Ram Cautionary Notes
Contents
1. MANUAL TRANSMISSION When installing a PTO unit on the G56 Chassis Cab only it is critical to follow the PTO manufacturer s installation instructions particularly regarding use of the correct gasket and additional fluid fill quantity For 2010 and beyond the correct transmission oil fill is 5 1 quarts was 6 1 quarts in previous years With a PTO installed the correct final fluid level is between 1 2 and 1 4 from the bottom of the fill hole 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 And will include the winch on box off models 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 Check engine coolant and antifreeze protection After storage for more than 21 days the battery should be recharged 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 Keep windows closed doors locked and trim covers intact and in position Keep engine steering wheel and cab back c2. and angling them forward Shear plates should not be welded to the frame Shear plate holes are sized to allow the use of 5 8 inch diameter fasteners Grade 8 or higher fasteners should be used with hardened washers They should be torqued to 65 ft lbs The final stage manufacturer who installs a second unit body on the chassis is responsible for compliance with FMVSS CMVSS 204 208 212 214 219 and 301 Federal regulations Questions regarding compliance with FMVSS CMVSS regulations should be directed to your legal counsel the National Highway Traffic Safety Administration or Transport Canada
3. RAM CAUTIONARY NOTES CAUTIONARY NOTES TO BODY BUILDERS 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 Do not revise tubes or hoses as service systems performance may be seriously impaired Locate body cross sills to avoid interference with chassis parts fuel lines or fuel gauge tank sending unit 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 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 systems or linkages PTO INSTALLATION ON G56 6 SPEED
4. 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 Note See Fuel Filler section for urea hose info Gas 68145496AA Chassis Cab 52121693AA Installation Suggestions e 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 Body Mount Guidelines for Ram Box 2500 Box Removal The following section shows suggested guidelines for Body Mounts for Ram 2500 applications Caution Use of proper safety equipment is recommended when performing any modification or alterations These guidelines apply to second stage manufacturers who mount a body to the Ram Pickup Truck This applies to trucks which have been ordered from the factory with the box deleted or tho
5. iate drilling practice and safety precautions 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 Components near the welding area which could be damaged by excessive heat must be removed or adequately shielded Disconnect the battery ies Precautionary measures should be used to prevent electrical system components or wiring damage 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 eINDEX eMAIN MENU 2500 3500 RAM HOME After welding 1 Carefully inspect electrical components and wiring for shorts or other damage 2 Apply protective coating to areas where coating was removed Ram 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 installation instructions various fill and vapor
6. overs intact and in position when applicable Do not use chalk or crayon on glass or painted surfaces Scratches may result 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 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 Toolbox Brackets When installing a toolbox to the front of your pickup bed you must use Mopar toolbox brackets available from your dealer Failure to install the additional support may lead to significant bed damage The part number for the toolbox brackets is 82205240 For more details please visit the Mopar website www mopar com Frame Alteration Information The following section shows suggested guidelines on modification of Ram frames for various after market applications Caution Use of proper safety equipment is recommended when performing any modifications or alterations The foll
7. owing recommendations are consistent with industry standards RAM CAUTIONARY NOTES Chrysler Group LLC 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 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 The minimum edge distance between any two 2 holes must be larger than twice the diameter of the larger hole Any thru fastener that torques down on both external surfaces of the rail must use an internal spacer to prevent crushing the rail tube All holes should be drilled in the frame using appropr
8. se where the factory installed box is removed after delivery The mounting location brackets on the chassis that are used for the pickup bed mounting should be utilized for RAM CAUTIONARY NOTES installing the new body On the short bed there are six mounting location brackets and on the long bed there are eight Grade 10 9 M12 Fasteners or equivalent should be used Torque to 60 ft lbs With the body in position the gap between the body mounting points and the chassis mounting brackets should be minimized to assure that there is no distortion of the chassis mounting brackets when the body mounting fasteners are torqued to specification Metal spacers are recommended in cases where the gap exceeds 2 mm Since the guidelines might not be appropriate for every application of a body installation following the guidelines listed above does not eliminate the responsibility of the second stage manufacturers to certify to compliance to FMVSS and CMVSS standards The final stage manufacturer who installs a second unit body on the chassis is responsible for compliance with FMVSS CMVSS 204 2087 212 214 219 and 301 Federal Regulations Questions regarding compliance with FMVSS CMVSS regulations should be directed to your legal counsel the National Highway Traffic Safety Administration or Transport Canada Body mounting Guidelines for Ram 3500 Chassis Cab These guidelines apply to second stage manufacturers who mount a bod
9. y to the Ram Chassis cab There are figures in the dimensions frame and exhaust section that show pierced holes that are provided for shear plate attachment Body Mounting Details 1 The applied body should be mounted a minimum of 3 inches away from the rear surface of the cab as measured at the center of the cab U Bolt attachment in the transition area of the frame i e the area behind cab where the frame transitions from a deep section to a narrow section is not recommended Shear plate holes are provided in this area The 84 CA frame does have a straight frame area beyond the transition where U bolts are allowed At the rear of the frame there are several options Two shear plate holes are provided at the rear of the frame as shown in the dimensions frame and exhaust section These holes may be combined with the pair of holes that attach the taillight They can be enlarged to 21 32 like the shear plate holes if required This can be used to attach the body as well as a bumper step trailer hitch bracket In addition space is provided at the rear of the frame for U bolt access There are relief areas at the corners of the rear fuel tank to allow U eINDEX eMAIN MENU 2500 3500 RAM HOME bolt installation with adequate clearance to the fuel tank Shear plates at the front attachment should be angled forward 45 to 60 degrees from the horizontal This is easily done by centering the shear plates on the two frame shear plate holes
Download Pdf Manuals
Related Search