Body - SuperCrew
BODY - SUPERCREW
Special Tool(s):
Body - SuperCrew:
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.
4. Drain the engine coolant.
5. Remove the running boards, if equipped.
6. Remove the pin-type retainers from the front splash shield-to-lower radiator support.
7. Remove the bolts from the auxiliary cooler and secure to the frame.
- To install, tighten to 15 Nm (11 lb-ft).
8. Release the parking brake tension and disconnect the parking brake cable at the intermediate connection.
9. Disconnect the automatic transmission cable from the manual valve and retainer clip.
10. 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.
11. Disconnect the right and left fog lamp connectors, if equipped.
12. Remove the 2 nuts from each body mount.
13. Lower the vehicle and chock the wheels to prevent the chassis from moving.
14. Recover the refrigerant.
15. Remove the air cleaner and inlet pipe assembly.
16. Disconnect the upper radiator hose from the radiator.
17. Disconnect the lower radiator hose from the radiator.
18. Disconnect the hose from the degas bottle.
19. Disconnect the cooling fan connector.
20. Remove the cooling fan.
21. Disconnect the heater core inlet hose quick disconnect on the right side of the bulkhead.
4.6L only
22. Disconnect the heater core outlet hose at the intake manifold inlet port on the right front of the engine.
5.4L only
23. Disconnect the heater core outlet hose at the intake manifold inlet port on the right front of the engine.
All vehicles
24. Using the special tool, disconnect the transmission cooler lines from the radiator.
25. Disconnect the A/C high-pressure switch electrical connector.
26. 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).
27. Remove the battery cover.
4.6L only
28. Disconnect the 2 electrical connectors and the wiring harness connector at the powertrain control module (PCM).
5.4L only
29. Remove the PCM.
- Disconnect the electrical connectors.
- Remove the 4 PCM bolts.
- To install, tighten to 7 Nm (62 lb-in).
All vehicles
30. Disconnect the master cylinder connector.
31. Disconnect the brake booster vacuum supply hose.
32. 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).
33. NOTE: Make sure that the vehicle wheels are straight.
Place the vehicle in PARK and remove the key.
34. 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).
35. Disconnect the right and left vacuum lines for the four wheel drive (4WD) hub actuators.
36. Disconnect the A/C vacuum supply hose at the right bulkhead over the PCM.
37. Disconnect the canister purge valve electrical connector and remove it from the bracket. Position the canister aside.
38. Disconnect the 12-pin connector over the PCM and remove it from the cowl.
4.6L only
39. Remove the ground wire on the bulkhead next to the PCM.
5.4L only
40. Remove the 2 ground wires on the bulkhead behind the PCM and on the bulkhead in the center of the engine compartment.
41. Disconnect the electrical connectors on the right side of the engine compartment.
All vehicles
42. Disconnect the anti-lock brake system (ABS) module connector.
43. NOTE: Left side shown, right side similar.
Disconnect the right and left ABS wheel speed sensor (WSS) connectors and remove from the splash shields.
44. 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.
45. 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).
46. Remove the right and left hood over-slam bumper bolt and bumper bracket.
47. Remove the hood release assembly bolt from the front bumper and position aside.
48. Remove the front bumper cover-to-bumper beam bolts.
49. Place several fender covers between the cab body and box.
50. 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.
51. 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.
52. WARNING: The cab will become unstable once it is lifted from the frame. It will be necessary to secure the cab to the hoist with the appropriate straps so that the cab does not come off of the hoist. Failure to follow these instructions may result in 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.
53. To install, reverse the removal procedure.
- Align the tires to the marks on the floor.
- Top off the fluids.