Body - Regular Cab
BODY - REGULAR CAB
Special Tool(s):
Body - Regular Cab:
All vehicles
1. NOTE: A 2-post hoist must be used to lift the body from the chassis.
Disconnect the battery cables.
2. Separate the terminal lead for the power distribution box (PDB) from the battery positive terminal.
3. With the vehicle in NEUTRAL, position it on a hoist.
Manual transmission only
4. Remove the shifter boot and position aside.
5. Remove the shifter lever bolt and shifter lever.
6. Remove the 4 shifter lever housing plate bolts and the shifter housing plate.
All vehicles
7. Drain the engine coolant.
8. Remove the running boards, if equipped.
9. NOTE: Vehicle with 4.6L shown, all other vehicles similar.
Remove the pin-type retainers from the front splash shield-to-lower radiator support.
Automatic transmission only
10. Remove the bolts from the auxiliary cooler and secure to the frame.
- To install, tighten to 15 Nm (11 lb-ft).
Manual transmission only
11. Using the special tool, disconnect the clutch hydraulic line.
All vehicles
12. Remove the bolt from the body-to-frame tether and position aside.
13. Release the parking brake tension and disconnect the parking brake cable at the intermediate connection.
Automatic transmission only
14. Disconnect the automatic transmission cable from the manual valve and retainer clip.
All vehicles
15. Remove the 2 pin-type retainers (1 each side) and the splash shield on the left frame rail below the door. Disconnect the electrical connectors.
16. Disconnect the right and left fog lamp connectors, if equipped.
17. Remove the 2 nuts from each body mount.
18. Lower the vehicle and chock the wheels to prevent the chassis from moving.
19. Recover the refrigerant.
20. Remove the air cleaner and inlet pipe assembly.
21. Disconnect the upper radiator hose from the radiator.
22. Disconnect the lower radiator hose from the radiator.
23. Disconnect the hose from the degas bottle.
24. Remove the cooling fan.
25. Disconnect the heater core inlet hose quick disconnect on the right side of the bulkhead.
26. Disconnect the heater core outlet hose at the intake manifold inlet port on the right front of the engine.
27. Disconnect the heater core outlet hose at the intake manifold inlet port on the right front of the engine.
28. Using the special tool, disconnect the transmission cooler lines from the radiator.
29. Disconnect the A/C high-pressure switch electrical connector.
30. Disconnect the compressor manifold tube assembly.
- Disconnect the tube assembly from the condenser.
- To install, tighten to 25 Nm (18 lb-ft).
- Remove the tube assembly nut from the accumulator.
- To install, tighten to 8 Nm (71 lb-in).
31. Remove the battery cover.
32. Disconnect the 2 electrical connectors and the wiring harness connector at the PCM.
33. Disconnect the master cylinder connector.
34. Disconnect the brake booster vacuum supply hose.
35. Remove the master cylinder nuts from the brake booster and secure the brake booster to the engine.
- To install, tighten to 25 Nm (18 lb-ft).
36. NOTE: Make sure that the vehicle wheels are straight.
Place the vehicle in PARK and remove the key.
37. CAUTION: Do not allow the steering column shaft to rotate while the intermediate shaft is disconnected or damage to the clockspring can result. If there is evidence that the shaft has rotated, the clockspring must be removed and recentered. For additional information, refer to Restraint Systems &/or Air Bag Systems.
Remove the steering shaft bolt at the joint between the intermediate and lower shafts and separate the shafts.
- To install, tighten to 25 Nm (18 lb-ft).
38. Disconnect the right and left vacuum lines for the four wheel drive (4WD) hub actuators.
39. Disconnect the A/C vacuum supply hose at the right bulkhead over the PCM.
40. Disconnect the canister purge valve electrical connector and remove it from the bracket. Position the canister aside.
41. Disconnect the 12-pin connector over the PCM and remove it from the cowl.
42. Remove the ground wire on the bulkhead next to the PCM.
43. Remove the 2 ground wires on the bulkhead behind the PCM and on the bulkhead in the center of the engine compartment.
44. Disconnect the electrical connectors on the right side of the engine compartment.
45. Disconnect the ABS module connector.
46. NOTE: Left side shown, right side similar.
Disconnect the right and left ABS wheel speed sensor (WSS) connectors and remove from the splash shields.
47. Remove the 4 pin-type retainers (2 each side) on the bumper beam from the right and left splash shields on the sides of the radiator.
48. Remove the 2 nuts (1 each side) on the right and left front end sheet metal body mounts.
- To install, tighten to 70 Nm (52 lb-ft).
49. Remove the right and left hood over-slam bumper bolt and bumper bracket.
50. Remove the hood release assembly bolt from the front bumper and position aside.
51. Remove the front bumper cover-to-bumper beam bolts.
52. Place several fender covers between the cab body and box.
53. 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.
54. 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 furthestmost possible front and rear positions.
55. 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.
CAUTION: 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.
56. To install, reverse the removal procedure.
- Align the tires to the marks on the floor.
- Top off the fluids.