Part 2
Body - 6.4L Diesel
Removal and Installation
NOTE: Crew Cab shown, all others similar.
41. Remove the 2 bolts from the top of the power steering fluid reservoir and remove the reservoir.
42. Disconnect the turbocharger-to-charger air pipe (left side).
43. Disconnect the cooler-to-engine Charge Air Cooler (CAC) pipe (right side).
44. Disconnect the radiator hose from the top of the upper shroud and position aside.
4WD vehicles
45. Disconnect the electrical connector from the 4WD vacuum switch.
46. Disconnect the 4WD vacuum hose and position aside.
All vehicles
47. Remove the 2 upper bolts (1 each side) from the radiator shroud.
- To install, tighten to 6 Nm (53 lb-in).
48. Remove the 2 lower bolts (1 each side) from the upper radiator shroud and remove the shroud.
- To install, tighten to 6 Nm (53 lb-in).
49. Disconnect the heater hose from the left side of the engine.
50. Disconnect the heater hose from the right side of the engine.
51. Remove the nut and disconnect the compressor manifold tube assembly from the accumulator.
- To install, tighten to 8 Nm (71 lb-in).
52. Remove the nut and disconnect the compressor manifold tube assembly from the condenser.
- To install, tighten to 8 Nm (71 lb-in).
53. Disconnect the electrical connector from the right side of the engine.
54. Remove the bolt and the ground wire from the right fender.
- To install, tighten to 12 Nm (106 lb-in).
55. Remove the bolt and the left upper ground wire from the right front of dash.
- To install, tighten to 12 Nm (106 lb-in).
56. Remove the wiring harness from the retaining clip and position aside.
57. Remove the 3 electrical connectors from the bracket on the left side of the engine compartment and disconnect the electrical connectors.
58. Disconnect the fog lamp electrical connector from the front of the radiator support and position aside, if equipped.
59. NOTE: Make sure the vehicle wheels are straight.
Place the vehicle in PARK and remove the key.
60. 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. For additional information, refer to Restraint Systems.
Remove the intermediate steering shaft bolt and separate the shafts. Discard the bolt.
- To install, tighten to 48 Nm (35 lb-ft).
61. Disconnect the 3 electrical connectors from the brake master cylinder.
62. 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).
63. Remove the hydraulic brake lines from the retainer.
64. 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).
65. Remove the bolt from the hood release assembly and position aside.
- To install, tighten to 12 Nm (106 lb-in).
66. Raise the vehicle.
Automatic transmission
67. Disconnect the auto transmission cable from the manual valve and retainer clip.
Manual transmission
68. Remove the clutch slave cylinder from the rear of the bell housing by turning counterclockwise.
4WD vehicles
69. Pull upward to release the manual 4x4 selector lever bezel clips and reposition the bezel.
70. Remove the manual 4x4 selector lever retainer bolt.
- To install, tighten to 115 Nm (85 lb-ft).
71. Remove the manual 4x4 selector lever.
All vehicles
72. Release the parking brake tension and disconnect the brake cable at the intermediate connection and remove from the retainer on the frame. For additional information, refer to Parking Brake System.
73. Remove the body/chassis ground on the right frame rail, behind the front wheel.
- To install, tighten to 25 Nm (18 lb-ft).
74. Remove the safety clips from the transmission cooler lines.
75. Using the Transmission Cooler Line Disconnect Tool, disconnect the transmission lines from the transmission cooler hoses and remove from the retainer on the frame.
76. Remove the retaining clip and separate the lower radiator hose.
77. Disconnect the lower radiator hose from the retainers on the frame.
78. If equipped, remove the running boards.
79. NOTE: Make sure to use only hand tools when removing the body mounting bolts.
NOTE: Make sure the insulator is removed with the body bolt.
NOTE: If the body mount bolts spin and cannot be removed, refer to Body Retainer Cage Nuts Body Retainer Cage Nuts.
Remove the body mounting bolts starting with the rear bolts.
- Discard the body bolts.
- To install, tighten to 103 Nm (76 lb-ft).
80. Lower the vehicle.
81. Place several fender covers between the cab and the pickup bed.
82. 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.
83. 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 furthest most possible front and rear positions.
84. 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.
85. NOTICE: 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.
86. To install, reverse the removal procedure.
- Align the tires to the marks on the floor.
- Top off the fluids.
- Install new body bolts.