Ram Cautionary Notes - Ram Body Builder`s Guide
Contents
1. the engine Approximately five inches of an orange 18 gauge is folded back and taped To aid in identification a white plastic tag is attached to this wire and is labeled PTO RAM CAUTIONARY NOTES For diesel applications the PTO circuit needs to be installed from the power train control module located on the lower driver side of the engine pin 38 of the 50 position connector to the PTO device See your dealership for the proper terminal part number To disable ODB Il monitoring a ground level signal needs to be applied to this circuit Diesel Exhaust Brake For Ram truck diesel applications the power train control module provides a control circuit for control of an aftermarket exhaust brake This control can be implemented by purchasing the appropriate Mopar kit from your dealership Follow the provided directions carefully Lighting considerations Cab Chassis As built the Cab Chassis provides combined rear turn stop lamp lighting A typical upfitter installation will remove the tail lamp assembly and replace it with one of their own Care must be exercised to match the original equipment lamp loads so that proper fault detection by the electronic control module is maintained Frame Alteration Information The following section shows suggested guidelines on modification of Dodge Ram frames for various after market applications Caution Use of proper safety equipment is recommended when performing any modifi2. RAM CAUTIONARY NOTES To provide a safe and serviceable vehicle to the customer certain precautions must be observed to ensure correct assembly and construction of the finished vehicle 1 Do not revise tubes or hoses as service systems performance may be seriously impaired 2 Locate body cross sills to avoid interference with chassis parts fuel lines or fuel gauge tank sending unit 3 Body interior layout body structure accessory installation water and holding tanks fuel and propane tank and motor generator locations should be designed to provide equal side to side loading on chassis to avoid vehicle lean and adverse effects on vehicle handling The combined weight of the chassis plus all items installed by the body builder and an additional load allowance for reasonably anticipated passengers liquids luggage and other equipment should not exceed the gross vehicle weight for which the particular chassis is designed and the weight should be distributed between the front and rear axles so the maximum capacity rating of each axle system is not exceeded 4 Undercoating or sound deadening material should not be sprayed on any chassis power train or suspension parts Hardware that requires special care includes such items as electrical wiring radiator engine accessory drive transmission prop shaft steering mechanism springs shocks exhaust pipes or linkages NV4500HD and NV5600 TRANSMISSIONS The NV4500 NV4500HD
3. allation instructions various fill and vapor hoses that can be cut and assembled per body applications hose clamps ground strap and a hose connector A DIESEL or GAS fuel label will also be included depending on application The part numbers for the kits are Diesel 52121252AA Gas 52121251AA RAM GAUTIONARY NOTES Installation Suggestions Always mount the fuel fill housing as high as possible and route the fuel fill tube on a continuous downward slope approx 37 to insure good fuel fill quality Mount the fuel fill tube upper with the vent tube at the 9 00 12 00 or 3 00 position When routing the vent tube make sure there are no dips or sags It should have a downward slope from the fuel filler tube upper to the fuel tank vent nipple Tie strap it to prevent any sags that may accumulate fuel in the hose Always connect the ground strap from the fuel fill upper to the frame This is a must If the ground strap is not attached Electro static build up could occur during refueling Roll Over Valves Warning After market bed box may not offer the desired protection from dirt and water to the roll over valves that the production box does After the installation of the aftermarket bed box it is necessary on all diesel fuel tanks to connect 1 4 fuel resistant hose to the roll over valves and vent them in a clean environment such as inside the frame rails The roll over valves must not be capped off an
4. and NV5600 transmissions are not fitted with a drain plug Under normal driving conditions it is not necessary to change the transmission fluid If however it is necessary to change or remove fluid the following procedure should be followed 1 Remove the bottom bolt from the left or right PTO opening This bolt hole is drilled through to the inside of the transmission and will allow the oil to drain 2 After draining replace bolt and torque to 20 40 Ib ft 3 Refill the NV4500 and NV4500HD transmission with Mopar synthetic gear lubricant only Available at Dodge truck dealers the Mopar part number is 04874459 Using mineral oil can result in damage to the transmission 4 Refill the NV5600 transmission with Mopar synthetic gear lubricant only Available at Dodge truck dealers the Mopar part number is 04874464 Using mineral oil can result in damage to the transmission Site map _ Main Menu _ SPARE TIRE Chassis Cab box off models do not include the winch Spare tire and spare wheel however the spare tire and wheel can be ordered as an option sales code TBE NEW VEHICLE STORAGE Protection of new vehicles from damage and deterioration prior to retail delivery is the body builder s and his dealer s responsibility as is any expense incurred as the result of such damage or deterioration 1 Check engine coolant and antifreeze protection After storage for more than 21 days the battery should be recharged
5. cations or alterations The following recommendations are consistent with industry standards DaimlerChrysler Corporation doesn t recommend any modifications or alterations to the frame assembly Modifications or alterations i e hole drilling welding etc to the frame assembly are the responsibility of persons performing these modifications or alterations Anyone altering the frame must assume complete responsibility for assembly performance reliability and compliance of applicable FMVSS requirements The following procedures and specific precautionary instructions are recommended for proper installation of special bodies and or equipment on the Ram Frame Failure to follow these recommendations could result in damage to the basic vehicle and possible injury to occupants Holes Holes are not to be drilled in the top or bottom of the frame rails Holes to mount out riggers brackets and supports must be drilled in the web vertical sides of the frame rail with the following restrictions Site map _ Main Menu _ 1 Hole diameter should not exceed 20 mm 0 75 in Material between edge of hole and top or bottom of the frame rail must not be less than 40 mm 1 60 in 3 The minimum edge distance between any two 2 holes must be larger than twice the diameter of the larger hole 4 Any thru fastener that torques down on both external surfaces of the rail must use an internal spacer to prevent crushing the
6. d be allowed to vent to atmosphere Individual hoses must be connected to each roll over valve Do not T the valves together Site map_ Main Menu _
7. for at a minimum of 24 hours For long storage in cold temperatures the battery should be disconnected removed and stored at a temperature above freezing Inflate tires to recommended pressure Place parking brake in off position Observe necessary security precautions to avoid pilferage and vandalism 6 Keep windows closed doors locked and trim covers intact and in position 7 Keep engine steering wheel and cab back covers intact and in position when applicable 8 Do not use chalk or crayon on glass or painted surfaces Scratches may result oa 2 Headlamp Taillamp Circuit Adding lamps to the headlamp taillamp circuit without a separate relay may damage the electrical system For all Ram 1500 2500 LD HD pickup models without cab clearance lamps the available current capacity is 3 5 amps For all other RAM HD pickup models NO additional lamps should be connected without using a separate relay Wiring Provisions PTO and ODB Il 2004 Dodge Ram trucks except 3 7L powertrain options have a provision that allows ODB II monitoring systems to be disabled while the PTO system is being operated This will prevent false lighting of the Check Engine lamp due to the engine PTO driven accessories For gasoline applications ODB II monitoring is disabled by applying a 12 volt ignition feed to circuit G113 This circuit is provided in the engine harness as a splice point at the left hand rear corner of
8. rail tube 5 All holes should be drilled in the frame using appropriate drilling practice and safety precautions 6 Avoid drilling holes near the fuel tank fuel and brake lines and other lines and wires to avoid damage to them Welding Prior to any welding the following must be done 1 Avoid welding near the fuel tank fuel and brake lines or other components that may be damaged by the heat of welding If it is necessary to weld near these areas use wet cloths to cover these components If it is necessary to remove the fuel tank lines or other components do it in accordance with applicable service manual procedure 2 Components near the welding area which could be damaged by excessive heat must be removed or adequately shielded 3 Disconnect the battery ies 4 Precautionary measures should be used to prevent electrical system components or wiring damage 5 Frame e coating must be removed from the welding and surrounding area Use proper welding techniques to avoid stress risers that may adversely affect frame performance After welding 1 Carefully inspect electrical components and wiring for shorts or other damage 2 Apply protective coating to areas where coating was removed Dodge Fuel Fill Tube Kit A new fuel fill housing will be included in box off models and has been designed for easy installation external flange mounted and to insure proper fuel tube fill angle of 37 Included in the kit are inst
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