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-   -   Driver's side seat foam problems? I have the cure! (http://www.ramforumz.com/showthread.php?t=39383)

TheAverageJoe 06-02-2009 04:52 PM

Driver's side seat foam problems? I have the cure!
 
For any of you driving a 2003, 2004, 2005, 2006, 2007, or 2008 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.

http://i6.photobucket.com/albums/y24.../truckseat.jpg

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.*****************/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.

http://216.77.188.54/coDataImages/p/...seat-frame.jpg

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.

http://216.77.188.54/coDataImages/p/...led--filed.jpg

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 don’t 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, doesn’t include all the layers. I’d get busy and forget to take pics.

http://216.77.188.54/coDataImages/p/...on-springs.jpg

All the tears I’ve seen, start along the bottom or the back corner, just like mine. I also noticed mine had a big air pocket where the mold wasn’t filled correctly. That’s exactly where the tear started.


http://216.77.188.54/coDataImages/p/...ng-to-tear.jpg

http://216.77.188.54/coDataImages/p/...oam-damage.jpg

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

http://216.77.188.54/coDataImages/p/...oam-repair.jpg

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 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.)

http://216.77.188.54/coDataImages/p/...oam-panels.jpg

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

http://216.77.188.54/coDataImages/p/...poofy-seat.jpg

I give all the credit to "cntryby" of the Dodge Diesel Cummins Forum.
http://www.*****************/

300 Addict 06-02-2009 05:29 PM

Wow man! That is an excellent writeup with great tips! Thanks for sharing it here with us!

kineticenrage 06-02-2009 06:43 PM

very nice write up.:smiley_thumbs_up:

Sparky 06-02-2009 11:55 PM

I noticed that my seat is starting to take some abuse, thanks for the info I'm sure I'll use it.

08quadram 06-03-2009 12:02 AM

Very nice. I was just thinking the other day when i got out, that the edge of the seats were probably not going to last long. They take a lot of abuse it would seem.

TheAverageJoe 06-03-2009 10:07 AM

Quote:

Originally Posted by 08quadram (Post 62073)
Very nice. I was just thinking the other day when i got out, that the edge of the seats were probably not going to last long. They take a lot of abuse it would seem.

It's an engineering flaw.
The 2009 models have been corrected of it, or so I'm told.

It's also rumored that the foam cushion supplier provided a faulty/substandard product.
I know mine was formed incorrectly.

I didn't buy my RAM new, but those who have, and caught it in time, said theirs was replaced under warranty by the dealership...sometimes under protest.
So if you have this problem within your warranty time/mileage, you may have to lobby with the service/parts manager(s).

As far as I can tell this is a cheap/easy/quick fix that will last the duration of the truck. Of course, in anyone else's situation, it may depend on the use/abuse you give your truck and the skill level in which you have applied said fix.

Good luck to everyone who had to follow this thread to fix where Dodge fell short.

chithead 06-03-2009 12:07 PM

Dang, that's an awesome write-up! Definitely don't want that chewed up driver's side seat like you always see with some of the older trucks. I will have to keep an eye on mine and see if made any changes on the 08 models.

CajunDodge 06-03-2009 01:14 PM

Funny you should write that, because I am noticing where mine is starting to show signs of "weakness" also, so I will definitely have to remember this, thank you for sharing. Very helpful. I just try not to slide out of the seat and actually climb out, make it last as long as possible.

TheAverageJoe 06-03-2009 01:59 PM

Quote:

Originally Posted by CajunDodge (Post 62143)
Funny you should write that, because I am noticing where mine is starting to show signs of "weakness" also, so I will definitely have to remember this, thank you for sharing. Very helpful. I just try not to slide out of the seat and actually climb out, make it last as long as possible.

Yeah, I can only figure that the previous owner of my truck was a short fat guy (not that there's anything wrong with that). It looks as if he just swiveled around in the seat and slid out.
Right after buying my Ram back in September, I put nerf bars on it just for that purpose. Not to mention the kids couldn't get in and out. I now, make a conscience effort not to slide or scoot in or out of my seat.

jamesb0 06-03-2009 09:22 PM

Thanks I was just thinking about that the other day when climbing in


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