Body and Frame: Service and Repair
Body
Special Tool(s)
Special Tool(s):
Body Off Mounting Locations
Body Off Mounting Locations:
1. NOTE: A 2-post hoist must be used to lift the body from the chassis.
Open the tailgate.
2. With the vehicle in NEUTRAL, position it on a hoist.
3. Disconnect the battery cables.
4. Remove the nut and separate the leads from the battery positive cable and position aside.
- To install, tighten to 9 Nm (80 lb-in).
5. Remove the nut and the ground wire from the right fender.
- To install, tighten to 12 Nm (106 lb-in).
6. Remove the ground wire from the clip on the battery tray.
7. Recover the refrigerant.
8. Drain the engine coolant.
9. Remove the front bumper cover.
10. Remove the rear bumper cover.
11. Raise the vehicle.
12. Remove the running boards, if equipped.
13. Release the parking brake tension and disconnect the parking brake cable at the intermediate connection.
14. Remove the parking brake cable-to-frame bolt.
- To install, tighten to 15 Nm (133 lb-in).
15. Disconnect the automatic transmission cable from the manual valve and retainer clip.
16. Disconnect the steering gear electrical connector and remove the connector from the frame.
17. Remove the retaining ring and disconnect the lower radiator hose from the radiator.
18. Remove the 4 pushpins (2 each side) from the frame-to-radiator air deflector.
19. Remove the safety clips from the transmission cooler lines.
20. Using the Transmission Cooler Lines Disconnect Tool, disconnect the transmission cooler lines from the auxiliary cooler.
21. Remove the retainer from the splash shield on the front LH frame.
22. Remove the retainer from the splash shield on the front RH frame.
23. Remove the 3 retainers from the splash shield on the lower condenser.
24. Rotate the fan shroud upward to open it.
25. If equipped, disconnect the air hose from the air suspension compressor.
26. Remove the bolt and the ground wire from the body.
NOTE: Right front body bolt shown, all other bolts similar.
27. NOTE: Front End Sheet Metal (FESM) body support bolt shown, all other bolts similar.
Remove the 6 body mount bolts and 2 front end sheet metal body support bolts.
- Discard the body bolts.
- To install, tighten the FESM body mount No. 2 and No. 3 to 80 Nm (59 lb-ft).
- To install, tighten No. 1 body mount to 103 Nm (76 lb-ft).
28. Lower the vehicle and chock the wheels to prevent the chassis from moving.
29. Remove the 2 bolt covers from the rear storage compartment.
30. Remove the 2 rear body mount nuts from the rear storage compartment.
- Discard the nuts.
- To install, tighten to 80 Nm (59 lb-ft).
31. NOTICE: The fuel tank filler pipe may become caught on the inside of the fender when lifting the vehicle. Make sure the fuel tank filler pipe is not binding when lifting the vehicle, or damage may occur.
Remove the 3 screws from the fuel tank filler pipe.
32. Remove the engine cover, if equipped.
33. Remove the air cleaner intake pipe.
34. Disconnect the fuel bundle wiring harness connector and remove from the splash shield.
35. Disconnect the left ABS wheel speed sensor connector.
36. Disconnect the master cylinder electrical connector.
37. Disconnect the brake booster electrical connector.
38. Disconnect the canister purge valve electrical connector and remove it from the bracket, position the canister aside.
39. Disconnect the electrical connector and the 2 hoses from the degas bottle/air cleaner module.
- Unclip the RH hose from the retainers on the side of the degas bottle/air cleaner module.
40. Remove the 2 bolts from the degas bottle/air cleaner module and remove the module.
41. Remove the 2 master cylinder nuts (1 each side) from the brake booster and secure the master cylinder to the engine.
42. Disconnect the brake booster vacuum supply hose and secure the hose to the engine.
43. NOTE: Make sure that the vehicle wheels are straight.
Place the vehicle in PARK and remove the key.
44. NOTICE: Do not allow the steering column shaft to rotate while the intermediate shaft is disconnected or damage to the clockspring may result. If there is evidence that the shaft has rotated, the clockspring must be removed and recentered. For additional information, refer to Air Bag Systems.
Remove the steering shaft bolt at the joint between the intermediate and lower shafts and separate the shafts.
- To install, refer to 48 Nm (35 lb-ft).
45. Disconnect the power steering reservoir-to-power steering pump hose.
46. Disconnect the power steering pump-to-power steering cooler line quick connect.
- Disconnect the hose from the retainer on the fan shroud.
47. Disconnect the ABS module connector.
48. Disconnect the upper radiator hose from the engine.
49. Remove the nut from the condenser-to-manifold and tube assembly and position aside.
- Install new O-rings before installing the manifold and tube assembly.
- To install, tighten to 25 Nm (18 lb-ft).
50. Remove the nut from the accumulator-to-manifold and tube assembly and position aside.
- Install new O-rings before installing the manifold and tube assembly.
- To install, tighten to 25 Nm (18 lb-ft).
51. Remove the nut and disconnect the electrical connector from the generator wiring harness and remove from the retainer.
52. Disconnect the electrical connector from the electrical thermal connector on the front of the engine.
53. NOTE: RH shown, LH similar.
Remove the bolts and the Camshaft Position (CMP) sensors (1 each side). Discard the O-ring seals.
- To install, tighten to 10 Nm (89 lb-in).
- Lubricate the O-ring seal with clean engine oil prior to installation.
54. If equipped, disconnect the right vacuum lines for the Four-Wheel Drive (4WD) hub actuators.
55. Disconnect the heater hose from the engine.
56. Disconnect the 3 heater hose quick disconnect fittings.
57. Disconnect the engine electrical connector from the PCM and remove the retainer from the bulkhead.
58. Disconnect the engine electrical connector from the wiring harness and position aside.
59. Disconnect the transmission electrical connector from the harness and the clip on the A/C line.
60. Disconnect the right side ABS wheel speed sensor connector.
61. Remove the bolt and the ground wire from the front of the bulkhead.
62. NOTE: Marking the position of the tires will aid in aligning the cab to the chassis.
Mark the position of the tires on the floor.
63. NOTE: A 2-post hoist must be used to lift the body from the chassis.
Position the hoist lift pads, equally side-to-side, below the pinch welds at the furthest most possible front and rear positions.
64. WARNING: Securely strap the cab to the lift using an appropriate tool. If the cab is not correctly secured, it could shift or fall. Failure to follow this instruction may result in serious personal injury.
NOTICE: An assistant will be necessary to make sure all the connections are disconnected and nothing interferes with the raising of the body while it is lifted.
With the aid of an assistant lift the body from the chassis.
65. To install, reverse the removal procedure.
- Align the tires to the marks on the floor.
- Top off the fluids.