Body

Body - Diesel





NOTE: Crew Cab shown, all others similar.









Removal and Installation

All vehicles

NOTE: Use a 2-post hoist to lift the body from the chassis.

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Jacking and Lifting Service and Repair.

2. Drain the engine coolant and secondary cooling system. For additional information, refer to Engine Cooling - Diesel Engine Cooling System Draining, Filling and Bleeding and Engine Cooling - 6.7L Diesel Powertrain Secondary Cooling Powertrain Secondary Cooling System Draining, Filling and Bleeding.

3. Disconnect the battery cables from the LH and RH batteries. For additional information, refer to Battery, Mounting and Cables Battery Disconnect / Connect.

4. Separate the leads from the RH battery positive cable.
- To install, tighten to 9 Nm (80 lb-in).

5. Separate the leads from the RH battery negative cable.
- To install, tighten to 9 Nm (80 lb-in).

6. Remove the LH and RH batteries. For additional information, refer to Battery, Mounting and Cables Battery and Battery Tray

7. Disconnect the hose from the degas bottle.





8. Detach the 2 pin-type retainers and position the LH battery cables aside.





Four-Wheel Drive (4WD) vehicles

9. Lift up on the transfer case shift lever boot to access the shift lever bolt.





10. Remove the bolt and the shift lever.
- To install, tighten to 27 Nm (20 lb-ft).





11. Remove the 2 screws and the transfer case shift lever bezel.





All vehicles

12. Disengage the retaining clip and disconnect the upper radiator hose from the radiator.

13. Position the LH battery tray aside.
- Remove the 6 bolts.

- Disconnect the vacuum hoses.

- To install, tighten to 25 Nm (18 lb-ft).





14. Disengage the retaining clip, then disconnect the fill hose from the degas bottle and remove the LH battery tray.

15. Disconnect the Mass Air Flow (MAF) sensor electrical connector and detach the harness from the Air Cleaner (ACL) housing.

16. Loosen the clamp on the ACL pipe.

17. Remove the ACL housing.

18. Disengage the 3 pin-type retainers (2 shown) from the RH battery tray and position the wiring harness aside.





19. Disengage the pin-type retainer from the RH battery tray and position the battery cables aside.





20. Detach the battery buss assembly from the RH battery tray and position the buss assembly aside.





21. Disconnect the RH battery positive cable from the battery buss.





22. Disengage the 5 pin-type retainers from the RH battery tray and disconnect.





23. Disconnect the RH hood strut at the lower end and position the hood strut aside.





24. Remove the 4 RH battery tray bolts.
- To install, tighten to 18 Nm (159 lb-in).





25. Remove the RH battery tray bolt.
- To install, tighten to 18 Nm (159 lb-in).





26. Position the RH battery tray aside.

27. Disconnect the washer pump electrical connector.





28. Disconnect the 3 glow plug relay electrical connectors located on the bottom of the RH battery tray.





29. Disconnect the washer pump hose.





30. Remove the RH battery tray.

31. Connect the RH hood strut.

32. Recover the A/C system refrigerant. For additional information, refer to Climate Control System - General Information and Diagnostics Air Conditioning (A/C) System Recovery, Evacuation and Charging.

33. Disconnect the A/C compressor-to-condenser discharge line at the condenser and position the line aside.
- Discard the O-rings and cap off the fittings.

- To install, tighten to 15 Nm (133 lb-in).





34. Disconnect the 2 EGR cooler lines from cooler.

35. Disconnect the 2 PCM electrical connectors.





36. Disconnect the electrical connector.





37. Disconnect the heater core hose to engine.





38. Disconnect the turbocharger air inlet hose and the Charge Air Cooler (CAC) outlet hose at the T-fitting.





39. Disconnect the Charge Air Cooler Temperature (CACT) sensor electrical connector.





40. Disconnect the CAC coolant inlet and outlet hoses.





41. Remove the CAC.

42. Using a suitable suction device, remove the power steering fluid from the power steering reservoir.

43. Disconnect the 3 hoses from the power steering fluid reservoir.





44. Remove the bolt and the power steering fluid reservoir.
- To install, tighten to 7 Nm (62 lb-in).





45. If equipped, disconnect the 2 brake Hydro-Boost power steering fluid lines.
- Discard the O-rings.

- To install, tighten to 62 Nm (46 lb-ft).





46. Disconnect the brake fluid level switch electrical connector.





47. NOTE: The brake master cylinder nuts are a torque-prevailing type and cannot be reused.

Remove and discard the 2 brake master cylinder nuts (1 shown) and then position the brake master cylinder aside.

- To install:
- For vacuum boost equipped vehicles, tighten the new nuts to 23 Nm (17 lb-ft).

- For Hydro-Boost(R) equipped vehicles, tighten the new nuts to 30 Nm (22 lb-ft).





48. Disconnect the degas bottle hose from the radiator outlet, then detach the hose from the top of the radiator.





49. Disconnect the degas bottle-to-coolant pump hose and coolant pump-to-radiator hose from the coolant pump, for additional information refer to Coolant Pump in Engine Cooling - 6.7L Diesel Powertrain Secondary Cooling Powertrain Secondary Cooling System - Coolant Pump.

50. Remove the 2 bolts from the degas bottle.
- To install, tighten to 7 Nm (62 lb-in).





51. Disconnect the 2 hoses from the bottom of the degas bottle and remove the degas bottle.





52. Detach the EGR cooler hose and the wiring harness from the RH side of the upper fan shroud.





53. Remove the upper fan shroud. For additional information, refer to the Radiator and Cooling Fan Exploded View in Engine Cooling - Diesel Engine Service and Repair.

54. Disconnect the fuel cooler hose from T-fitting at CAC.

55. Remove the radiator grille. For additional information, refer to Exterior Trim and Ornamentation Radiator Grille.

56. Remove the nut and disconnect the A/C evaporator-to-compressor suction line fitting.
- Discard the O-rings and cap off the fittings.

- To install, tighten to 15 Nm (133 lb-in).





57. 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, remove and recenter the clockspring. For additional information, refer to Supplemental Restraint System Service and Repair.

Remove and discard the intermediate shaft bolt, then disconnect the lower steering column shaft from the upper steering column shaft.

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





58. Remove the bolt and position the RH engine ground strap aside.
- To install, tighten to 10 Nm (89 lb-in).





59. Remove the 4 deflector pushpins from the lower radiator.

60. Disconnect the lower power steering cooler hose and remove from hose retainer.





61. Detach the radiator hose from the lower radiator support.





62. Position a suitable drain pan under the radiator hose and release the radiator hose coupling locking clip.





63. Disconnect the radiator hose coupling and allow the coolant to drain.





64. Disconnect the hose from the transmission cooler.





65. Remove the bolt and position the body ground strap aside.
- To install, tighten to 25 Nm (18 lb-ft).





66. Separate the parking brake cable at the cable union.





67. Release the parking brake cable retainer and route the front parking brake cable out of the frame.





68. Disconnect the transmission selector linkage.





69. Remove the transmission selector linkage locking clip and position the linkage aside.





70. NOTE: LH shown, RH similar.

Remove and discard the 2 Front End Sheet Metal (FESM) body mount bolts, then remove the body mount lower insulators.

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





71. NOTE: LH shown, RH similar.

Remove and discard the 2 No. 1 body mount bolts, then remove the No. 1 body mount lower insulators.

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





72. NOTE: LH shown, RH similar.

If equipped, remove and discard the 2 No. 2 body mount bolts, then remove the No. 2 body mount lower insulators.

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





73. NOTE: LH shown, RH similar.

Remove and discard the 2 No. 3 body mount bolts, then remove the No. 3 body mount lower insulators.

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





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

75. NOTE: Mark the position of the tires to aid in aligning the cab to the chassis.

Mark the position of the tires on the floor.

76. NOTE: Use 2-post hoist to lift the body from the chassis.

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

77. 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.





78. NOTICE: Use an assistant 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.

79. To install, reverse the removal procedure.
- Align the tires to the marks on the floor.

- Top off the fluids.

- Install new body mount bolts.

- Connect all disconnected electrical connectors.