Body - 6.4L Diesel

Body - 6.4L Diesel









Removal and Installation

NOTE: Crew Cab shown, all others similar.











All Vehicles

NOTE: A 2-post hoist must be used to lift the body from the chassis.

1. With the vehicle in NEUTRAL, position it on a hoist.

2. NOTE: Make sure the vehicle wheels are straight.

Place the vehicle in PARK and remove the key.

Manual Transmission

3. Lift upward on the gear shift boot to access the gear shift bolt.





4. Remove the gear shift bolt.
- To install, tighten to 30 Nm (22 lb-ft).





4WD vehicles

5. Pull upward to release the manual 4WD selector lever bezel clips and reposition the bezel.





6. Remove the manual 4WD selector lever retainer bolt.
- To install, tighten to 115 Nm (85 lb-ft).





7. Remove the manual 4WD selector lever.

All vehicles

8. NOTE: Left Hand (LH) side shown, Right Hand (RH) side similar.

NOTE: Make sure the insulator is removed with the body bolt.

NOTE: If the captured cage nut spins, refer to Spun Cab Retainer Cage Nut - 6.4L Diesel Spun Cab Retainer Cage Nut - 6.4L Diesel.
Remove the FESM body mounting bolts.
- Position a floor jack on the FESM core support and apply pressure to cage nuts to prevent spinning during removal.

- Remove the FESM bolts using an impact wrench.

- To install, tighten to 103 Nm (76 lb-ft).





9. NOTE: Make sure the insulator is removed with the body bolt.

NOTE: If the captured cage nut spins, refer to Spun Cab Retainer Cage Nut - 6.4L Diesel Spun Cab Retainer Cage Nut - 6.4L Diesel.
Remove the remaining body mounting bolts with an impact wrench starting with the rear bolts.
- To install, tighten to 103 Nm (76 lb-ft).





10. If equipped, disconnect the running boards electrical connectors.

Automatic transmission

11. Disconnect the auto transmission cable from the manual valve and retainer clip.





Manual transmission

12. Remove the clutch slave cylinder from the rear of the bell housing by turning counterclockwise.





All Vehicles

13. Release the parking brake tension and disconnect the brake cable at the intermediate connection and remove from the retainer on the frame.

14. Remove the body/chassis ground on the right frame rail, behind the front wheel.
- To install, tighten to 25 Nm (18 lb-ft).





15. Drain the engine coolant.

16. Remove the retaining clip and separate the lower radiator hose.





17. Disconnect the lower radiator hose from the retainers on the frame.





18. NOTE: If there is any oil residue, clean both connecting ports and the inside surface of the Charge Air Cooler (CAC) tube to prevent the tube from blowing off.

Loosen the clamp and disconnect the lower CAC tube flex joint from the CAC.

- To install, tighten to 12 Nm (106 lb-in).

19. Disconnect the Mass Air Flow (MAF) sensor connector and unclip from the Air Cleaner (ACL) housing.





20. Disconnect the air filter restriction indicator connector from the air filter restriction indicator.





21. Loosen the clamp on the ACL pipe.





22. NOTE: The ACL housing must be removed to access the A/C fitting. Install the ACL housing after the A/C system has been charged.

Remove the air cleaner housing.





23. NOTE: The connector must be removed to access the A/C fitting. Install the connector after the A/C system has been charged.

Disconnect the electrical connector and clip from the Powertrain Control Module (PCM).





24. Disconnect the engine wiring harness located below the PCM.





25. Recover the refrigerant.

26. Disconnect the electrical connector from the right side of the engine.





27. NOTE: The quick disconnect retainer is the only serviceable component. Damage to any other portion of the disconnect fitting requires replacement of the entire heater hose assembly.

Using the Heater Hose Disconnect tool (412-130), disconnect the Right Hand (RH) heater hose from the heater core.

- If the retainer is damaged, replace with part number 18D434.





28. Remove the bolt and the ground wire from the right fender.
- To install, tighten to 12 Nm (106 lb-in).





29. Remove the bolt and the left upper ground wire from the right front of dash.
- To install, tighten to 12 Nm (106 lb-in).





30. Disconnect the battery cables from the left and right batteries.

31. Separate the leads from the right positive battery cable.





32. Separate the leads from the right negative battery cable.





33. Remove the left battery.

34. Remove the 3 wiring harnesses from the top of the right battery tray.





35. Remove the A/C line from the right battery tray.
- To install, tighten to 15 Nm (133 lb-in).





36. Remove the battery cable from the retainer on the side of the right battery tray.





37. Remove the wiring harness from the retaining clip and position aside.





38. Disconnect the cooler-to-engine Charge Air Cooler (CAC) pipe (right side).
- To Install, tighten to 12 Nm (106 lb-in).





Four-Wheel Drive (4WD) vehicles

39. Disconnect the 4WD vacuum hose and position aside.





40. Disconnect the check valve from the vacuum hose on the degas bottle.





All vehicles

41. Remove the nut and disconnect the compressor manifold tube assembly from the accumulator.
- To install, tighten to 8 Nm (71 lb-in).





42. Remove the nut and disconnect the compressor manifold tube assembly from the condenser.
- To install, tighten to 8 Nm (71 lb-in).





43. Remove the 2 hoses from the degas bottle.





44. Remove the retaining clip and disconnect the upper radiator hose from the radiator.





45. Remove the bolts from the left battery tray and position aside.
- To install, tighten to 16 Nm (142 lb-in).





46. Remove the retaining clip and disconnect the fill hose from the degas bottle and remove the degas bottle.





Four-Wheel Drive (4WD) vehicles

47. If equipped, unclip the vacuum hose from the degas bottle fill hose.





48. Unclip the vacuum hose from the brake Hydro-Boost(R) hose and position aside.





All vehicles

49. Disconnect the turbocharger actuator cooler-to-radiator hose from the cooler.

50. Disconnect the coolant pump-to-fuel cooler hose at the fuel cooler.

51. Using a suitable suction device, drain the power steering fluid reservoir.

52. NOTE: New O-rings must be installed before the brake Hydro-Boost(R) lines are installed.

Remove the 2 hoses and O-rings from the brake Hydro-Boost(R).

- To install, tighten to 27 Nm (20 lb-ft).





53. Disconnect the heater hose from the left side of the engine.





54. Disconnect the 3 electrical connectors from the brake master cylinder.





55. Remove the 2 nuts and the brake master cylinder from the Hydro-Boost(R) and position aside.
- To install, tighten to 30 Nm (22 lb-ft).





56. Remove the hydraulic brake lines from the retainer.





57. Disconnect the 3 electrical connectors on the left side of the engine compartment.





58. NOTICE: 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.

Remove the intermediate steering shaft bolt and separate the shafts. Discard the bolt.

- To install, tighten to 48 Nm (35 lb-ft).

59. Disconnect the upper hose from the power steering fluid reservoir.

60. Disconnect the hose from the power steering auxiliary cooler line and remove the retaining clip.

61. Disconnect the fog lamp electrical connector from the front of the radiator support and position aside, if equipped.

Automatic transmission

62. NOTICE: Failure to plug the openings for the transmission cooler hoses may result in siphoning of the transmission fluid. This may result in damage to the transmission, if the transmission fluid is not checked and topped-off after the repair is complete.

NOTE: Install plugs in the transmission cooler hoses.

Disconnect the transmission fluid cooler hoses and drain the fluid into a suitable container.

All vehicles

63. If equipped, remove the bolt from the hood release assembly and position aside.
- To install, tighten to 12 Nm (106 lb-in).





64. Place several fender covers between the cab and the pickup bed.

65. 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.

66. NOTE: A 2-post hoist must be used to lift the body from the chassis.

NOTE: Lift extensions may be required on vehicles equipped with running boards

Position equally side-to-side the hoist lift pads below the pinch welds at the furthest most possible front and rear positions.

67. 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: Prior to raising cab on lift, verify that the steering shaft is clear of obstruction and has been positioned aside to prevent damage to shaft assembly.

Using the Universal Cab Hold-Down Strap, secure the vehicle cab to the hoist.





68. Carefully lift the body from the chassis making sure all connections are disconnected and nothing interferes with the raising of the body while it is lifted.

69. NOTICE: Prior to lowering cab on lift, verify that the steering shaft is clear of obstruction and has been positioned aside to prevent damage to shaft assembly.

To install, reverse the removal procedure.

- Align the tires to the marks on the floor.

- Prior to reusing the body support mounting bolts, use a wire wheel to clean all thread lock material from the threads.

- Apply threadlock and sealer to the threads of all body support mounting bolts prior to installation.

- Top off the fluids.