Heater Plenum Issue

[brucejohnson]

Well, I hit a road block. Have removed all the nuts/bolts mentioned in the threads however I cannot get the dash to lift off. It moves up and down slightly on the driver side but almost nothing on the passenger side. And I did remove the one hidden nut. I have a Laramie and none of the videos show my exact dash but am I missing something? The steering column is down and I got the two hidden bolts behind that mounting plate. I removed the two on the floor beneath the ash tray/cup holder. The six below the window. I did not remove any of the screws holding the cup holder and the plastic facia above the floor bolts. Did not want to put too much force on it until I checked on suggestions. I cannot see anything keeping this dash from moving up but it's hard to see anything back there. Maybe I should take those out too? But the videos did not show that. Any thoughts appreciated.

Go to this link for a 2003 Dodge Ram FSM download. Page 23-50. Maybe that will be more detailed than a video.
http://www.wedophones.com/Manuals/Dodge/Dodge 2003 RAM Manual.pdf

 

[Mike Wenrich]

Went thru the manual description which was not quite as thorough as the videos and I have removed all of the screws and bolts depicted. The manual indicates removal of the cup holder and ash tray but it appears the reason is service them and not to remove the dash. Maybe if I get a helper and we both tug on the dash it will break free but right now I have put a lot of force under the dash on the passenger side and I'm getting very little movement. I was thinking I should look under the hood but there is no reference for that re: the dash removal. Appears it's only for the evap box once you get the dash out. The manual seems to stop short of mentioning things like steering column removal, etc as one might expect. Very good info once the dash is out of the way for replacing the blend doors. I might keep searching for videos on this or just look again at the ones posted by Blend Door.

 

[bcbender]

I had a Laramie dual zone also, I'll go back and see if I can remember anything, stupid question, you disconnected the electrical connectors on both ends right? And removed the end cap covers to confirm there were nothing there, I think I had the kick panels off also to make disconnection things easier, I also vaguely remember having to mess with the parking brake assy.. I have a FSM, I'll look at it later and see if anything jogs the memory, I know once it's loose, its awkward to move around, definitely a 2 man job if you can swing it, but you should be able to lift is a few cm on either end when its ready. Bolts along the top, bottom center, and ends was my memory, as well as a few around the column (and the column).

 

[bcbender]

Here is the FSM I have. shows a screw in the center lower of the HVAC unit, below the glove box. Also on the Pass side, they are showing what looks like a bolt going in from the side (footwell area) but its not called out. (red arrows). Id take another look once over for hidden bolts etc, wiring pigtails and christmas trees under tension can keep it from moving also. Manual said to pull both A pillar garnish, I assume that was to get to the bolts but may also limit movement.
\\

View attachment 139710

 

[Mike Wenrich]

Yes on disconnecting the electrical and the parking brake. The FSM pictures above are what I reviewed in the link you sent and I have done all of those except removing the cup holder and ash tray. The screw in FIg 13 and screw?? in 14 with the red arrow I don't believe have been removed. I will look at those today. They might be why I am not getting much movement on the passenger side.

 

[bcbender]

The screw in FIg 13 and screw?? in 14 with the red arrow I don't believe have been removed.

It may be that simple,... I don't remember as its been many years since I did mine but I don't remember fighting it though so another once over and you should be good.

 

[Mike Wenrich]

Do you recall which side you lifted first? I can get help for that part but I recall from a video you have to lift up on the passenger side to "unhook" and then pull away on the driver side at the same time.

 

[bcbender]

I do not, but there are a couple alignment pins in there, I do not recall the orientation though

 

[Mike Wenrich]

I found that I had not removed the one bolt below the glove box so that help free it up somewhat. It also appears I need to disconnect the airbag electrical under the cup holder. may have to remove the holder to do that if I cannot reach behind. Went over a lot of videos on this and a couple that removed the steering column. Somehow I created a new problem for myself when I removed the cover off the column by the tilt lever and the cable came off. So now I can't adjust the tilt. I believe I see where it goes but may need a third hand to squeeze/draw it back in place. One dang thing after another. But first I need to get this dash off. Still doesn't move freely but I will see if I can get a friend to help jiggle it loose.

 

[Mike Wenrich]

That tilt cable I mentioned is worse than I thought. There is a white plastic retainer further down the column that has secures a toothed ring and it's broken. When I removed the trim from the column it fell out. Have no idea how it was broken but the tilt worked before I started this so somehow I did it. I might be able to clamp it into place but it's what activates the tilt when you push on the lever. So what I thought was a problem at the lever is further down. I'm going to look at the manual to see what it might take to replace it but at this point it appears I might have to remove the column.

On the good news side I can now pull back the dash on the passenger side.

Also, below the column is a wire harness that that goes from left to right behind the dash and I dont see it in any videos. I believe it might have been intended to be above the column and then would come out with the dash. Cannot see where it plugs in on either side and might have to remove the instrument cluster or if I remove the column I can reroute it then. And all I wanted to do was repair the blend doors. SHEEESH!

 

[User113]

Yes, as I recall, you do have to remove the cup holder/ash tray unit. And while your back there, I think you also have to disconnect the air bag control unit. The wire harness below the column comes with the dash. The dash lifts up a tiny bit and then slides back off of a shelf-like thing that the steering wheel bolts to.

 

[User113]

This is what it looks like under the dash. I took my front seats and steering column out before removing the dash as I was planning to replace the carpet and seat covers since I was already in that far. I did not remove the steering wheel. Note that there is a black rubber extension thing on the tilt lever that just sort of pulls off the shaft leaving a small stub (1/2"x3/8"). Also, in the dash removal process step 5 the manual specifically refers you to section 19 for the steering column removal procedures. Note also there are 4 bolts that hold the steering column to the aluminum shelf, two that are hard to see and two that are impossible to see, near the round tube that the dash is built upon.

 

[User113]

You have to have the column down on the seat before the dash will budge.

 

[Mike Wenrich]

Thanks all and I have the column down. I think I wish I had the kind of access as in the picture. My arthritic neck would appreciate that. The picture also helps me know that although some do not have to pull the cup holder assembly I think, as mentioned above, I will need to. I've adjusted my git er done estimate from two to three days to two to three weeks. It's inside the shop but just barely with the other two vehicles in there end to end and it's about to start raining heavy. Wanted to get this done before then. Oh well.

 

[User113]

BTW, here is what the tilt shaft looks like once you remove the "lever"

 

[bcbender]

Wanted to get this done before then. Oh well.

Yeah.. Its one of those two steps fwd one back sometimes... The first time is the hardest, the second will go much smoother.

 

[Mike Wenrich]

Houston...The plenum is out. Now for the rebuild.

 

[bcbender]

Time for a celebratory beverage.....

 

[Topzide]

@Mike Wenrich, I hope you were taking notes for the next one.
Glad you didn't let you win. The next one will go so smooth that you'll be standing there wondering why the first one didn't work out as well. Take the time to inspect everything and maybe do a write up to help another looking to do this. Everything has a bit of a learning curve! Job well done and your a great neighbor to undertake the challenge in you're own, let alone another's!

 

[Mike Wenrich]

Thank you for the positive comments. I need that reenforcement about now while I'm licking my wounds. Another neighbor who came by to help me lift the dash also crawled up in the engine compartment to remove one more nut holding the plenum that was behind the coolant reservoir. Did I mention he is younger??? He had removed the dash off of his 2015 Hemi to replace a leaking heater core. His has a center console that had to be removed of course and that also lead to removing the front seat. Made access to the dash much easier but what I am learning is that even on our Gen 3 trucks the removal is not all the same. So if I wrote something up it would be specific to a diesel. The Hemi has a different arrangement under the hood so I will be experiencing that next.

I'm also thinking I will buy the new MOPAR heater core if it's still available. I don't want to do this again on my truck no matter HOW MUCH I KNOW! The fellow who helped me has about the same mileage on the 2015 and his failed. Mine of course is much older so maybe the seals around the pipes could go bad even if the core is good. I would think the evaporator would be OK. So this saga will continue for awhile. Really, really appreciate the help on this forum. I don't mind the challenge and actually enjoy working/solving problems on vehicles. It's my old body that isn't liking it. Been going thru the Ibuprofin!