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Driver's side seat foam problems? I have the cure!

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Old 06-04-2009, 04:11 PM
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Default Driver's side seat foam problems? I have the cure!

For any of you driving a 3rd Gen. Dodge Ram 1500, 2500, or 3500 and have had your driver's side seat foam fail you. I have the cure. If you have a Lowe's and a Hobby Lobby near you, it'll only cost you around $13.00 and a little skill rather than $152.00 for new foam from the dealer. Not to mention, that new foam is going to fail you just like the old one.

Here's what you'll find when you peal back the upholstery.

Click the image to open in full size.

While searching the web for an after market part or easy inexpensive fix, I came across this link in a Dodge Cummins Diesel forum.

http://www.cumminsforum.com/forum/6-...98-seat-2.html

The frames of theses seats have a boxed frame that joins on the top of the frame and leaves an exposed sheet metal edge. This edge in addition to the sliding motion getting in and out of the trucks is tearing our foam.

Seat frame; notice the metal edge, but also notice the wires held by springs, more of that later.

Click the image to open in full size.

The weld at the very back had some burrs, they may have started the tearing of the foam. I took a ball peen hammer, rolled the edge of the metal down, and then filed the burrs and any protrusion I thought might tear the foam.

Click the image to open in full size.

Before reinstalling the foam, I glued some burlap over the frame. (Sorry no pic of that.)
(Burlap is approx. $2.99 a yard at Hobby Lobby. 1 yd will do 2 seats.)

For the wires with the springs, this is where the pad needs to go, directly on these springs. The springs are what provide the cushion when hitting bumps and stuff. The foam design intends to distribute the weight with out fatiguing your butt. (I donít think they quite got that part down yet.)

I used 2 inches of foam, 1 inch of 20 lb & 1 inch of 40 lb. I also place a piece of vinyl between the foam and the springs to prevent the springs / wire from tearing the foam. 20lb goes on top, it's softer.
(Hobby Lobby carries a 14"x14"x2" piece of foam that works perfectly. No cutting necessary.)
(Also, be sure to glue a piece of burlap to the bottom of the 2" foam. If you don't it'll start snowing under your seat from deterioration. The burlap strengthens it too.)

Pic just shows where it goes, doesnít include all the layers. Iíd get busy and forget to take pics.

Click the image to open in full size.

All the tears Iíve seen, start along the bottom or the back corner, just like mine. I also noticed mine had a big air pocket where the mold wasnít filled correctly. Thatís exactly where the tear started.


Click the image to open in full size.

Click the image to open in full size.

I filled all the torn gaps with glue, (Weldwood landau top adhesive.) and pressed it back together. Then I glued several layers of thin burlap to the foam.
(Lowe's carries a spray on 3M water based adhesive...works great.)
http://www.shop3m.com/62497749309.html

Click the image to open in full size.

The center of the seat will rise with the pad added between the frame and factory foam, while the sides stay the same height, this takes the pressure off the hips & or butt.


The edges at the frame are fairly thin because the factory cushion is molded to fit around the frame. To help offset these deficiencies, I added a Ĺ inch of foam to the outer and back panels.
(The 1" green foam at Hobby Lobby works just fine. You sit a little higher than you used to, but it'll settle in time.)

Click the image to open in full size.

Pulled all back together, the seat has a slight ďpoofyĒ look, but itís a heck of a lot more comfortable, and should last much longer too.
(Mine looks like a pillow top mattress...and I love it.)

Click the image to open in full size.

I give all the credit to "cntryby" of the Dodge Diesel Cummins Forum.
http://www.cumminsforum.com/
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  #2  
Old 06-04-2009, 04:23 PM
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Great write up, Joe. Your post has also been copied to the FAQ section as a DIY. Thank you...
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  #3  
Old 06-04-2009, 07:48 PM
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Thanks for the write-up. I know it's only a matter of time before I have to do exactly what you have shown. No matter how careful I am getting in and out, I know what's happening under that nice gray fabric.
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Old 06-04-2009, 07:56 PM
Off_Road_Teacher Off_Road_Teacher is offline
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Good write up, I am glad it got posted to the FAQ section. I was considering eating less as a solution to my seat problem but I like your solution much better .
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  #5  
Old 06-04-2009, 07:57 PM
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Thank you for the how-to. How long do the seats generally last before they wear out like that?
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Old 06-04-2009, 08:02 PM
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im sure this may have been discussed but will warranty cover this if you are still in your 3 year/36k miles?
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Old 06-04-2009, 08:25 PM
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Very Good write up. This is the kinda stuff I need to know.
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  #8  
Old 06-04-2009, 08:39 PM
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Nice! Had to do this with my mustang seats. The sides were wiped.
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Old 06-04-2009, 09:12 PM
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nice write up lots of info great idea will need this soon i fear as i think the prev owner was a lil hefty so maybe sooner than later thanx....
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  #10  
Old 06-04-2009, 09:24 PM
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good write up i noticed my foam adge was looking a little low or flat and could always go with a more comfortable seat and how long did this take you to complete just for a time window
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Old 06-04-2009, 09:46 PM
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Quote:
Originally Posted by Off_Road_Teacher View Post
Good write up, I am glad it got posted to the FAQ section. I was considering eating less as a solution to my seat problem but I like your solution much better .
yep, I was in the same boat but we're good to go now! haha. good write-up!
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  #12  
Old 06-08-2009, 07:52 AM
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I did the passenger side seat for good measure.
Although there wasn't anything wrong with the seat, I went ahead and, shall we say, performed preventative maintanance on it.

My original post on this topic was from another forum by another author.
The following post is from my truck with my pictures.
Enjoy.

Click the image to open in full size.
Amazingly enough, it was in perfect shape. But I just bought this babee in September of 2008 and I want it to last me through the long haul. So I went to work on it just as I'd done the driver's side.

Important Note:
The initial post and pictures are from cntryby of the Dodge Diesel Forum. They are his pictures and his truck. The pictures to follow are from my project on my truck.

The tools you'll need:

Click the image to open in full size.
Ball Peen Hammer and Phillips Head Screw Driver.
I don't have heated or motorized seats so the upholstery removal was quite easy.
If you have either, it may involve more screws or a bit more intense and detailed parts removal.

The Materials:


Click the image to open in full size.
3M Super 77 (washes off your hands with soap & water)

Click the image to open in full size.
1"x22"x22" Green Foam from Hobby Lobby (approx. $5.99)

Click the image to open in full size.
1"x14"x14" White Foam from Hobby Lobby (approx. $3.99)
I used 2" on my driver's side and I like it better.
But, the store was out and i settled for 1".

Click the image to open in full size.
1 - Half Yard of Burlap from Hobby Lobby (approx. $2.99)
If you cut your pieces right, you can use 1/2 yd for both seats.
It all depends on the condition of the foam. Get 1 yrd for good measure.

Removal of the upholstery is pretty easy, except for the front hook. The nice thing about this is Dodge no longer uses the old hog rings. The plastic hooks are sewn right in. It can get tricky. Push down on the seat cushion for slack in the material and the hooks won't give you much problem.
Here's what you'll have after you unhook the seat cover and remove the cushion.

Click the image to open in full size.
Take your ball peen hammer and knock down any slag, sharp metal edges and so on.
You can glue burlap over the edges if you'd like.
I didn't on either seat, but it can't hurt.

Click the image to open in full size.

Glue the burlap to the bottom of the foam to prevent snowing under the seat as age and wear sets in.

Click the image to open in full size.

Although nothing was wrong with this cushion, I went in and reinforced it with extra burlap for good measure.

Click the image to open in full size.

Use the 1" green Foam on the top of the cushion.
I'm not a professional at this as you can tell.
Thank goodness the seat cover will help the foam conform to the right shap.
Also, if you can find 1/2" foam, it'll probably do you better.

Click the image to open in full size.

The knuckle buster of it all is getting the cushion back in position.
There's a tab that has to be pulled over the back part of the seat.
Once you've got the seat in position and aligned with the recliner adjustment arm, you're ready to take it home.
BE SURE to match up and attach the velcro parts of the seat cover to keep definition in the seat.

Click the image to open in full size.

Viola! Ready for the road.
The passenger side seat isn't as POOFY as my driver's side, because I only used the 1" foam under the base of the seat. If you use the 2", be prepared to ride in luxury
and a little higher than usual until the seat settles in. My passenger seat won't be used as much as some others, so I'm not concerned with the difference. It just looked really flat along side my newly repaired driver's side. I had to attempt to make them match....and they do to the unknowing rider.

Hope you guys like and approve this thread.
I hope you get your seats back in shape as easily as I did.
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  #13  
Old 06-08-2009, 07:42 PM
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I had mine replaced under warenty.. in a nut shell the foam goes away and the metal frame wears out the fabric and you get a pain the *** cheek...verry commom issue with the Ram... In canada 3 years or 60,000 km full warenty on the 06, if your 1 km over,, your SOL....
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  #14  
Old 08-02-2009, 01:16 PM
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Great thread. I did my seat last night. It's fairly straightforward as this post shows. My main issue was with power seats there isn't much room to get my meat hooks (hands) in there. Removing the front clip was an exercise in frustration. I finally modified a door panel removal tool to hook the top of the clip and pull it off. I got a 1 1/2" foam mattress pad topper from Walmart for $12, as well as the burlap. And then before clipping the cover back on I sat in it to test, and added one more layer of foam.
I now have a proper throne for my Ram!
Thanks for the photos and inspiration to "get r done".

o.r.
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  #15  
Old 09-14-2009, 04:07 PM
ebiniser ebiniser is offline
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hey great info, thanks for posting it. i have a dakota which had the same problem. i called all over and apparently they stopped making the cushion replacement for my truck. you inspired me to tackle it and it was actually surprisingly easy to fix. i'm sitting level on a comfortable seat again for under $30. thanks again!!!!!
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  #16  
Old 11-02-2010, 06:20 PM
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Quote:
Originally Posted by TheAverageJoe View Post
I did the passenger side seat for good measure.
Although there wasn't anything wrong with the seat, I went ahead and, shall we say, performed preventative maintanance on it.

My original post on this topic was from another forum by another author.
The following post is from my truck with my pictures.
Enjoy.

Click the image to open in full size.
Amazingly enough, it was in perfect shape. But I just bought this babee in September of 2008 and I want it to last me through the long haul. So I went to work on it just as I'd done the driver's side.

Important Note:
The initial post and pictures are from cntryby of the Dodge Diesel Forum. They are his pictures and his truck. The pictures to follow are from my project on my truck.

The tools you'll need:

Click the image to open in full size.
Ball Peen Hammer and Phillips Head Screw Driver.
I don't have heated or motorized seats so the upholstery removal was quite easy.
If you have either, it may involve more screws or a bit more intense and detailed parts removal.

The Materials:


Click the image to open in full size.
3M Super 77 (washes off your hands with soap & water)

Click the image to open in full size.
1"x22"x22" Green Foam from Hobby Lobby (approx. $5.99)

Click the image to open in full size.
1"x14"x14" White Foam from Hobby Lobby (approx. $3.99)
I used 2" on my driver's side and I like it better.
But, the store was out and i settled for 1".

Click the image to open in full size.
1 - Half Yard of Burlap from Hobby Lobby (approx. $2.99)
If you cut your pieces right, you can use 1/2 yd for both seats.
It all depends on the condition of the foam. Get 1 yrd for good measure.

Removal of the upholstery is pretty easy, except for the front hook. The nice thing about this is Dodge no longer uses the old hog rings. The plastic hooks are sewn right in. It can get tricky. Push down on the seat cushion for slack in the material and the hooks won't give you much problem.
Here's what you'll have after you unhook the seat cover and remove the cushion.

Click the image to open in full size.
Take your ball peen hammer and knock down any slag, sharp metal edges and so on.
You can glue burlap over the edges if you'd like.
I didn't on either seat, but it can't hurt.

Click the image to open in full size.

Glue the burlap to the bottom of the foam to prevent snowing under the seat as age and wear sets in.

Click the image to open in full size.

Although nothing was wrong with this cushion, I went in and reinforced it with extra burlap for good measure.

Click the image to open in full size.

Use the 1" green Foam on the top of the cushion.
I'm not a professional at this as you can tell.
Thank goodness the seat cover will help the foam conform to the right shap.
Also, if you can find 1/2" foam, it'll probably do you better.

Click the image to open in full size.

The knuckle buster of it all is getting the cushion back in position.
There's a tab that has to be pulled over the back part of the seat.
Once you've got the seat in position and aligned with the recliner adjustment arm, you're ready to take it home.
BE SURE to match up and attach the velcro parts of the seat cover to keep definition in the seat.

Click the image to open in full size.

Viola! Ready for the road.
The passenger side seat isn't as POOFY as my driver's side, because I only used the 1" foam under the base of the seat. If you use the 2", be prepared to ride in luxury
and a little higher than usual until the seat settles in. My passenger seat won't be used as much as some others, so I'm not concerned with the difference. It just looked really flat along side my newly repaired driver's side. I had to attempt to make them match....and they do to the unknowing rider.

Hope you guys like and approve this thread.
I hope you get your seats back in shape as easily as I did.
Your post was very helpfull, I have a 2004 ram 1500 that the seat fome had broken down on. the dealer wanted 800.00 to fix it 150.00 for foam 500.00 for a new cover, mine had a quarter size hole in it, and 150.00 for labor. I did it just like you said to and it is great, the only difference is mine had a hole in the cover. my hobby is machine embroidery so I took the cover glued a small piece of fabric over the whole and then embriodered a dodge ram logo right over the hole, it turned out perfect so I did one on the other side of the seat so it wouldn't look like a repair, the whole thing 25.00 thanks for the help.
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  #17  
Old 11-03-2010, 07:47 AM
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This is a bit of an old thread but a good and informative none the less. I need to pull my seats apart now that i think of it.
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  #18  
Old 11-04-2010, 09:05 AM
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Quote:
Originally Posted by all of 75 View Post
Thank you for the how-to. How long do the seats generally last before they wear out like that?
My Ram is a 2006. I bought it in Sept of 2008. I posted this about a week after fixing my driver's seat (June 4, 2009).
So, I'd say about 2 years on average. I guess it would depend on the usage and seating habits of the truck owner.

I'm happy to report as of November 4, 2010, my seats are still seating me and my passengers comfortably.
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Old 11-04-2010, 09:26 AM
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TheAverageJoe TheAverageJoe is offline
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Quote:
Originally Posted by weedahoe View Post
This is a bit of an old thread but a good and informative none the less. I need to pull my seats apart now that I think of it.
It wouldn't have been a "bit old" if you had gotten to it sooner.Click the image to open in full size.
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Old 11-04-2010, 09:43 AM
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Well my list of things to do is extensively long and detailed. So the term "eventually" is how I define when my things get done.
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Old 11-04-2010, 09:43 AM
 
 
 
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