Air Dam removal on 06

[navyjoe]

I'm replacing my air dam on my 06 3500. I removed 3 of the 5 fasterners. Each end one and the one in the center. The remaining two are under the tow hook area. So far I cant get a socket to the bolt. I was wondering if removing the fog lights would allow access to them. Anyone out there already been there and figured out a good way?

 

[Crunch]

I'm replacing my air dam on my 06 3500. I removed 3 of the 5 fasterners. Each end one and the one in the center. The remaining two are under the tow hook area. So far I cant get a socket to the bolt. I was wondering if removing the fog lights would allow access to them. Anyone out there already been there and figured out a good way?

I replaced the air dam on my '03 about 6 weeks ago. In reading the '03 Dodge Repair Manual I saw that you should use trim stick to pop out the bezels where the fog lights go, so I did, and it made it easier to get a ratchet in there. I don't have fog lights, so I didn't read the section about removing them. The removal and installation was pretty straight forward, but there were two issues that were kind of aggravating. One, the carrot fasteners were a pain to snap in. Maybe there is a tool for that, but I used my hands and it was tough to get them positioned correctly. Second, those bolts, at least for the '03 are barely long enough to reach the fastener. I actually have one bolt, in the passenger outside position that I couldn't get to catch. I ended up running a longer, thinner bolt up from the bottom and using a wing not to hold it in place until I could spend more time on it. Funny thing is, I haven't lost too much sleep over it and haven't gotten around to putting the original bolt back in yet. I think what I will end up doing is putting a 9/16" socket on the lift of a floor jack, then positioning it underneath the air dam to force it up that last 1/32" - 1/16" and putting enough pressure on it to get the bolt to catch.

 

[navyjoe]

I replaced the air dam on my '03 about 6 weeks ago. In reading the '03 Dodge Repair Manual I saw that you should use trim stick to pop out the bezels where the fog lights go, so I did, and it made it easier to get a ratchet in there. I don't have fog lights, so I didn't read the section about removing them. The removal and installation was pretty straight forward, but there were two issues that were kind of aggravating. One, the carrot fasteners were a pain to snap in. Maybe there is a tool for that, but I used my hands and it was tough to get them positioned correctly. Second, those bolts, at least for the '03 are barely long enough to reach the fastener. I actually have one bolt, in the passenger outside position that I couldn't get to catch. I ended up running a longer, thinner bolt up from the bottom and using a wing not to hold it in place until I could spend more time on it. Funny thing is, I haven't lost too much sleep over it and haven't gotten around to putting the original bolt back in yet. I think what I will end up doing is putting a 9/16" socket on the lift of a floor jack, then positioning it underneath the air dam to force it up that last 1/32" - 1/16" and putting enough pressure on it to get the bolt to catch.

Thanks for that!! It was looking to me like that might be the only way. Now all I have to do is figure out how to get that bezel out. I do have fog lights and so far I cant tell if the bezel is attached to the light or what. Now that I know that is the correct way I will get in there with an inspection mirror and give it a good look. Ref those fasteners, mine are pretty rusted, I had thought about using stainless along with a fender washer. Thanks again

 

[Crunch]

Thanks for that!! It was looking to me like that might be the only way. Now all I have to do is figure out how to get that bezel out. I do have fog lights and so far I cant tell if the bezel is attached to the light or what. Now that I know that is the correct way I will get in there with an inspection mirror and give it a good look. Ref those fasteners, mine are pretty rusted, I had thought about using stainless along with a fender washer. Thanks again

I think the bezels on my non-fog light bumper have tabs in back that compress when you replace the bezel and pop back out into a keyed notch. I didn't have trim sticks at the time, so I used a slotted screwdriver. Here's the removal instructions for the '03 models, from the Dodge Repair Manual. I don't know if the way they attach to the bumper has changed:

FOG LAMP
REMOVAL
NOTE: The fog lamps are serviced from the rearward side of the front bumper.
(1) Disconnect and isolate the battery negative cable.
(2) Disengage fog lamp harness connector.
(3) Remove the bolts attaching the fog lamp to the bumper (Fig. 6).
(4) Separate fog lamp from bumper.​

 

[navyjoe]

Crunch,
Thanks so much for the directions. Weather permitting I'll give that a try tomorrow. It sure will be nice to get that new air dam on.
Thanks again, Joe

 

[navyjoe]

Well about 3 weeks later I was able to get back to this job! Yes removing the fog lamp bezel was all that was required. It was easy using a 1/4 inch flat screwdriver and a gentle pry on the long side of the bezel (from the outside of the bumper). Just a small added note here. The bezel was greatly oxidized so I borrowed one of my wife's "Mr Clean" magic sponge and vola, it removed all of the residue! Touched up with armor-all and its like new.

Another suggestion. Throw all of that old RUSTED hardware away, go to Lowes and buy stainless 1/4"-20 x 1" hex bolts, stainless Nylon insert lock nuts, and stainless fender washers to use on the plastic surfaces. If you keep the truck, you'll be back and it will be a lot easier the next time. If you don't keep it the next person will say what a great guy you were