Body - Regular Cab
BODY - REGULAR CAB
Special Tool(s):
Body - Regular Cab:
Removal and Installation
All vehicles
NOTE: A 2-post hoist must be used to lift the body from the chassis.
1. 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 4 pin-type retainers from the lower radiator air deflector.
7. Using the Transmission Cooler Line Disconnect Tool, disconnect the transmission fluid cooler tubes from the transmission fluid cooler and reposition the transmission fluid cooler tubes through the radiator air deflector.
8. Release the parking brake cable tension.
9. Disconnect the parking brake cable at the intermediate connection.
10. Remove the parking brake cable from the frame.
4R75
11. Disconnect the selector lever cable from the manual control valve and retainer clip.
6R807
12. Disconnect the selector lever cable from the manual control valve and retainer clip.
4X4 vehicles
13. Disconnect the manual 4x4 cable.
All vehicles
14. If equipped, disconnect the right and left fog lamp connectors.
15. Remove the 2 nuts from each body mount.
- To install, tighten to 70 Nm (52 lb-ft).
16. Reposition the flip-up fan shroud.
17. Remove the body ground strap bolt and reposition the body ground strap.
18. NOTE: Use hand tools to break the body mount bolts loose.
Remove the Front End Sheet Metal (FESM) bolts.
- To install, tighten to 80 Nm (59 lb-ft).
19. Lower the vehicle and chock the wheels to prevent the chassis from moving.
20. Recover the refrigerant.
21. Remove the lower pin-type retainers from the left and right radiator air deflectors.
22. Remove the hood latch bolt and reposition the latch.
23. Remove the bumper cover-to-bumper bolts.
24. Disconnect the fresh air tube quick disconnect.
25. Remove the air inlet pipe hose clamps and remove the air inlet pipe.
26. Disconnect the upper radiator hose from the engine.
27. Disconnect the generator wiring harness electrical connector, release the harness pin-type retainers, remove the harness nut and reposition the wiring harness.
28. Disconnect the cooling fan electrical connector.
4X4 vehicles
29. Disconnect the Integrated Wheel End (IWE) solenoid vacuum hoses.
All vehicles
30. Disconnect the heater core outlet hose from the nipple on the right front of the engine.
31. Disconnect the heater core inlet hose from the heater core quick disconnect.
32. Disconnect the PCM engine and transmission electrical connectors and release the wiring harness pin-type retainer.
33. Disconnect the bulk head electrical connectors on the passenger side inner fender well, release pin-type retainers and reposition the wiring harness.
34. Disconnect the bulk head ground strap from the bulk head.
35. Disconnect the right and left ABS sensor electrical connectors.
36. Remove the negative battery cable-to-body bolt.
37. Release the negative battery cable pin-type retainer and disconnect the in-line electrical connector.
38. Release the pin-type retainers and position aside the starter solenoid positive cable and the PDB positive battery cable.
39. Disconnect the A/C suction line fitting.
40. Disconnect the A/C condenser inlet fitting.
41. Using a suitable suction device, remove the power steering fluid from the fluid reservoir.
42. Disconnect the power steering reservoir return and supply hose and reposition.
43. Remove the upper radiator air deflector pin-type retainers and remove the upper radiator air deflector.
44. Disconnect the lower radiator hose.
45. NOTICE: Do not allow the steering column shaft to rotate while the steering knuckle 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 Restraint Systems &/or Air Bag Systems.
Remove the steering shaft bolt and reposition the steering shaft.
- To install, tighten to 48 Nm (35 lb-ft).
46. Remove the vacuum booster check valve.
47. Disconnect master cylinder electrical connector and remove the axle vent from the master cylinder stud and reposition.
4X4 vehicles
48. NOTE: The 4X4 vacuum feed line is located on the passenger side of the radiator.
Disconnect the 4x4 vacuum feed line.
All vehicles
49. Remove the master cylinder nuts and reposition the master cylinder.
- To install, tighten to 25 Nm (18 lb-ft).
50. Disconnect the chassis wiring harness electrical connectors, release the wiring harness from the inner fender well and reposition.
51. Disconnect the ABS module electrical connector.
52. Place several fender covers between the cab and the pick-up bed.
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 equally side-to-side the hoist lift pads below the pinch welds at the furthermost 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.
Using the Universal Cab Hold-Down Strap, secure the vehicle to the hoist.
56. NOTE: An assistant will be necessary to make sure all 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.
57. To install, reverse the removal procedure.
- Align the tires to the marks on the floor.
- Top off the fluids.