Ram Truck 1500, 2500 & 3500 (2006-2008)

Removal & Installation

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Dual Zone Passenger's Side



  1. Disconnect and isolate the negative battery cable.
  2.  
  3. Remove the instrument panel from the vehicle, as follows:
    1. Remove the left A-pillar trim.
    2.  
    3. Remove the instrument panel top cover.
    4.  
    5. Disconnect the headliner wire harness connector located at the A-pillar.
    6.  
    7. Using a trim stick C-4755 or equivalent, from the notch on the bottom, remove the left instrument panel side cover.
    8.  
    9. Remove the left cowl trim panel.
    10.  
    11. Remove the steering column.
    12.  
    13. Remove the two bolts that secure the steering column support bracket to the instrument panel.
    14.  
    15. Remove the park brake release handle actuator rod.
    16.  
    17. Disconnect the instrument panel wire harness connector located above the brake pedal from the bulkhead wire harness connector.
    18.  
    19. Remove the instrument panel drivers side bezel.
    20.  
    21. Remove the three bolts that secure the left side of the instrument panel to the dash panel.
    22.  
    23. Remove the floor console, if equipped.
    24.  
    25. Remove the air bag control module cover, if equipped.
    26.  
    27. Disconnect the air bag control module electrical connector.
    28.  
    29. Remove the two bolts that secure the instrument panel to the center of the floor panel.
    30.  
    31. Remove the right cowl trim cover.
    32.  
    33. Disconnect the two instrument panel wire harness connectors from the two body wire harness connectors located on the right side of the cowl panel.
    34.  
    35. Disconnect the antenna coaxial cable connector from the radio coaxial cable connector located on the right side of the cowl panel.
    36.  
    37. Remove the one bolt that secures the instrument panel to the HVAC housing below the glove box opening.
    38.  
    39. Using a trim stick C-4755 or equivalent, from the notch on the bottom, remove the right instrument panel side cover from the instrument panel.
    40.  
    41. Remove the right A-pillar trim.
    42.  
    43. Remove the three bolts that secure the right side instrument panel bracket to the dash panel.
    44.  
    45. Remove the four screws that secure the instrument panel to the top of the cowl panel.
    46.  
    47. Remove the two bolts that secure the instrument panel to the top of the cowl panel.
    48.  
    49. With the help of an assistant, lift the instrument panel up and off of the cowl panel and remove the instrument panel from the vehicle.
    50.  
    51. If required, remove the four plastic screws inserts from the top of the cowl panel.
    52.  

  4.  
  5. Remove the blend door lever (1) from the blend door actuator output shaft (2) and the blend door linkage (3).

    Click image to see an enlarged view

    Fig. Remove the blend door lever (1) from the blend door actuator output shaft (2) and the blend door linkage (3)

  6.  
  7. Remove the two screws (1) that secure the blend door actuator and bracket assembly (2) to the top of the HVAC housing (3).
  8.  
  9. Remove the blend door actuator and bracket assembly from the HVAC housing and disconnect the HVAC wire harness connector (4) from the actuator.
  10.  
  11. Remove the blend door actuator and bracket assembly from the vehicle.

    Click image to see an enlarged view

    Fig. Remove the two screws (1) that secure the blend door actuator and bracket assembly (2) to the top of the HVAC housing (3). Remove the blend door actuator and bracket assembly from the HVAC housing and disconnect the HVAC wire harness connector (4) from the actuator.

  12.  

To install:

  1. Install the blend door actuator and bracket assembly onto the top of the HVAC housing.
  2.  
  3. Install the screws that secure the blend door actuator and bracket assembly to the HVAC housing. Tighten the screws to 20 inch lbs. (2.2 Nm).
  4.  
  5. Connect the HVAC wire harness connector to the blend door actuator.
    NOTE
    Align the guide pin on the blend door lever with the guides on the blend door linkage during installation of the blend door lever.

  6.  
  7. Install the blend door lever onto the blend door actuator output shaft and the blend door linkage.
  8.  
  9. Install the instrument panel, as follows:
    1. If removed, install the four plastic screw inserts into the top of the cowl panel.
    2.  
    3. With the help of an assistant, position the instrument panel into the vehicle and install the right side guide pin and the left side guide hook to the sides of the cowl panel.
    4.  
    5. Install the two bolts that secure the instrument panel to the top of the cowl panel. Tighten the bolts to 9 ft. lbs. (12 Nm).
    6.  
    7. Install the four screws that secure the instrument panel to the top of the cowl panel. Tighten the screws to 20 inch lbs. (2.2 Nm).
    8.  
    9. Install the three bolts that secure the right side instrument panel bracket to the cowl panel. Tighten the bolts to 9 ft. lbs. (12 Nm).
    10.  
    11. Install the right A-pillar trim.
    12.  
    13. Install the right instrument panel side cover.
    14.  
    15. Install the one bolt that secures the instrument panel to the HVAC housing below the glove box opening. Tighten the bolt securely.
    16.  
    17. Connect the radio coaxial cable connector to the antenna coaxial cable connector located on the right side of the cowl panel.
    18.  
    19. Connect the two instrument panel wire harness connectors to the two body wire harness connectors located on the right side of the cowl panel.
    20.  
    21. Install the right cowl trim panel.
    22.  
    23. Install the two bolts that secure the instrument panel to the center of the floor panel. Tighten the bolts to 9 ft. lbs. (12 Nm).
    24.  
    25. Connect the air bag control module electrical connector.
    26.  
    27. Install the air bag control module cover, if equipped.
    28.  
    29. Install the floor console, if equipped.
    30.  
    31. Install the three bolts that secure the left side of the instrument panel to the dash panel. Tighten the bolts to 9 ft. lbs. (12 Nm).
    32.  
    33. Install the instrument panel drivers side bezel.
    34.  
    35. Install the left cowl trim panel.
    36.  
    37. Connect the instrument panel wire harness connector located above the brake pedal to the bulkhead wire harness connector.
    38.  
    39. Install the park brake release handle actuator rod.
    40.  
    41. Install the two bolts that secure the steering column support bracket to the instrument panel. Tighten the bolts to 10 ft. lbs. (14 Nm).
    42.  
    43. Install the steering column.
    44.  
    45. Install the left cowl trim cover.
    46.  
    47. Install the left instrument panel side cover.
    48.  
    49. Connect the headliner wire harness connector located at the A-pillar.
    50.  
    51. Install the instrument panel top cover.
    52.  
    53. Install the left A-pillar trim.
    54.  

  10.  
  11. Reconnect the negative battery cable.
  12.  

Single Zone & Dual Zone Driver's Side




CAUTION
On vehicles equipped with airbags, disable the airbag system before attempting any steering wheel, steering column, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to take the proper precautions could result in accidental airbag deployment and possible personal injury or death.


NOTE
The single zone heating-A/C system is equipped with a single blend door actuator. The dual zone system has two blend door actuators, one for the driver side blend-air door and one for the passenger side blend-air door.

  1. Disconnect and isolate the negative battery cable.
  2.  
  3. Remove the instrument panel from the vehicle, as follows:
    1. Remove the left A-pillar trim.
    2.  
    3. Remove the instrument panel top cover.
    4.  
    5. Disconnect the headliner wire harness connector located at the A-pillar.
    6.  
    7. Using a trim stick C-4755 or equivalent, from the notch on the bottom, remove the left instrument panel side cover.
    8.  
    9. Remove the left cowl trim panel.
    10.  
    11. Remove the steering column.
    12.  
    13. Remove the two bolts that secure the steering column support bracket to the instrument panel.
    14.  
    15. Remove the park brake release handle actuator rod.
    16.  
    17. Disconnect the instrument panel wire harness connector located above the brake pedal from the bulkhead wire harness connector.
    18.  
    19. Remove the instrument panel drivers side bezel.
    20.  
    21. Remove the three bolts that secure the left side of the instrument panel to the dash panel.
    22.  
    23. Remove the floor console, if equipped.
    24.  
    25. Remove the air bag control module cover, if equipped.
    26.  
    27. Disconnect the air bag control module electrical connector.
    28.  
    29. Remove the two bolts that secure the instrument panel to the center of the floor panel.
    30.  
    31. Remove the right cowl trim cover.
    32.  
    33. Disconnect the two instrument panel wire harness connectors from the two body wire harness connectors located on the right side of the cowl panel.
    34.  
    35. Disconnect the antenna coaxial cable connector from the radio coaxial cable connector located on the right side of the cowl panel.
    36.  
    37. Remove the one bolt that secures the instrument panel to the HVAC housing below the glove box opening.
    38.  
    39. Using a trim stick C-4755 or equivalent, from the notch on the bottom, remove the right instrument panel side cover from the instrument panel.
    40.  
    41. Remove the right A-pillar trim.
    42.  
    43. Remove the three bolts that secure the right side instrument panel bracket to the dash panel.
    44.  
    45. Remove the four screws that secure the instrument panel to the top of the cowl panel.
    46.  
    47. Remove the two bolts that secure the instrument panel to the top of the cowl panel.
    48.  
    49. With the help of an assistant, lift the instrument panel up and off of the cowl panel and remove the instrument panel from the vehicle.
    50.  
    51. If required, remove the four plastic screws inserts from the top of the cowl panel.
    52.  

  4.  
  5. Remove the two screws (1) that secure the blend door actuator (2) to the back of the HVAC housing (3).
  6.  
  7. Remove the blend door actuator from the HVAC housing and disconnect the HVAC wire harness connector (4) from the actuator.

    Click image to see an enlarged view

    Fig. Remove the two screws (1) that secure the blend door actuator (2) to the back of the HVAC housing (3). Remove the blend door actuator from the HVAC housing and disconnect the HVAC wire harness connector (4) from the actuator

  8.  
  9. Remove the blend door actuator from the vehicle.
  10.  

To install:


NOTE
The single zone heating-A/C system is equipped with a single blend door actuator. The dual zone system has two blend door actuators, one for the driver side blend-air door and one for the passenger side blend-air door.

  1. Install the blend door actuator (1) onto the back of the HVAC housing (2). If necessary, rotate the actuator slightly to align the splines on the actuator output shaft (3) with those on the blend door lever (4).

    Click image to see an enlarged view

    Fig. Install the blend door actuator (1) onto the back of the HVAC housing (2). If necessary, rotate the actuator slightly to align the splines on the actuator output shaft (3) with those on the blend door lever (4)

  2.  
  3. Install the screws that secure the blend door actuator to the HVAC housing. Tighten the screws to 20 inch lbs. (2.2 Nm).
  4.  
  5. Connect the HVAC wire harness connector to the blend door actuator.
  6.  
  7. Install the instrument panel, as follows:
    1. If removed, install the four plastic screw inserts into the top of the cowl panel.
    2.  
    3. With the help of an assistant, position the instrument panel into the vehicle and install the right side guide pin and the left side guide hook to the sides of the cowl panel.
    4.  
    5. Install the two bolts that secure the instrument panel to the top of the cowl panel. Tighten the bolts to 9 ft. lbs. (12 Nm).
    6.  
    7. Install the four screws that secure the instrument panel to the top of the cowl panel. Tighten the screws to 20 inch lbs. (2.2 Nm).
    8.  
    9. Install the three bolts that secure the right side instrument panel bracket to the cowl panel. Tighten the bolts to 9 ft. lbs. (12 Nm).
    10.  
    11. Install the right A-pillar trim.
    12.  
    13. Install the right instrument panel side cover.
    14.  
    15. Install the one bolt that secures the instrument panel to the HVAC housing below the glove box opening. Tighten the bolt securely.
    16.  
    17. Connect the radio coaxial cable connector to the antenna coaxial cable connector located on the right side of the cowl panel.
    18.  
    19. Connect the two instrument panel wire harness connectors to the two body wire harness connectors located on the right side of the cowl panel.
    20.  
    21. Install the right cowl trim panel.
    22.  
    23. Install the two bolts that secure the instrument panel to the center of the floor panel. Tighten the bolts to 9 ft. lbs. (12 Nm).
    24.  
    25. Connect the air bag control module electrical connector.
    26.  
    27. Install the air bag control module cover, if equipped.
    28.  
    29. Install the floor console, if equipped.
    30.  
    31. Install the three bolts that secure the left side of the instrument panel to the dash panel. Tighten the bolts to 9 ft. lbs. (12 Nm).
    32.  
    33. Install the instrument panel drivers side bezel.
    34.  
    35. Install the left cowl trim panel.
    36.  
    37. Connect the instrument panel wire harness connector located above the brake pedal to the bulkhead wire harness connector.
    38.  
    39. Install the park brake release handle actuator rod.
    40.  
    41. Install the two bolts that secure the steering column support bracket to the instrument panel. Tighten the bolts to 10 ft. lbs. (14 Nm).
    42.  
    43. Install the steering column.
    44.  
    45. Install the left cowl trim cover.
    46.  
    47. Install the left instrument panel side cover.
    48.  
    49. Connect the headliner wire harness connector located at the A-pillar.
    50.  
    51. Install the instrument panel top cover.
    52.  
    53. Install the left A-pillar trim.
    54.  

  8.  
  9. Reconnect the negative battery cable.
  10.  

 
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