Part 1
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. For additional information, refer to Vehicle Jacking and Lifting.
2. Drain the engine coolant. For additional information, refer to Cooling System &/or Engine Block Heater.
3. Disconnect the battery cables from the left and right batteries. For additional information, refer to Battery.
4. Separate the leads from the left positive battery cable.
5. Separate the leads from the right positive battery cable.
6. Separate the leads from the right negative battery cable.
7. Remove the left and right batteries.
8. Remove the 2 hoses from the degas bottle.
Manual transmission
9. Lift upward on the gear shift boot to access the gear shift bolt.
10. Remove the gear shift bolt.
- To install, tighten to 30 Nm (22 lb-ft).
Four-Wheel Drive (4WD) vehicles
11. Disconnect the check valve from the vacuum hose on the degas bottle.
All vehicles
12. Remove the retaining clip and disconnect the upper radiator hose from the radiator.
13. Remove the bolts and position the left battery tray aside.
- To install, tighten to 16 Nm (142 lb-in).
14. Remove the retaining clip and disconnect the fill hose from the degas bottle and remove the degas bottle.
Four-Wheel Drive (4WD) vehicles
15. Unclip the vacuum hose from the degas bottle fill hose.
16. Unclip the vacuum hose from the brake Hydro-Boost(R) hose and position aside.
All vehicles
17. Disconnect the Mass Air Flow (MAF) sensor connector and unclip from the Air Cleaner (ACL) housing.
18. Disconnect the air filter restriction indicator connector from the air filter restriction indicator.
19. Loosen the clamp on the ACL pipe.
20. 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.
21. Remove the 3 wiring harnesses from the top of the right battery tray.
4WD vehicles
22. Remove the vacuum line and A/C line from the right battery tray.
All vehicles
23. Remove the A/C line from the right battery tray.
24. Remove the 2 bolts and the ACL bracket.
- To install, tighten to 16 Nm (142 lb-in).
25. Remove the battery cable from the retainer on the side of the right battery tray.
26. Remove the bolts from the right battery tray.
- To install, tighten to 16 Nm (142 lb-in).
27. Position the right battery tray for access to the washer fluid bottle.
- Disconnect the washer fluid bottle electrical connector.
- Disconnect the washer fluid bottle hose.
- Remove the right battery tray.
28. 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 PCM.
29. Disconnect the engine wiring harness located below the PCM.
30. Recover the refrigerant. For additional information, refer to Heating and Air Conditioning.
31. Remove the banjo fittings and the sealing washers from the fuel cooler.
- Discard the sealing washers.
- To install, tighten the banjo fittings and the new sealing washers to 25 Nm (18 lb-ft).
32. Remove the 3 turbocharger actuator cooler front housing bolts.
- To install, tighten to 13 Nm (115 lb-in).
33. Remove the 2 fuel cooler mounting bolts.
34. Remove the studs for the fuel cooler.
- To install, tighten to 38 Nm (28 lb-ft).
35. Remove the retaining nuts for the fuel cooler.
- To install, tighten to 19 Nm (168 lb-in).
36. Remove the 3 bolts (2 shown) from the fuel cooler and coolant expansion tank. Position the fuel cooler and expansion tank aside.
- To install, tighten to 9 Nm (80 lb-in).
37. Using a suitable suction device, drain the power steering fluid reservoir.
38. Disconnect the hose from the power steering auxiliary cooler line and remove the retaining clip.
39. Unclip the fuel cooler line from the side of the power steering fluid reservoir.
40. Disconnect the 3 hoses from the power steering fluid reservoir.
