center punch the 5 rivet hole locations in the berry box flange as shown in Figure 2. Use caution to position the rivet locations so that the rivets will not penetrate the inside reinforcement flanges too close to the edges.

10. From inside the cab, drill the first often 1/4" holes in the berry box flange and cab floor using the holes located in the inside reinforcement as locators. Apply the sealant to the hole and install a 1/4" rivet (P/N 6033864) from the underside of the cab up into passenger compartment. Complete the procedure by installing the remaining 8, one rivet at a time as shown in Figure 2.

11. Repeat steps 6 through 10 for the other side.

12. Refinish underside and cab back as needed where reinforcements were added by referring to Page 23-43.

13. Position carpet back into place.

14. Install cab back trim panel.

15. Install "B" pillar trim.

16. Install stowage box.

17. Reposition seats and install nuts and torque to 40 Nm (30 ft. lbs).

BOX INSTALLATION:

1. Using helpers or a suitable lifting device position the box on the vehicle.

2. Open fuel fill door align fuel filler neck.

CAUTION:
NEW BOX CHASSIS BOLTS (P/N 6503298) MUST BE USED WHEN INSTALLING THE CARGO BOX.

3. Install the new bolts (6 for 6'5" box - 8 for 8' box) (P/N 6503298) holding the cargo box to frame rails and torque to 20 ft.lbs.

4. Engage tail lamp wire connector to main body harness at left rear frame rail.

5. Install fuel fill neck to cargo box.

6. Install rear wheel splash shields.

7. Install tailgate.

8. Install the rear bumper assembly.

NOTE:
THE VEHICLE SHOULD NOT BE DRIVEN UNTIL THE ADHESIVE CURES IN APPROXIMATELY 24 HOURS.