1. The entire dash including the headlamp switch are all illuminated. If you are good at taking things apart,you can disassemble the headlamp switch. For $15, just replace it.

2. The tailgate latch is simple. There should be 3 (4)? screws on the inside back of the gate. Remove them and the handle will pull away from the gate. There are 2 plasitic clips that you have to remove, so you can get to the pushrods. Pop the pushrods out, and then if you want, you can unbolt the catches on the sides of the gate. The entire latch/pushrod assembly will pull out. You will see that where the pushrods meet the tailgate handle, that's where the rust build up is that hampers smooth movement.


Now, here is the trick to reinstalling the pushrods. Before you initially pull the rods out, tie a string to the rod ends. Make them long enough to tie the strings off, after they come through the sides of the gate. Tie off both ends on BOTH strings..........lol.

Wire brush all the rods ends and the handle mechanism. Check the latches as well. If the pushrods should be replaced, use chain. It holds up very well. Lube everything with wheel bearing grease. I personally think it holds up better than anything. When you put it all back together, use the strings to pull the rods back up to the handle.


3. As far as mods, I'm a CTD owner.


Good luck.

 

I would just take a wire wheel on a drill to the worst of the surface rust underneath, or if you have access to some kind of media blaster, use that. There are many different spray paints out there that are "rust destroying" or "rust preventers". You could use one of those after rust removal, or use those as a primer and get some spray can undercoating to really fix it up.
On the mods - I would do a tune up first - the CAI is a good idea, but I would really look at the Fastman TB and a Hypertech Power Programmer. I love what mine did to the power. Mileage increased a little - but the power difference was really noticeable. I know you want to improve fuel economy more than power - that was my thing also. I have not been able to get more than a 1 mpg increase with my mods. I think crappy mileage is inherent with these trucks - make it run as efficiently as possible, and live with it.

 

Shocha_62, I contacted Geno's tech line and they told me their products will fit my 1500, so I placed the order today.

steve00ram360 & Racinfan83, I already started cleaning up the rust; it really wasn't as bad as I originally thought. I will primer and undercoat when I am done cleaning to protect it. As far as mods go, I thing I will do the CAI and possibly the hypertech since it appears I have the death flash. Where is the best place to get the hypertech? It already has the 180 tstat and I think I will hold off on the TB and exhaust until I know the truck is a keeper. I know this truck will never be even a decent fuel milage vehicle, but I want to make sure I am getting what I can.

DieselDemon, this is a bad way to start a sentence but....the dealer says "The headlamp background light bulb can't be purchased seperately from the switch"! What the #$%*? The dealer wants $66.75 for the switch and dodgeparts.com wants $52.xx. I can't believe how stupid that is, like they didn't expect the bulb to ever burn out! To remove the bulb all I had to do was remove the switch and turn the bulb 1/8 turn. Does anyone know where to get obscure parts like that? Oh, I already fixed the tailgate, a lot of lube and a little tweaking.

Thanks for all the replies, I think in the future I will try to keep topics in seperate posts!

 

The light bulb is an awkward type. It might be at an electronics, or Radio Shack type store. The headlamp switch is pretty intricate. I suggest a junk yard? Or Autozone, Pep Boys type stores.

Good luck.

 

If your looking for no-cost help with the death-flash problem look around the forum for one of the hundred other topics that explain how to do the Crankshaft Position Sensor Mod. basically you remove two bolts, disconnect the sensor from the wiring harness and remove it. Then you elongate the mounting holse with a round metal file and remount the sensor. Took me all of 15 minutes to do and really helped my truck. It may not solve it all, but it is a great no-cost start.

 

Here is a link to a site where you can get a Hypertech for $281.95 - free shipping. (Thats where I got mine) http://www.truckaddons.com/Catalog/s...t;KW=hypertech