Navistar, Inc.: 2701 Navistar Drive, Lisle, IL 60532 USA

EPA 10 - US, Canada, Mexico
CAB - DuraStar®, TerraStar®

SERVICE MANUAL
SERVICE MANUAL
CAB
DuraStar® - 4100, 4200, 4300, 4400

TerraStar®
0000002322
Navistar, Inc.
Revision 1
July 2013
2701 Navistar Drive, Lisle, IL 60532 USA
© 2013 Navistar, Inc. All rights reserved. All marks are trademarks of their respective owners.
Summary of Changes
Section / Location Changes

Sunshade Removal Illustration was revised to show gaskets, and
procedure was changed to prevent damage to
electrical cable and eliminate unnecessary removals.
Sunshade Installation Procedure has been modified to include Loctite for
fasteners, prevent damage to electrical cable, and
correct torque values.
TABLE OF CONTENTS
TABLE OF CONTENTS
1. DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1. STANDARD CAB, EXTENDED CAB AND CREW CAB. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2. VEHICLE IDENTIFICATION NUMBER (VIN) TAG LOCATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.3. ELECTRIC WINDSHIELD WIPERS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.4. WINDSHIELD WASHER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2. OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.1. ELECTRIC WINDSHIELD WIPERS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3. MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4. REMOVE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4.1. ONE PIECE ENCAPSULATED WINDSHIELD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Remove One Piece Encapsulated Windshield on Standard Cab, Extended Cab and
Crew Cab for all Models. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4.2. REAR WINDOW GLASS ON VEHICLES WITHOUT VAN BODY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Remove Rear Window Glass on Vehicles without Van Body on Standard Cab, Extended
Cab and Crew Cab for all Models. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4.3. REAR WINDOW GLASS ON VEHICLES WITH VAN BODY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Remove Rear Window Glass on Vehicles with Van Body on Standard Cab, Extended
4.4. HOOD SEAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Remove Hood Seal on Standard Cab, Extended Cab and Crew Cab for All Models. . . . . . . . . . . . . . 26
4.5. SUNSHADE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Remove Sunshade on Standard Cab, Extended Cab and Crew Cab for all Models. . . . . . . . . . . . . . 27
4.6. SUN VISOR AND CLIP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Remove Sun Visor and Clip on Standard Cab, Extended Cab and Crew Cab for all Models. . . . 27
4.7. IGNITION SWITCH AND IGNITION SWITCH CYLINDER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Remove Ignition Switch on Standard Cab, Extended Cab and Crew Cab for all Models. . . . . . . . . 30
Remove Ignition Switch Cylinder on Standard Cab, Extended Cab and Crew Cab for all
Models. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
4.8. INSTRUMENT PANEL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Remove Instrument Panel on Standard Cab, Extended Cab and Crew Cab for all Models. . . . . . 34
4.9. CAB DOORS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Remove Front Cab Door on Standard Cab, Extended Cab and Crew Cab for all Models. . . . . . . . 38
Remove Rear Cab Door on Crew Cab for All Models. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
4.10. CAB DOOR HINGE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Remove Front Cab Door Hinge on Standard Cab, Extended Cab and Crew Cab for all
Models. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Remove Rear Cab Door Hinge on Crew Cab for all Models. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
4.11. CAB DOOR STRIKER PIN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Remove Front Cab Door Striker Pin on Standard Cab, Extended Cab and Crew Cab for
All Models. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Remove Rear Cab Door Striker Pin on Crew Cab for all Models. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
4.12. CAB DOOR CHECK BRACKET. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Remove Front Cab Door Check Bracket on Standard Cab, Extended Cab and Crew Cab
for all Models. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Remove Crew Cab rear Door Check Bracket on Crew Cab for all Models. . . . . . . . . . . . . . . . . . . . . . . . . 53
4.13. CAB DOOR CHECK LINK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
i
TABLE OF CONTENTS
TABLE OF CONTENTS (CONT.)

Remove Front Cab Door Check Link on Standard Cab, Extended Cab and Crew Cab for
all Models. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Remove Rear Door Check Link on Crew Cab for all Models. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
4.14. CAB DOOR TRIM PANEL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Remove Front Cab Door Trim Panel with Electric Door Window and Locks on Standard
Cab, Extended Cab and Crew Cab for all Models. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Remove Front Cab Door Trim Panel with Manual Door Window and Locks on Standard
Cab, Extended Cab and Crew Cab for all Models. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Remove Crew Cab Rear Cab Door Trim Panel with Electric Door Window and Locks on
Crew Cab for all Models. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Remove Crew Cab Rear Cab Door Trim Panel with Manual Door Window and Locks on
4.15. CAB DOOR INNER DOOR PANEL WATER SHIELD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Remove Front Cab Door Inner Panel Water Shield on Standard Cab, Extended Cab and
Remove Rear Cab Door Inner Panel Water Shield on Crew Cab for all Models. . . . . . . . . . . . . . . . . . . 66
4.16. CAB DOOR WINDOW SLIDE BLOCK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Remove Front Cab Door Window Slide Block on Standard Cab, Extended Cab and Crew
Cab for all Models. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Remove Rear Cab Door Window Slide Block on Crew Cab for all Models. . . . . . . . . . . . . . . . . . . . . . . . . 68
4.17. CAB DOOR GLASS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Remove Front Cab Door Glass on Standard Cab, Extended Cab and Crew Cab for all
Models. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Remove Rear Cab Door Glass on Crew Cab for all Models. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
4.18. MODULAR DOOR HARDWARE ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Remove Front Cab Door Modular Door Hardware Assembly on Standard Cab, Extended
Remove Rear Cab Door Modular Door Hardware Assembly on Crew Cab for all Models. . . . . . . . 82
4.19. CAB DOOR VENT WINDOW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Remove Front Cab Door Vent Window on Standard Cab, Extended Cab and Crew Cab
for all Models. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
4.20. CAB DOOR VENT WINDOW HINGE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Remove Front Cab Door Vent Window Hinge on Standard Cab, Extended Cab and Crew
4.21. CAB DOOR VENT WINDOW SEAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Remove Front Cab Door Vent Window Seal on Standard Cab, Extended Cab and Crew
4.22. CAB DOOR LOCK CYLINDER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Remove Cab Door Lock Cylinder on Front Cab Door of Standard Cab or Extended Cab
Models and on Front and Rear Cab Doors of Crew Cab Models. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
4.23. CAB DOOR WINDOW ELECTRIC MOTOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Remove Front Cab Door Window Electric Motor on Standard Cab, Extended Cab and
Remove Rear Cab Door Window Electric Motor on Crew Cab for all Models. . . . . . . . . . . . . . . . . . . . . . 91
4.24. CAB DOOR WINDOW REGULATOR ARM ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Remove Front Cab Door Window Regulator Arm Assembly on Standard Cab, Extended
Remove Rear Cab Door Window Regulator Arm Assembly on Crew Cab for all Models. . . . . . . . . 96
4.25. OUTER CAB DOOR HANDLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Remove Front Cab Door Outer Cab Door Handle on Standard Cab, Extended Cab and
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TABLE OF CONTENTS

Remove Rear Cab Door Outer Cab Door Handle on Crew Cab for all Models. . . . . . . . . . . . . . . . . . . 101
4.26. CAB DOOR LATCH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Remove Front Cab Door Latch on Standard Cab, Extended Cab and Crew Cab for all
Models. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Remove Rear Cab Door Latch on Crew Cab for all Models. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
4.27. INNER CAB DOOR HANDLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Remove Front Cab Door Inner Cab Door Handle on Standard Cab, Extended Cab and
Crew Cab for all Models. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Remove Rear Cab Door Inner Cab Door Handle on Crew Cab for all Models. . . . . . . . . . . . . . . . . . . . 107
4.28. CAB DOOR WINDOW RUN CHANNELS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Remove Front Cab Door Window Run Channels on Standard Cab, Extended Cab and
Remove Rear Cab Door Window Run Channels on Crew Cab for all Models. . . . . . . . . . . . . . . . . . . . 111
4.29. CAB DOOR ELECTRIC WINDOW AND DOOR LOCK SWITCH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Remove Front Cab Door Electric Window and Door Lock Switch on Standard Cab,
Extended Cab and Crew Cab for all Models. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Remove Rear Cab Door Electric Window and Door Lock Switch on Crew Cab for all Models. . . 113
4.30. CAB DOOR ELECTRIC MIRROR SWITCH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Remove Front Cab Door Electric Mirror Switch on Standard Cab, Extended Cab and
Crew Cab for all Models. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
4.31. SEATS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Remove Passenger Bucket Seat on Standard Cab, Extended Cab and Crew Cab for all
Models. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Remove Fixed Passenger Seat on Standard Cab, Extended Cab and Crew Cab for all
Models. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Remove Two Man Fixed Bench Seat without Tool Box on Standard Cab, Extended Cab
and Crew Cab for all Models. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Remove Two Man Fixed Bench Seat with Tool Box on Standard Cab, Extended Cab and
Crew Cab for all Models. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Remove Full Width Rear Bench Seat on Extended Cab and Crew Cab for all Models. . . . . . . . . . 119
4.32. CAB DOOR OPENING SCUFF PLATE AND SEAT BELT RETRACTOR COVER. . . . . . . . . . . . . . . 121
Remove Cab Door Opening Scuff Plate and Seat Belt Retractor Cover on Standard Cab,
4.33. EXTENDED CAB BUNK/STORAGE UNIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Remove Bunk/Storage Unit on Extended Cab for all Models. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
4.34. SIDE AND CORNER INTERIOR TRIM PANEL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
Remove Side and Corner Interior Trim Panel on Standard Cab for all Models. . . . . . . . . . . . . . . . . . . 123
Remove Side and Corner Interior Trim Panel on Extended Cab for all Models. . . . . . . . . . . . . . . . . . . 124
Remove Side and Corner Interior Trim Panel on Crew Cab for all Models. . . . . . . . . . . . . . . . . . . . . . . . 125
4.35. EXTENDED CAB REAR SIDE WINDOW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
Remove Rear Side Window on Extended Cab for all Models. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
Remove Rear Side Window Latch from Rear Side Window on Extended Cab for all Models. . . 129
4.36. REAR INTERIOR TRIM PANEL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
Remove Rear Interior Trim Panel on Standard Cab, Extended Cab and Crew Cab for all
Models. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
4.37. HEADER CONSOLE PANEL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
Remove Header Console Panel on Standard Cab, Extended Cab and Crew Cab for all
Models. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
4.38. HEADLINER TRIM PANEL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Remove Headliner Trim Panel on Standard Cab for all Models. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Remove Front Headliner Trim Panel on Extended Cab for all Models. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
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Remove Rear Headliner Trim Panel on Extended Cab for all Models. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
Remove Front Headliner Trim Panel on Crew Cab for all Models. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
Remove Rear Headliner Trim Panel on Crew Cab for all Models. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
4.39. CREW CAB B - PILLAR TRIM PANEL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
Remove B - Pillar Trim Panel on Crew Cab for all Models. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
4.40. CAB DOOR OPENING WEATHER SEALS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
Remove Front Cab Door Opening Weather Seals on Standard Cab, Extended Cab and
Remove Rear Cab Door Opening Weather Seals on Crew Cab for all Models. . . . . . . . . . . . . . . . . . . 142
4.41. WINDSHIELD WIPER ARM AND BLADE ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
Remove Windshield Wiper Arm and Blade Assembly on Standard Cab, Extended Cab
4.42. CAB COWL TRAY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
Remove Cab Cowl Tray on Standard Cab, Extended Cab and Crew Cab for all Models
before September 2000. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
after September 2000. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
after February 2002. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
4.43. WINDSHIELD WIPER ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
Remove Windshield Wiper Assembly on Standard Cab, Extended Cab and Crew Cab for
all Models. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
4.44. ELECTRIC WINDSHIELD WIPER MOTOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
Remove Electric Windshield Wiper Motor on Standard Cab, Extended Cab and Crew
Cab for all Models. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
4.45. WINDSHIELD WASHER BOTTLE AND/OR PUMP MOTOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
Remove Windshield Washer Bottle and/or Pump Motor on Standard Cab, Extended Cab
4.46. ENGINE COVER AND CUP HOLDER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
Remove Cup Holder on Standard Cab, Extended Cab and Crew Cab for all Models. . . . . . . . . . . 158
Remove Engine Cover on Standard Cab, Extended Cab and Crew Cab for all Models. . . . . . . . . 158
4.47. CAB. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
General Procedures for Cab Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
Remove Cab with Low Mount Front Cab Mounting and Low Mount Rear Cab Mounting
for 4100, 4200, 4300 and 4400 Standard Cab and Extended Cab Models. . . . . . . . . . . . . . . . . . . . . . . 162
Cab with Low Mount Front Cab Mounting for 4100, 4200, 4300 and 4400 Standard Cab
and Extended Cab Models. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
Cab with Low Mount Rear Cab Mounting for 4100, 4200, 4300 and 4400 Standard Cab
and Extended Cab Models. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
Remove Low Mount Front Cab Mounting Isolators for 4100, 4200, 4300 and 4400
Standard Cab and Extended Cab before January 2003. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
Remove Low Mount Rear Cab Carriage Bolts and Compression Isolators for 4100, 4200,
4300 and 4400 Standard Cab and Extended Cab Models before January 2003. . . . . . . . . . . . . . . . . 166
Remove Cab with Low Mount Front Cab Mounting for all Crew Cabs and 4100, 4200,
4300 and 4400 Standard Cab and Extended Cab Models after January 2003 and Low
Mount Rear Cab Air Suspension Mounting for all Crew Cab Models. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
Cab with Low Mount Front Cab Mounting for all Crew Cabs and 4100, 4200, 4300 and
4400 Standard Cab and Extended Cab Models after January 2003. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
Cab with Low Mount Rear Cab Air Suspension Mounting for all Crew Cab Models. . . . . . . . . . . . . 168
Remove Low Mount Rear Cab Air Suspension for all Crew Cab Models. . . . . . . . . . . . . . . . . . . . . . . . . 169
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Remove Low Mount Rear Cab Air Suspension Mounting Carriage Bolts for all Crew Cab
Models. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
Remove Cab with Mid High Front Cab Mounting and Mid High Rear Cab Air Suspension
Mounting for 4400 Model for City Tractor Applications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
Cab with Mid High Front Cab Mounting and Mid High Rear Cab Air Suspension Mounting
for 4400 Model for City Tractor Applications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
Remove Mid High Mount Rear Cab Air Suspension for 4400 Model for City Tractor
Applications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
Remove Mid High Mount Rear Cab Air Suspension Mounting Carriage Bolts for 4400
Model for City Tractor Applications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
5. INSTALL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
5.1. ONE PIECE ENCAPSULATED WINDSHIELD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
Install One Piece Encapsulated Windshield using Two Part U216 Urethane Adhesive
(adhesive A and curative B) on Standard Cab, Extended Cab and Crew Cab for all Models. . . 173
Install One Piece Encapsulated Windshield using One Part U400HV Urethane Adhesive
on Standard Cab, Extended Cab and Crew Cab for all Models. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
5.2. REAR WINDOW GLASS ON VEHICLES WITHOUT VAN BODY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
Install Rear Window Glass on Vehicles without Van Body on Standard Cab, Extended
Cab and Crew Cab for all Models. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
5.3. REAR WINDOW GLASS ON VEHICLES WITH VAN BODY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
Install Rear Window Glass on Vehicles with Van Body on Standard Cab, Extended Cab
5.4. HOOD SEAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
Install Hood Seal on Standard Cab, Extended Cab and Crew Cab for all Models. . . . . . . . . . . . . . . 228
5.5. SUNSHADE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
Install Sunshade on Standard Cab, Extended Cab and Crew Cab for all Models. . . . . . . . . . . . . . . . 228
5.6. SUN VISOR AND CLIP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229
Install Sun Visor and Clip on Standard Cab, Extended Cab and Crew Cab for all Models. . . . . . 229
5.7. IGNITION SWITCH AND IGNITION SWITCH CYLINDER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229
Install Ignition Switch Cylinder on Standard Cab, Extended Cab and Crew Cab for all
Models. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229
Install Ignition Switch on Standard Cab, Extended Cab and Crew Cab for all Models. . . . . . . . . . . 230
5.8. INSTRUMENT PANEL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230
Install Instrument Panel on Standard Cab, Extended Cab and Crew Cab for all Models. . . . . . . . 230
5.9. CAB DOORS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
Install Front Cab Door on Standard Cab, Extended Cab and Crew Cab for all Models. . . . . . . . . . 233
Install Rear Cab Door on Crew Cab for all Models. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
5.10. CAB DOOR HINGE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235
Install Front Cab Door Hinge on Standard Cab, Extended Cab and Crew Cab for all Models. . . 235
Install Rear Cab Door Hinge on Crew Cab for all Models. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235
5.11. CAB DOOR STRIKER PIN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236
Install Front Cab Door Striker Pin on Standard Cab, Extended Cab and Crew Cab for all
Models. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236
Install Rear Cab Door Striker Pin on Crew Cab for all Models. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236
5.12. CAB DOOR CHECK BRACKET. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236
Install Front Cab Door Check Bracket on Standard Cab, Extended Cab and Crew Cab
for all Models. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236
Install Crew Cab Rear Door Check Bracket on Crew Cab for all Models. . . . . . . . . . . . . . . . . . . . . . . . . . 236
5.13. CAB DOOR CHECK LINK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237
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Install Front Cab Door Check Link on Standard Cab, Extended Cab and Crew Cab for all
Models. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237
Install Crew Cab Rear Door Check Link on Crew Cab for all Models. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237
5.14. CAB DOOR TRIM PANEL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237
Install Front Cab Door Trim Panel with Electric Door Window and Locks on Standard
Cab, Extended Cab and Crew Cab for all Models. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237
Install Front Cab Door Trim Panel with Manual Door Window and Locks on Standard
Cab, Extended Cab and Crew Cab for all Models. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
Install Crew Cab Rear Cab Door Trim Panel with Electric Door Window and Locks on
Install Crew Cab Rear Cab Door Trim Panel with Manual Door Window and Locks on
5.15. CAB DOOR INNER DOOR PANEL WATER SHIELD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240
Install Front Cab Door Inner Door Panel Water Shield on Standard Cab, Extended Cab
Install Rear Cab Door Inner Door Panel Water Shield on Crew Cab for all Models. . . . . . . . . . . . . . 240
5.16. CAB DOOR WINDOW SLIDE BLOCK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240
Install Front Cab Door Window Slide Block on Standard Cab, Extended Cab and Crew
Install Rear Cab Door Window Slide Block on Crew Cab for all Models. . . . . . . . . . . . . . . . . . . . . . . . . . 242
5.17. CAB DOOR GLASS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243
Install Front Cab Door Glass on Standard Cab, Extended Cab and Crew Cab for all Models. . . 243
Install Rear Cab Door Glass on Crew Cab for all Models. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247
5.18. MODULAR DOOR HARDWARE ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251
Install Front Cab Door Modular Door Hardware Assembly on Standard Cab, Extended
Install Rear Cab Door Modular Door Hardware Assembly on Crew Cab for all Models. . . . . . . . . 252
5.19. CAB DOOR VENT WINDOW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254
Install Front Cab Door Vent Window on Standard Cab, Extended Cab and Crew Cab for
all Models. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254
5.20. CAB DOOR VENT WINDOW HINGE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254
Install Front Cab Door Vent Window Hinge on Standard Cab, Extended Cab and Crew
5.21. CAB DOOR VENT WINDOW SEAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254
Install Front Cab Door Vent Window Seal on Standard Cab, Extended Cab and Crew
5.22. CAB DOOR LOCK CYLINDER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255
Install Cab Door Lock Cylinder on Front Cab Door on Standard Cab, Extended Cab and
Crew Cab Models and Rear Cab Doors on Crew Cab Models. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255
5.23. CAB DOOR WINDOW ELECTRIC MOTOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255
Install Front Cab Door Window Electric Motor on Standard Cab, Extended Cab and Crew
Install Rear Cab Door Window Electric Motor on Crew Cab for all Models. . . . . . . . . . . . . . . . . . . . . . . 256
5.24. CAB DOOR WINDOW REGULATOR ARM ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 256
Install Front Cab Door Window Regulator Arm Assembly on Standard Cab, Extended
Install Rear Cab Door Window Regulator Arm Assembly on Crew Cab for all Models. . . . . . . . . . 258
5.25. OUTER CAB DOOR HANDLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260
Install Front Cab Door Outer Cab Door Handle on Standard Cab, Extended Cab and
Install Rear Cab Door Outer Cab Door Handle on Crew Cab for all Models. . . . . . . . . . . . . . . . . . . . . . 261
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5.26. CAB DOOR LATCH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263
Install Front Cab Door Latch on Standard Cab, Extended Cab and Crew Cab for all Models. . . 263
Install Rear Cab Door Latch on Crew Cab for all Models. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 264
5.27. INNER CAB DOOR HANDLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 264
Install Front Cab Door Inner Cab Door Handle on Standard Cab, Extended Cab and
Install Rear Cab Door Inner Cab Door Handle on Crew Cab for all Models. . . . . . . . . . . . . . . . . . . . . . . 265
5.28. CAB DOOR WINDOW RUN CHANNELS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267
Install Front Cab Door Window Run Channels on Standard Cab, Extended Cab and
Install Rear Cab Door Window Run Channels on Crew Cab for all Models. . . . . . . . . . . . . . . . . . . . . . . 268
5.29. CAB DOOR ELECTRIC WINDOW AND DOOR LOCK SWITCH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269
Install Front Cab Door Electric Window and Door Lock Switch on Standard Cab,
Install Rear Cab Door Electric Window and Door Lock Switch on Crew Cab for all Models. . . . 269
5.30. CAB DOOR ELECTRIC MIRROR SWITCH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269
Install Front Cab Door Electric Mirror Switch on Standard Cab, Extended Cab and Crew
5.31. SEATS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270
Install Passenger Bucket Seat on Standard Cab, Extended Cab and Crew Cab for all
Models. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270
Install Fixed Passenger Seat on Standard Cab, Extended Cab and Crew Cab for all Models. . . 270
Install Two Man Fixed Bench Seat without Tool Box on Standard Cab, Extended Cab and
Install Two Man Fixed Bench Seat with Tool Box on Standard Cab, Extended Cab and
Install Full Width Rear Bench Seat on Extended Cab and Crew Cab for all Models. . . . . . . . . . . . . 271
5.32. CAB DOOR OPENING SCUFF PLATE AND SEAT BELT RETRACTOR COVER. . . . . . . . . . . . . . . 271
Install Cab Door Opening Scuff Plate and Seat Belt Retractor Cover on Standard Cab,
5.33. EXTENDED CAB BUNK/STORAGE UNIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272
Install Bunk/Storage Unit on Extended Cab for all Models. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272
5.34. SIDE AND CORNER INTERIOR TRIM PANEL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272
Install Side and Corner Interior Trim Panel on Standard Cab for all Models. . . . . . . . . . . . . . . . . . . . . . 272
Install Side and Corner Interior Trim Panel on Extended Cab for all Models. . . . . . . . . . . . . . . . . . . . . . 273
Install Side and Corner Interior Trim Panel on Crew Cab for all Models. . . . . . . . . . . . . . . . . . . . . . . . . . . 273
5.35. EXTENDED CAB REAR SIDE WINDOW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274
Install Rear Side Window Latch onto Rear Side Window on Extended Cab for all Models. . . . . . 274
Install Rear Side Window on Extended Cab for all Models. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274
5.36. REAR INTERIOR TRIM PANEL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276
Install Rear Interior Trim Panel on Standard Cab, Extended Cab and Crew Cab for all
Models. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276
5.37. HEADER CONSOLE PANEL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276
Install Header Console Panel on Standard Cab, Extended Cab and Crew Cab for all Models. . . 276
5.38. HEADLINER TRIM PANEL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277
Install Headliner Trim Panel on Standard Cab for all Models. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277
Install Front Headliner Trim Panel on Extended Cab for all Models. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 278
Install Rear Headliner Trim Panel on Extended Cab for all Models. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 278
Install Front Headliner Trim Panel on Crew Cab for all Models. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 279
Install Rear Headliner Trim Panel on Crew Cab for all Models. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 279
5.39. CREW CAB B - PILLAR TRIM PANEL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280
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TABLE OF CONTENTS
Install B - Pillar Trim Panel on Crew Cab for all Models. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280
5.40. CAB DOOR OPENING WEATHER SEALS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281
Install Front Cab Door Opening Weather Seals on Standard Cab, Extended Cab and
Install Rear Cab Door Opening Weather Seals on Crew Cab for all Models. . . . . . . . . . . . . . . . . . . . . . 281
Install Windshield Wiper Arm and Blade Assembly on Standard Cab, Extended Cab and
5.42. CAB COWL TRAY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282
Install Cab Cowl Tray on Standard Cab, Extended Cab and Crew Cab for all Models
before September 2000. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282
Install Cab Cowl Tray on Standard Cab, Extended Cab and Crew Cab for all Models after
September 2000. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 283
Install Cab Cowl Tray on Standard Cab, Extended Cab and Crew Cab for all Models after
February 2002. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 284
5.43. WINDSHIELD WIPER ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 284
Install Windshield Wiper Assembly on Standard Cab, Extended Cab and Crew Cab for
all Models. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 284
Install Electric Windshield Wiper Motor on Standard Cab, Extended Cab and Crew Cab
for all Models. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285
5.45. WINDSHIELD WASHER BOTTLE AND/OR PUMP MOTOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 286
Install Windshield Washer Bottle and/or Pump Motor on Standard Cab, Extended Cab
5.46. ENGINE COVER AND CUP HOLDER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 286
Install Engine Cover on Standard Cab, Extended Cab and Crew Cab for all Models. . . . . . . . . . . . 286
Install Cup Holder on Standard Cab, Extended Cab and Crew Cab for all Models. . . . . . . . . . . . . . 287
5.47. CAB. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 288
Cab Squaring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 288
Install Cab with Low Mount Front Cab Mounting and Low Mount Rear Cab Mounting for
4100, 4200, 4300 and 4400 Standard Cab and Extended Cab Models. . . . . . . . . . . . . . . . . . . . . . . . . . . 288
Install Low Mount Front Cab Mounting Isolators for 4100, 4200, 4300 and 4400 Standard
Cab and Extended Cab Models Before January 2003. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 288
Install Low Mount Rear Cab Carriage Bolts and Compression Isolators for 4100, 4200,
4300 and 4400 Standard Cab and Extended Cab Models Before January 2003. . . . . . . . . . . . . . . . . 289
Cab with Low Mount Front Cab Mounting and Low Mount Rear Cab Mounting for 4100,
4200, 4300 and 4400 Standard Cab and Extended Cab Models. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 289
Install Cab with Low Mount Front Cab Mounting for all Crew Cabs and 4100, 4200, 4300
and 4400 Standard Cab and Extended Cab Models after January 2003 and Low Mount
Rear Cab Air Suspension Mounting for all Crew Cab Models. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 290
Install Low Mount Rear Cab Air Suspension Mounting Carriage Bolts for all Crew Cab
Models. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 290
Install Low Mount Rear Cab Air Suspension for all Crew Cab Models. . . . . . . . . . . . . . . . . . . . . . . . . . . . 290
Cab with Low Mount Front Cab Mounting for all Crew Cab Models and 4100, 4200, 4300
and 4400 Standard Cab and Extended Cab Models after January 2003 and Low Mount
Rear Cab Air Suspension Mounting for all Crew Cab Models. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 290
Install Cab with Mid High Front Cab Mounting and Mid High Rear Cab Air Suspension
Mounting for 4400 Model for City Tractor Applications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 291
Install Mid High Mount Rear Cab Air Suspension Mounting Carriage Bolts for 4400 Model
for City Tractor Applications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 291
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TABLE OF CONTENTS
Install Mid High Mount Rear Cab Air Suspension for 4400 Model for City Tractor
Applications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 291
Cab with Mid High Front Cab Mounting and Mid High Rear Cab Air Suspension Mounting
for 4400 Model for City Tractor Applications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 292
General Procedures for Cab Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 292
6. TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 294
6.2. WASHER PUMP MOTOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 295
7. LUBRICATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 296
7.1. 4000 MILES (6000 KM) OR MONTHLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 296
7.2. AS REQUIRED. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 296
8. ADJUSTMENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 297
8.1. CAB DOOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 297
8.2. HINGE AT CAB HINGE PILLAR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 297
8.3. STRIKER PIN AT LOCK PILLAR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 298
8.5. CAB AIR SUSPENSION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301
9. FORMS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 304
9.1. BONDED WINDSHIELD REPLACEMENT REPORT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 304
10. TORQUE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 306

10.1. TORQUE CHART. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 306
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TABLE OF CONTENTS
x
STANDARD CAB, EXTENDED CAB AND CREW CAB DESCRIPTION
1. DESCRIPTION
1.1. STANDARD CAB, EXTENDED CAB AND CREW CAB
The cab for the 4100, 4200, 4300 and 4400 Models, including extended cab and crew cab Models, is made of
double sided galvanized steel which provides a strong cab with less weight and excellent corrosion protection.
Figure 1 illustrates the standard cab for the model/series covered in this section.
Figure 1 Standard Cab for 4100, 4200, 4300 and 4400 Models
Figure 2 illustrates the extended cab and crew cab for the model/series covered in this section.
1
DESCRIPTION VEHICLE IDENTIFICATION NUMBER (VIN) TAG LOCATION
Figure 2 Extended Cab and Crew Cab for 4100, 4200, 4300 and 4400 Models
1.2. VEHICLE IDENTIFICATION NUMBER (VIN) TAG LOCATION

Refer to Figure 3 for Items in parentheses.
VIN's are necessary if the need for replacement parts should occur. For this reason, you will want to know the
location for these important numbers. Cab and Chassis VINs (Items 1 and 2) are located on the face of cab
door latch pillar (Item 3), driver's side.
2
ELECTRIC WINDSHIELD WIPERS DESCRIPTION
1. CAB “ VIN ” TAG 3. CAB DOOR LATCH PILLAR

2. CHASSIS “ VIN ” TAG
Figure 3 VIN Tag Location
1.3. ELECTRIC WINDSHIELD WIPERS

The windshield wiper system consists of a single unitized 12 volt electric wiper motor (Item 1) that operates the
wiper arms (Item 2) through wiper linkage (Item 3). The motor has two speeds (low and high), and a park
position which is controlled by a three-position switch.
Since the electric wiper motor is of unitized construction, there is no need for motor rebuild or adjustments.
There are no serviceable parts; the complete assembly is replaced.
3
DESCRIPTION WINDSHIELD WASHER
1. ELECTRIC WIPER MOTOR 3. WIPER LINKAGE

2. WIPER ARM
Figure 4 Electric Windshield Wipers
1.4. WINDSHIELD WASHER

The windshield washer consists of a washer bottle mounted, motor driven, displacement type pump that
delivers washer solution to the windshield through hoses and nozzles in the wiper arms. The pump motor
(Item 1) may be integral with washer bottle (Item 2) or removable Figure 5 (See Figure 5, page 5) and Figure 6
(See Figure 6, page 6).
4
WINDSHIELD WASHER DESCRIPTION
1. PUMP MOTOR 2. WASHER BOTTLE

Figure 5 Washer Bottle Location without Hood Access Hatch
5
DESCRIPTION WINDSHIELD WASHER
1. PUMP MOTOR 2. WASHER BOTTLE

Figure 6 Washer Bottle Location with Hood Access Hatch
6
ELECTRIC WINDSHIELD WIPERS OPERATION
2. OPERATION
2.1. ELECTRIC WINDSHIELD WIPERS
The windshield wiper motor is a permanent magnet electric motor with a worm gear on the armature shaft
which drives a follower gear on the crankshaft. A cam is molded on the output gear and operates against a
switch mounted on the molded cover and is connected in the motor circuit.
When the motor is turned on, the switch floats in the circuit. When the motor is turned off, the switch continues
to supply current to the motor until the molded cam reaches the switch. This opens the circuit in the motor
and stops the wipers in the park position.
CAUTION
Do not attempt to move the blades through their sweep by grasping the wiper arm. This
action may result in the teeth being broken off the drive gear or the linkage bent. If blades
are frozen to windshield, do not operate control switch until they have been freed.
The three-position switch located on a knob at the end of the turn signal lever controls off, low speed, or high
speed operation and intermittent wiper (five pre-set delay settings) by rotating the knob.

The control knob located at the end of the turn signal lever controls the mist and windshield washer features by
pressing in on the end of the knob. Pressing in and instantly releasing the knob activates the mist wipe feature
(one pass only). Pressing in and holding momentarily will start the washer feature and activate the wipers.
7
MAINTENANCE WINDSHIELD WASHER
3. MAINTENANCE
A minimum of service is required to keep the windshield washer operating. Keep reservoir filled with windshield
washer solvent and keep wiper nozzles clean. If dirt enters the reservoir, remove reservoir and flush out with
clean water. Refill reservoir with specified solvent after re-installing.
8
ONE PIECE ENCAPSULATED WINDSHIELD REMOVE
4. REMOVE
4.1. ONE PIECE ENCAPSULATED WINDSHIELD
Remove One Piece Encapsulated Windshield on Standard Cab, Extended Cab and Crew Cab for
all Models
The 4100, 4200, 4300 and 4400 model vehicles come standard with a one piece encapsulated windshield
Figure 7.
Figure 7 One Piece Encapsulated Windshield
IMPORTANT – To remove a one piece encapsulated windshield you will need to have the INTERNATIONAL®
Bonded Windshield Tool Kit ZTSE4470. This kit has a tool box that includes the tools required to remove
and install bonded windshields. To order, call toll free in U. S. and Canada 1–800–520–2584 or Fax
1–800–578–7375. NOTE - The INTERNATIONAL® Bonded Windshield Tool Kit ZTSE4470 is no longer
available through the INTERNATIONAL® tool supplier. For materials that are available contact
INTERNATIONAL® service parts.
NOTE – Before starting to remove and replace a windshield, it is required that a self-carboning form from
INTERNATIONAL® titled “Bonded Windshield Replacement Report” be filled out completely to confirm
the condition of the vehicle and record the lot numbers of the Essex materials used before starting the
work. Refer to Figure 205 (See Figure 206, page 305) for a sample form at the back of this Manual.
1. Chock the wheels and unlatch fiberglass tilt hood on both sides and raise hood to full open position.
2. Place protective coverings over areas near windshield.
9
REMOVE ONE PIECE ENCAPSULATED WINDSHIELD
3. Before removing windshield, it will be necessary to remove the windshield wiper arms and blades. Refer to
WINDSHIELD WIPER ARM AND BLADE ASSEMBLY (See WINDSHIELD WIPER ARM AND BLADE
ASSEMBLY, page 143).
4. If the unit is equipped with an exterior sunshade (Item 1) place a piece of tape (Item 2) on bottom side of
the three sunshade mounting brackets (Item 3). This will protect sunshade mounting bracket paint while
using cutting tool to remove windshield. If it is desired to remove the sunshade, refer to SUNSHADE (See
SUNSHADE, page 27), for 4100, 4200, 4300 and 4400 models as required.
1. SUNSHADE 3. SUNSHADE MOUNTING

2. TAPE BRACKET
Figure 8 Taping Sunshade Mounting Brackets
10
1. DRIVER SIDE A PILLAR TRIM 6. GRAB HANDLE

PANEL 7. HEADER TRIM PANEL
2. HEADER TRIM PANEL 8. CAB A PILLAR
3. CAB A PILLAR 9. RETAINING CLIPS
4. HEX FLANGED BOLTS
5. PASSENGER SIDE A PILLAR
TRIM PANEL
Figure 9 Driver and Passenger Side A Pillar Trim Panel
5. Remove one piece encapsulated windshield as follows.
11
6. Work your fingers in behind driver side A pillar trim panel (Item 1) at the top between A pillar trim panel and
header trim panel (Item 2). Carefully pull the A pillar trim panel off the cab A pillar (Item 3). Lay A pillar
trim panel out of the way and save for installation.
7. Remove two hex flanged bolts (Item 4) from passenger side A pillar trim panel (Item 5) and remove
passenger side grab handle (Item 6). Work your fingers in behind passenger side A pillar trim panel at the
top between A pillar trim panel and header trim panel (Item 7). Carefully pull the A pillar trim panel off
the cab A pillar (Item 8). Lay A pillar trim panel, grab handle and hex bolts out of the way and save for
installation.
8. Once both driver and passenger side A pillar trim panels (Items 1 and 4) are removed, remove windshield
as follows.
WARNING
Wear protective eye wear and work gloves when removing windshield.
9. Using a utility knife (Item 1) lift outer flange of encapsulation rubber trim (Item 2) and cut encapsulation
rubber trim flange off all the way around windshield.
1. UTILITY KNIFE
12
2. ENCAPSULATION RUBBER
TRIM
Figure 10 Cutting Rubber Trim Flange Off
NOTE – When using a power knife to cut around the old windshield, use a spray bottle and lubricate
the cutting area with water (Figure 11). This will prevent burning of the urethane and re-bonding of the
windshield.
Figure 11 Spraying Cutting Area with Water while Cutting Windshield Out
13
1. POWER KNIFE 4. OUTSIDE CUTTING BLADE

2. SHORT INSIDE CUTTING BLADE 5. LONG HANDLE UTILITY KNIFE
3. LONG INSIDE CUTTING BLADE
Figure 12 Cutting Windshield Out
14
REAR WINDOW GLASS ON VEHICLES WITHOUT VAN BODY REMOVE
10. Using a power knife (Item 1) with short inside cutting blade (Item 2) or long inside cutting blade (Item 3)
and/or outside cutting blade (Item 4), cut all the way around windshield until it is able to be lifted off the
cab windshield fence. If necessary use a long handle utility knife (Item 5) to cut through adhesive if
windshield will not lift off cab windshield fence.
11. Once the windshield (Item 1, Figure 13) is cut free from cab windshield fence, lift it off the cab. Place
windshield out of the way.
1. WINDSHIELD
Figure 13 Removing Windshield from Vehicle
4.2. REAR WINDOW GLASS ON VEHICLES WITHOUT VAN BODY

Remove Rear Window Glass on Vehicles without Van Body on Standard Cab, Extended Cab and
Crew Cab for all Models
The 4100, 4200, 4300 and 4400 model vehicles come standard with a bonded in rear window glass (Figure 14).
15
REMOVE REAR WINDOW GLASS ON VEHICLES WITHOUT VAN BODY
1. REAR WINDOW GLASS 3. SPRING CLIP

2. LOCATOR TAB
Figure 14 Rear Window Glass
IMPORTANT – To remove a rear window glass you will need to have the INTERNATIONAL® Bonded
Windshield Tool Kit ZTSE4470. This kit has a tool box that includes the tools required to remove and
install the bonded rear window glass. To order, call toll free in U. S. and Canada 1–800–520–2584 or
Fax 1–800–578–7375. NOTE - The INTERNATIONAL® Bonded Windshield Tool Kit ZTSE4470 is no
longer available through the INTERNATIONAL® tool supplier. For materials that are available contact
NOTE – Before starting to remove and replace a rear window glass, it is required that a self-carboning
form from INTERNATIONAL® titled “Bonded Windshield Replacement Report” be filled out completely
to confirm the condition of the vehicle and record the lot numbers of the Essex materials used before
starting the work. Refer to Figure 205 (See Figure 206, page 305) for a sample form at the back of this
Manual.
1. Chock the vehicle wheels.
2. Place protective coverings over areas near rear window glass inside the cab.
3. Before removing rear window glass, it may be necessary to remove the seats. Refer to SEATS, Remove
driver or passenger seats (See SEATS, page 115).
4. Remove bonded rear window glass as follows.
16
REAR WINDOW GLASS ON VEHICLES WITHOUT VAN BODY REMOVE
WARNING
Wear protective eye wear and work gloves when removing rear window glass.
NOTE – When using a power knife to cut around the old rear window glass, use a spray bottle and
lubricate the cutting area with water (Figure 11) (See Figure 11, page 13). This will prevent burning of
the urethane and re-bonding of the windshield.
5. Using a power knife (Item 1) with short inside cutting blade (Item 2), work cutting blade between rear
window and rear window glass fence (Item 3). Cut all the way around the rear window glass until it is free
from the cab rear window glass fence all the way around the rear window.
1. POWER KNIFE 3. REAR WINDOW GLASS FENCE

2. SHORT INSIDE CUTTING BLADE
Figure 15 Cutting Rear Window Glass Out
6. Once the rear window glass (Item 1, Figure 16) is cut free from the cab rear window glass fence, lift it off
the cab. Place rear window glass out of the way.
17
REMOVE REAR WINDOW GLASS ON VEHICLES WITH VAN BODY
1. REAR WINDOW GLASS

Figure 16 Removing Rear Window Glass from Vehicle
4.3. REAR WINDOW GLASS ON VEHICLES WITH VAN BODY

Remove Rear Window Glass on Vehicles with Van Body on Standard Cab, Extended Cab and Crew
Cab for all Models
The 4100, 4200, 4300 and 4400 model vehicles come standard with a bonded in rear window glass (Figure
14) (See Figure 14, page 16).
IMPORTANT – To remove a rear window glass you will need to have the INTERNATIONAL® Bonded
Windshield Tool Kit ZTSE4470. This kit has a tool box that includes the tools required to remove and
install the bonded rear window glass. To order, call toll free in U. S. and Canada 1–800–520–2584 or
Fax 1–800–578–7375. NOTE - The INTERNATIONAL® Bonded Windshield Tool Kit ZTSE4470 is no
longer available through the INTERNATIONAL® tool supplier. For materials that are available contact
NOTE – Before starting to remove and replace a rear window glass, it is required that a self-carboning
form from INTERNATIONAL® titled “Bonded Windshield Replacement Report” be filled out completely
to confirm the condition of the vehicle and record the lot numbers of the Essex materials used before
starting the work. Refer to Figure 205 (See Figure 206, page 305) for a sample form at the back of this
Manual.
1. Chock the vehicle wheels.
2. Place protective coverings over areas near rear window glass inside the cab.
3. Before removing rear window glass, it may be necessary to remove the seats. Refer to SEATS, Remove
4. Remove bonded rear window glass as follows.
18
REAR WINDOW GLASS ON VEHICLES WITH VAN BODY REMOVE
WARNING
Wear protective eye wear and work gloves when removing rear window glass.
NOTE – When using a power knife to cut around the old rear window glass, use a spray bottle and
lubricate the cutting area with water (Figure 11) (See Figure 11, page 13). This will prevent burning of
the urethane and re-bonding of the windshield.
To remove a rear window glass from a vehicle with a van body, you will need to have the INTERNATIONAL®
Bonded Windshield Tool Kit ZTSE4470. This kit has two special suction cups (Item 1) and a slide rail (Item 2),
which will need to be assembled. (NOTE - The INTERNATIONAL® Bonded Windshield Tool Kit ZTSE4470
is no longer available through the INTERNATIONAL® tool supplier. For materials that are available
contact INTERNATIONAL® service parts.) They are required to remove and install the bonded rear window
glass from between the cab and the van body.
1. SUCTION CUP 5. FLAT HEAD SCREW

2. SLIDE RAIL 6. WING NUT
3. TOP RAIL 7. RED LINE ON PLUNGER
4. BOTTOM RAIL
Figure 17 Rear Window Removal and Installation Tool
5. Assemble slide rail (Item 2) by assembling the two top rails (Item 3) to the bottom rail (Item 4). The three
rails are identical and can be assembled in any one of the three locations. Line up holes in two top rails
with holes in the bottom rail. Install four flat head screws (Item 5) into two holes in each top rail and through
four holes in bottom rail. Install four wing nuts (Item 6) and tighten securely.
19
6. Before installing the two suction cups on the back of the van body, clean the area on the van body where
the suction cups will be installed, so that the suction cups will stick securely to the back of the van body.
CAUTION
It is very important that the area on the back of the van body where the suction cups
are being installed, is cleaned properly before the suction cups are installed on the van
body. If the suction cups come off during the removal or installation of the rear window
glass, the rear window glass would be destroyed and the vehicle damaged.
Refer to Figure 18 (See Figure 18, page 20) for Items in parentheses unless otherwise noted.
7. Install one suction cup (Item 1) on the van body between the back of the cab and the van body on the
driver's side, so that the slide rail will be just below the bottom edge of the rear window glass. With the
suction cup placed against the back of the van body, repeatedly push plunger (Item 2) until the red line
(Item 7, Figure 17) (See Figure 17, page 19) on the plunger is not visible. Throughout the procedure of
removing and installing a rear window glass, check to see if the red line is starting to appear on the suction
cup, if the red line is visible, push the plunger until the red line is no longer visible.
8. Install the other suction cup (Item 3) on the van body between the back of the cab and the van body on the
passengers side, so that the slide rail will be just below the bottom edge of the rear window glass. With the
suction cup placed against the back of the van body, repeatedly push plunger until the red line (Item 7,
Figure 17) (See Figure 17, page 19) on the plunger is not visible. Throughout the procedure of removing
and installing a rear window glass, check to see if the red line is starting to appear on the suction cup, if the
red line is visible, push the plunger until the red line is no longer visible.
1. DRIVER'S SIDE SUCTION CUP 3. PASSENGER'S SIDE SUCTION

2. SUCTION CUP PLUNGER CUP
Figure 18 Install Suction Cups on Van Body
20
Refer to Figure 19 (See Figure 19, page 21) for Items in parentheses.
9. Once both suction cups (Item 1) have been properly install to the back of the van body, position the slide
rail (Item 2) across the block (Item 3) on each suction cup.
1. SUCTION CUP 3. BLOCK ON SUCTION CUP

2. SLIDE RAIL
Figure 19 Install Slide Rail on Suction Cups on Van Body
21
10. On driver side, align the hole in the slide rail (Item 1) with the hole in the block (Item 2) on the suction cup
(Item 3). Install pin (Item 4) through slide rail and suction cup to secure slide rail on the suction cup.
1. SLIDE RAIL 3. SUCTION CUP

2. BLOCK ON SUCTION CUP 4. PIN
Figure 20 Install Pin Through Slide Rail into Suction Cup Block on Driver Side
22
11. It will be necessary to reposition the suction cup (Item 1) on the passenger side to align the hole in the
slide rail (Item 2) with the hole in the block (Item 3) on the suction cup. Install pin (Item 4) through slide rail
and suction cup to secure slide rail on the suction cup. With the suction cup placed against the back of the
van body, repeatedly push plunger (Item 2, Figure 18) (See Figure 18, page 20)) until the red line (Item 7,
Figure 17) (See Figure 17, page 19) on the plunger is not visible.
1. SUCTION CUP 3. BLOCK ON SUCTION CUP

2. SLIDE RAIL 4. PIN
Figure 21 Install Pin Through Slide Rail into Suction Cup Block on Passenger Side
23
12. Before the rear window glass (Item 1) is cut completely free from window fence, install a suction cup (Item
2) on the left hand side of the rear window glass
1. REAR WINDOW GLASS 2. SUCTION CUP

Figure 22 Installing Suction Cup on Rear Window Glass
13. Using a power knife (Item 1) with short inside cutting blade (Item 2), work cutting blade between rear
window and rear window glass fence (Item 3). Cut all the way around the rear window glass until it is free
from the cab rear window glass fence all the way around the rear window.
14. Once the rear window glass (Item 1) is cut free from the cab rear window glass fence, using the suction
cup (Item 2), tilt the top of rear window glass out enough to grab the top of rear window glass with the
other hand. Lift the rear window glass off window glass fence and place it in the slide rail. Lean the
top of rear window glass against the van body.
15. Using the suction cup (Item 2), slide the rear window glass (Item 1) down the slide rail enough to grab the
rear window glass from outside the cab.
16. Remove the suction cup (Item 2) from the rear window glass (Item 1).
24
1. REAR WINDOW GLASS 2. SUCTION CUP

17. From outside the cab, slide the rear window glass (Item 1) down the slide rail and lift the rear window glass
off the slide rail. Place rear window glass out of the way.
1. REAR WINDOW GLASS

25
REMOVE HOOD SEAL
4.4. HOOD SEAL

Remove Hood Seal on Standard Cab, Extended Cab and Crew Cab for All Models
The hood seal is pushed onto the hood seal flange of the cowl tray.
1. Unlatch fiberglass tilt hood on both sides and raise hood to full open position.
2. Remove hood seal (Item 1) from cowl tray (Item 2) by pulling it off the hood seal flange of the cowl tray,
starting at one end or the other. Save the hood seal for installation, if not damaged.
1. HOOD SEAL 3. WINDSHIELD

2. COWL TRAY
Figure 25 Hood Seal
26
SUNSHADE REMOVE
4.5. SUNSHADE
Remove Sunshade on Standard Cab, Extended Cab and Crew Cab for all Models
1. MOUNTING BRACKET 5. MOUNTING BOLTS

2. ELECTRICAL CONNECTOR 6. CLEARANCE LIGHT
3. GASKET 7. SCREWS
4. SUNSHADE
Figure 26 Sunshade
1. Remove 6 screws from left, center, and right clearance lights (See Figure 26, page 27).
2. Pull clearance lights partially out of sunshade to expose mounting bolts.
3.
CAUTION
Do not allow sunshade to fall or hang from electrical cable when removing mounting
bolts. This can damage cable wires and result in inoperative clearance lights.
Support sunshade, and remove three mounting bolts from mounting bracket.
4. Disconnect electrical connector, and remove sunshade.
4.6. SUN VISOR AND CLIP

Remove Sun Visor and Clip on Standard Cab, Extended Cab and Crew Cab for all Models
1. Remove three torx head screws (Item 1) securing sun visor (Item 2) to the header console panel (Item 3)
and remove the sun visor from the sun visor clip (Item 4) at the center of the header console panel. Lay it
out of the way and save for installation, unless damaged and being replaced.
27
REMOVE SUN VISOR AND CLIP
IMPORTANT – If sun visor (Item 2) will not drop down out of header console panel (Item 3) once the torx head
screws (Item 1) have been removed. It will be necessary to drop the corner of the header console panel down
far enough to remove the retaining washer (Item 5), used during assembly, holding the sun visor to the inside
of the header console panel before sun visor will drop down out of header console panel. To lower header
console panel, refer to HEADER CONSOLE PANEL (See HEADER CONSOLE PANEL, page 130).
2. Remove the torx head screw (Item 6) securing the sun visor clip (Item 4) to the header console panel (Item
3). Lay the torx head screw out of the way and save for installation.
3. Once the torx head screw (Item 6) securing the sun visor clip (Item 4) to the header console panel (Item 3)
is removed, push the front edge (Item 7) nearest the windshield of the sun visor clip in and pull it out of
header console panel. Lay the sun visor clip out of the way and save for installation, unless damaged and
being replaced.
1. TORX HEAD SCREW 5. RETAINING WASHER

2. SUN VISOR 6. TORX HEAD SCREW
3. HEADER CONSOLE PANEL 7. FRONT EDGE OF SUN VISOR
4. SUN VISOR CLIP CLIP
Figure 27 Sun Visor and Clip
28
IGNITION SWITCH AND IGNITION SWITCH CYLINDER REMOVE
4.7. IGNITION SWITCH AND IGNITION SWITCH CYLINDER

The ignition switch and door locks are coded the same so that one key operates ignition switch and door locks.
The code number is stamped and bar coded on a plastic bag that the ignition switch and door lock cylinders
are supplied in at the assembly plant. This plastic bag is to remain with the vehicle when it is delivered to the
customer. It is very important that this plastic bag be kept by the customer in a safe, secure place, so that if a
replacement key is required, the key can be replaced.
The code number does not appear on ignition switch body or door lock assembly.
29
REMOVE IGNITION SWITCH AND IGNITION SWITCH CYLINDER
Remove Ignition Switch on Standard Cab, Extended Cab and Crew Cab for all Models
1. The ignition switch is located to the right of the driver in the dash panel (Item 1) below instrument panel.
Remove ignition switch as follows.
2. Remove rubber trim (Item 2) from around ignition switch (Item 3).
3. Using a 1–1/8 inch thin wall socket, unscrew mounting cap nut (Item 4) and remove it from ignition
switch (Item 3).
1. DASH PANEL 3. IGNITION SWITCH

2. RUBBER TRIM 4. MOUNTING CAP NUT
Figure 28 Ignition Switch Rubber Trim and Cap Nut
30
4. Reach up behind dash panel (Item 1) and pull ignition switch (Item 2) out of dash panel and pull it down
below dash panel.
1. DASH PANEL 2. IGNITION SWITCH

Figure 29 Ignition Switch
5. Disconnect ignition switch connector (Item 1) from the back of the ignition switch (Item 2) and remove
ignition switch from vehicle.
1. IGNITION SWITCH CONNECTOR 2. IGNITION SWITCH

Figure 30 Ignition Switch Connector
31
REMOVE IGNITION SWITCH AND IGNITION SWITCH CYLINDER
Remove Ignition Switch Cylinder on Standard Cab, Extended Cab and Crew Cab for all Models
1. Insert ignition key (Item 1) into ignition switch (Item 2) and rotate counterclockwise to accessory position,
so that the key is lined up with release hole (Item 3) in ignition switch body (Item 4).
1. IGNITION KEY 3. RELEASE HOLE

2. IGNITION SWITCH 4. IGNITION SWITCH BODY
Figure 31 Position Ignition Switch in Accessory Position
32
Refer to Figure 32 for Items in parentheses unless otherwise noted.
2. Insert a 1/16 inch (1.6 mm) diameter rod (paper clip) (Item 1) into release hole (Item 3, Figure 31) (See
Figure 31, page 32) in ignition switch body (Item 2) of ignition switch and depress switch cylinder retainer.
1. ROD 3. IGNITION KEY

2. IGNITION SWITCH BODY
Figure 32 Switch Cylinder and Ignition Switch Body
33
REMOVE INSTRUMENT PANEL
3. Pull complete ignition switch cylinder (Item 1) using ignition key (Item 3) from ignition switch body (Item 2).
1. IGNITION SWITCH CYLINDER 3. IGNITION KEY

2. IGNITION SWITCH BODY
Figure 33 Remove or Install Switch Cylinder
NOTE – If vehicle keys are lost, drill out switch cylinder. Using a 5/16 inch (8 mm) drill bit, drill 1/2 to 3/4
inch (12.7 to 19 mm) deep. This will permit tumblers to drop out and free switch cylinder.
4.8. INSTRUMENT PANEL

Remove Instrument Panel on Standard Cab, Extended Cab and Crew Cab for all Models
Remove instrument panel to provide for easy access to speedometer, cables, gauges, bulbs, wiring, plumbing,
switches, valves, etc. For further information on the instrument panel, refer to GROUP 08 - ELECTRICAL
in the Master Service Manual.
34
INSTRUMENT PANEL REMOVE
1. HEX BOLT ASSEMBLY (M8 X 2. INSTRUMENT PANEL

1.25) 3. FUSE PANEL ACCESS COVER
35
REMOVE INSTRUMENT PANEL
4. AUTOMATIC TRANSMISSION 24. TRAILER AIR SUPPLY

SHIFTER UNIT CONTROL (AIR BRAKES ONLY)
5. HEX FLANGED BOLT (M8 X 25. PARKING BRAKE CONTROL
77MM) (AIR BRAKES ONLY)
6. AUTOMATIC TRANSMISSION 26. OPTIONAL GAUGES AND
SHIFTER UNIT MOUNTING ACCESSORIES PANEL
BRACKET 27. THREE POSITION SWITCH
7. CENTER DASH PANEL BANK (OPTIONAL)
8. HEX BOLT ASSEMBLY (M8 X 28. THREE POSITION SWITCH
1.25) BANK (OPTIONAL)
9. STEERING COLUMN 29. DRIVER DASH PANEL
10. TORX HEAD BOLT ASSEMBLY 30. ENGINE OIL PRESSURE
(6MM X 15) GAUGE
11. AIR BRAKE CONTROL UNIT 31. ENGINE WATER
12. TORX HEAD BOLT ASSEMBLY TEMPERATURE GAUGE
13. HEX BOLT ASSEMBLY (M6 X 32. TACHOMETER
1.0) 33. SPEEDOMETER
14. U-SHAPED SPEED NUT (M6 34. FUEL GAUGE
SHORT LOCKING) 35. VOLTS GAUGE
15. COWL PANEL 36. AIR 1 PRIMARY PRESSURE
16. AIR CONDITIONING/HEAT GAUGE (AIR BRAKES ONLY)
VENT 37. AIR 2 SECONDARY PRESSURE
17. CENTER INSTRUMENT PANEL GAUGE (AIR BRAKES ONLY)
COVER 38. HEAD LIGHT SWITCH
18. AIR CONDITIONING/HEAT (OFF/PARK/HEAD)
VENT 39. DASH PANEL LIGHT DIMMER
19. AIR CONDITIONING/HEAT SWITCH
CONTROLS 40. OPTIONAL SWITCH LOCATION
20. RADIO 41. OPTIONAL GAUGE LOCATION
21. IGNITION SWITCH 42. INDICATOR LIGHT PANEL
22. THREE POSITION SWITCH 43. ODOMETER/TRANSMISSION
BANK METER
23. THREE POSITION SWITCH 44. WARNING LIGHT PANEL
BANK (OPTIONAL) 45. ETHER SWITCH START
46. OPTIONAL SWITCH LOCATION
Figure 34 Instrument Panel
IMPORTANT – Always disconnect battery ground before servicing or removing instrument panel.
WARNING
Batteries expel explosive gases. Keep sparks, flames, burning cigarettes, or other
ignition sources away at all times. Always wear safety glasses and a face shield when
working near batteries
1. With driver side door open, remove two hex bolt assemblies (Item 1) under the left end of the driver side,
lower instrument panel (Item 2). Lay hex bolt assemblies out of the way and save for installation.
2. With passenger side door open, carefully pull the top of fuse panel access cover (Item 3) away from
instrument panel (Item 2). Then lift fuse panel access cover up to clear tabs at the bottom of the fuse panel
36
INSTRUMENT PANEL REMOVE
access cover. Lay it out of the way and save for installation, unless being replaced. Remove two hex bolt
assemblies (Item 1) under the right end of the passenger side, lower instrument panel (Item 2). Lay hex
bolt assemblies out of the way and save for installation.
3. If equipped with automatic transmission shifter unit (Item 4), remove two hex flanged bolts (Item 5) from
automatic transmission shifter unit mounting bracket (Item 6) at the left edge of the center dash panel (Item
7) of instrument panel (Item 2). Lay automatic transmission shifter unit and hex flanged bolts out of the
way and save for installation.
4. Remove two hex bolt assemblies (Item 8) from underneath steering column (Item 9). Lay hex bolt
assemblies out of the way and save for installation.
5. Using a flat blade screw driver, carefully slide it between the center dash panel (Item 1) and center dash
panel trim bezel (Item 2). Carefully pry the center dash panel trim bezel out of the center dash panel. Lay it
6. Remove four torx head bolt assemblies (Item 10) from the air brake control unit (Item 11) in the center
dash panel (Item 7). Lay hex bolt assemblies out of the way and save for installation.
7. Remove six torx head bolt assemblies (Item 12) from the center dash panel (Item 7). Lay torx head bolts
out of the way and save for installation.
8. Remove courtesy lights under the instrument panel on both driver and passenger side. Lay them out of the
9. Disconnect ignition switch connector (Item 1) from the back of the ignition switch (Item 2).
10. Remove five hex bolt assemblies (Item 13) from five U-shaped speed nuts (Item 14) at the front edge
of the upper instrument panel (Item 2) and cowl panel (Item 15). Lay hex bolt assemblies out of the
installation.
13. Once both driver and passenger side A pillar trim panels (Items 1 and 5) are removed, remove instrument
panel as follows.
37
REMOVE CAB DOORS
14. Remove instrument panel (Item 2) by carefully lifting it forward away from the windshield and then upward
over the steering wheel. This will allow for disconnecting warning harness connectors and air ducts so the
instrument panel can removed from the vehicle.
15. To access fuse panel, carefully pull the top of fuse panel access cover (Item 3) away from instrument panel
(Item 2). Then lift fuse panel access cover up to clear tabs at the bottom of the fuse panel access cover.
Lay it out of the way and save for installation, unless being replaced.
4.9. CAB DOORS

Remove Front Cab Door on Standard Cab, Extended Cab and Crew Cab for all Models
Doors are of all steel-welded construction. The front cab door is mounted on hinges located on the front cab
door hinge pillar and door adjustment is provided by enlarged holes in front cab door hinge. Door check
stop is located just below upper hinge on the front cab door hinge pillar. Front cab door latch striker pin is
also adjustable on front cab door lock pillar. Service on the door and its components is covered in sections
which follow.
38
CAB DOORS REMOVE
1. Remove door wiring harness rubber boot (Item 1) from the cab hinge pillar (Item 2), driver side shown.
1. DOOR WIRING HARNESS 2. CAB HINGE PILLAR

RUBBER BOOT
Figure 35 Door Wiring Harness Rubber Boot
2. Reach up under the instrument panel to the left of the steering wheel and locate wiring harness coming
from the front cab door, pull cab door wiring harness (Item 1) down to access connectors (Item 2), driver
side shown.
1. CAB DOOR WIRING HARNESS 2. CONNECTOR

Figure 36 Door Wiring Harness and Connectors
39
REMOVE CAB DOORS
3. Once access to the connectors is accomplished, disconnect CB radio cable connector (Item 1), electric
window and electric door lock wiring harness connector (Item 2) and lighted, heated or electric mirror
wiring harness connector (Item 3), if so equipped, driver side shown.
1. CB RADIO CONNECTOR 3. LIGHTED, HEATED

2. ELECTRIC WINDOW AND DOOR OR ELECTRIC MIRROR
LOCK CONNECTOR CONNECTOR
Figure 37 Disconnected Connectors
4. Use a sling or padded chain through top of window opening and attach sling to an overhead hoist to
support front cab door.
5. Remove front cab door check stop pin (Item 1) from front cab door check link (Item 2) and front cab
door check bracket (Item 3), driver side shown.
6. Remove four hex nuts with washers (Item 4) from threaded studs (Item 5) of front cab door (Item 6),
driver side shown.
7. Slide four threaded studs (Item 5) of front cab door (Item 6) out of upper and lower front cab door hinges
(Items 7 and 8), driver side shown.
8. Carefully pull the wiring harness and connectors of front cab door (Item 6) through front cab door hinge
pillar.
9. Using overhead hoist move front cab door (Item 6) to a padded work bench, or cover with a material that
will not scratch painted surfaces of the door a work bench or other suitable support.
40
CAB DOORS REMOVE
1. FRONT CAB DOOR CHECK 5. THREADED STUD

STOP PIN 6. FRONT CAB DOOR
2. FRONT CAB DOOR CHECK LINK 7. UPPER FRONT CAB DOOR
3. FRONT CAB DOOR CHECK HINGE
BRACKET 8. LOWER FRONT CAB DOOR
4. HEX NUT WITH WASHER HINGE
Figure 38 Front Cab Door
10. Repeat procedure to remove passenger side front door.
41
REMOVE CAB DOORS
Remove Rear Cab Door on Crew Cab for All Models
Doors are of all steel-welded construction. The rear cab door is mounted on hinges located on the cab B - pillar
and door adjustment is provided by enlarged holes in rear cab door hinge. Rear cab door check stop is located
just below upper rear cab door hinge on the cab B - pillar. Rear cab door latch striker pin is also adjustable on
rear cab door lock pillar. Service on the door and its components is covered in sections which follow.
1. Remove door wiring harness rubber boot (Item 1) from the cab hinge pillar (Item 2).
2. Remove torx head bolt (Item 1) securing shoulder belt D - ring (Item 2) to the B - pillar trim panel (Item
3), driver side shown. Lay shoulder belt and D - ring out of the way, discard the D - ring torx head bolt.
A new torx head bolt is required at installation.
1. TORX HEAD BOLT 3. B - PILLAR TRIM PANEL

2. SHOULDER BELT D - RING
Figure 39 Shoulder Belt D - ring on B - pillar Trim Panel
42
CAB DOORS REMOVE
3. Remove push-in fastener (Item 1) securing the seat belt retractor cover (Item 2) to the seat belt retractor
bracket, driver side shown. Save push-in fastener for installation.
4. Remove torx head screw (Item 3) nearest the B - pillar securing the rear door seal plate (Item 4) to the
cab floor, driver side shown. Save torx head screw for installation.
1. PUSH-IN FASTENER 3. TORX HEAD SCREW

2. SEAT BELT RETRACTOR COVER 4. REAR DOOR SEAL PLATE
Figure 40 Seat Belt Retractor Cover and Rear Door Seal Plate
43
REMOVE CAB DOORS
5. Using a removal tool (Item 1), remove six push-in fasteners (Item 2) from the B - pillar trim panel (Item 3),
driver side shown. Lay push-in fasteners out of the way and save for installation.
1. REMOVAL TOOL 3. B - PILLAR TRIM PANEL

2. PUSH-IN FASTENER
Figure 41 B - pillar Trim Panel
6. Lift seat belt retractor cover (Item 2) and rear door seal plate (Item 4) up enough to allow removal of B -
pillar trim panel. Lay B - pillar trim panel out of the way and save for installation.
7. Disconnect cab wiring harness electrical connector (Item 1) from cab door wiring harness electrical
connector (Item 2), driver side shown.
8. Disconnect cab door light switch connector (Item 3) from cab wiring harness light switch connector (Item
4), driver side shown.
44
CAB DOORS REMOVE
1. CAB WIRING HARNESS 3. CAB DOOR LIGHT SWITCH

ELECTRICAL CONNECTOR CONNECTOR
2. CAB DOOR WIRING HARNESS 4. CAB WIRING HARNESS LIGHT
ELECTRICAL CONNECTOR SWITCH CONNECTOR
Figure 42 Rear Cab Door Wiring Harness and Connectors
support rear cab door.
10. Remove rear cab door check stop pin (Item 1) from rear cab door check link (Item 2) and rear cab door
check bracket (Item 3), driver side shown.
11. Remove four hex nuts with washers (Item 4) from threaded studs (Item 5) of rear cab door (Item 6),
driver side shown.
12. Slide four threaded studs (Item 5) of rear cab door (Item 6) out of upper and lower rear cab door hinges
(Items 7 and 8), driver side shown.
13. Carefully pull the wiring harness and connectors of rear cab door (Item 6) through B - pillar.
14. Using overhead hoist move rear cab door (Item 6) to a padded work bench or other suitable support, or
cover with a material that will not scratch painted surfaces of the door.
15. Repeat procedure to remove passenger side rear door.
45
REMOVE CAB DOORS
46
1. REAR CAB DOOR CHECK STOP 2. REAR CAB DOOR CHECK LINK
PIN
CAB DOOR HINGE REMOVE
3. REAR CAB DOOR CHECK 6. REAR CAB DOOR

BRACKET 7. UPPER REAR CAB DOOR HINGE
4. HEX NUT WITH WASHER 8. LOWER REAR CAB DOOR
5. THREADED STUD HINGE
Figure 43 Crew Cab Rear Cab Door and Crew Cab Rear Cab Door Hinge
4.10. CAB DOOR HINGE

Remove Front Cab Door Hinge on Standard Cab, Extended Cab and Crew Cab for all Models
The front cab door is mounted on upper and lower cab door hinges (Items 1 and 2) located on the cab hinge
pillar (Item 3). Front cab door adjustment is provided by enlarged holes in front cab door hinge mounting holes.
If cab door hinges are removed from the cab, upper and lower hinges can be interchanged.
1. Before removing upper and lower cab door hinges (Items 1 and 2) from cab hinge pillar (Item 3), remove
the front cab door from front cab door hinges. Refer to CAB DOORS (See CAB DOORS, page 38).
2. Before removing upper and lower cab door hinges (Items 1 and 2) from cab hinge pillar (Item 3), mark
upper and lower hinge position on cab hinge pillar with grease pencil or similar marker to simplify door
adjustment on reassembly.
3. To remove upper cab door hinge (Item 1), remove one hex bolt with washer (Item 4) and one hex flanged
locking bolt (Item 5) from the upper cab door hinge and remove it from the cab hinge pillar (Item 3).
Note the location of the hex flanged shoulder bolt so it can be installed back in the correct location,
driver side shown.
4. To remove lower cab door hinge (Item 2), remove two hex bolts with washer (Item 4) from lower cab door
hinge and remove it from the cab hinge pillar (Item 3), driver side shown.
47
REMOVE CAB DOOR HINGE
1. UPPER CAB DOOR HINGE 4. HEX BOLT WITH WASHER

2. LOWER CAB DOOR HINGE 5. HEX FLANGED LOCKING BOLT
3. CAB HINGE PILLAR
Figure 44 Cab Door Hinge Mounted on Cab Hinge Pillar
5. Repeat procedure to remove upper and lower passenger side front cab door hinges.
Remove Rear Cab Door Hinge on Crew Cab for all Models
The crew cab rear door is mounted on upper and lower cab door hinges (Items 1 and 2) located on the crew
cab B - pillar (Item 3). Rear cab door adjustment is provided by enlarged holes in rear cab door hinge mounting
holes. If hinges are removed from the crew cab B - pillar, upper and lower hinges can be interchanged.
1. Before removing crew cab rear door hinges (Items 1 and 2) from crew cab B - pillar (Item 3), remove the
rear cab door from crew cab rear door hinges. Refer to CAB DOORS (See CAB DOORS, page 38).
2. Before removing crew cab rear door hinges (Items 1 and 2) from crew cab B - pillar (Item 3), mark
upper and lower hinge position on crew cab B - pillar with grease pencil or similar marker to simplify
door adjustment on reassembly.
48
CAB DOOR HINGE REMOVE
3. To remove upper crew cab rear door hinge (Item 1), remove two hex bolts with washer (Item 4) from the
upper crew cab rear door hinge and remove it from the crew cab B - pillar (Item 3), driver side shown.
4. To remove lower crew cab rear door hinge (Item 2), remove two hex bolts with washer (Item 4) from lower
crew cab rear door hinge and remove it from the crew cab B - pillar (Item 3), driver side shown.
1. UPPER CREW CAB REAR DOOR 3. CREW CAB B - PILLAR

HINGE 4. HEX BOLT WITH WASHER
2. LOWER CREW CAB REAR
DOOR HINGE
Figure 45 Crew Cab Rear Door Hinge Mounted on Cab B - Pillar
5. Repeat procedure to remove upper and lower passenger side crew cab rear door hinges.
49
REMOVE CAB DOOR STRIKER PIN
4.11. CAB DOOR STRIKER PIN

Remove Front Cab Door Striker Pin on Standard Cab, Extended Cab and Crew Cab for All Models
1. FRONT CAB DOOR STRIKER 4. TORX HEAD BOLT

PIN 5. FLOATING TAPPED STRIKER
2. CAB LOCK PILLAR PIN MOUNTING PLATE
3. TORX HEAD TOOL
Figure 46 Front Cab Door Striker Pin
Front cab door striker pin (Item 1) mounted on cab lock pillar (Item 2) provides for positive engagement with
the door latch assembly (Item 7, Figure 72) (See Figure 72, page 80). Front cab door striker pin removal and
installation requires a torx head tool (Item 3). Enlarged mounting holes in cab lock pillar and floating tapped
striker pin mounting plate (Item 5) located inside cab lock pillar permits adjustment.
1. Use a torx head tool (Item 3) and remove two torx head bolts (Item 4) to remove the front cab door striker
pin (Item 1) from the floating tapped striker pin mounting plate (Item 5) located inside cab lock pillar
(Item 2), driver side shown.
2. Repeat procedure to remove passenger side front cab door striker pin.
50
CAB DOOR STRIKER PIN REMOVE
Remove Rear Cab Door Striker Pin on Crew Cab for all Models
Crew cab rear door striker pin (Item 1) mounted on cab lock pillar (Item 2) provides for positive engagement
with the door latch assembly (Item 7, Figure 74) (See Figure 74, page 83). Crew cab rear door striker pin
removal and installation requires a torx head tool (Item 3). Enlarged mounting holes in cab lock pillar and
floating tapped striker pin mounting plate (Item 5) located inside cab lock pillar permits adjustment.
1. Use a torx head tool (Item 3) and remove two torx head bolts (Item 4) to remove the crew cab rear door
striker pin (Item 1) from the floating tapped striker pin mounting plate (Item 5) located inside cab lock pillar
1. CREW CAB REAR DOOR 4. TORX HEAD BOLT

STRIKER PIN 5. FLOATING TAPPED STRIKER
2. CAB LOCK PILLAR PIN MOUNTING PLATE
3. TORX HEAD TOOL
Figure 47 Crew Cab Rear Door Striker Pin
2. Repeat procedure to remove passenger side crew cab rear door striker pin.
51
REMOVE CAB DOOR CHECK BRACKET
4.12. CAB DOOR CHECK BRACKET

Remove Front Cab Door Check Bracket on Standard Cab, Extended Cab and Crew Cab for all Models
1. Use a torx head tool (Item 1) and remove two torx head bolts (Item 2) to remove the front cab door check
bracket (Item 3) from the cab hinge pillar (Item 4), driver side shown.
1. TORX HEAD TOOL 4. CAB HINGE PILLAR

2. TORX HEAD BOLT
3. FRONT CAB DOOR CHECK
BRACKET
Figure 48 Front Cab Door Check Bracket
2. Repeat procedure to remove passenger side front cab door check bracket.
52
CAB DOOR CHECK LINK REMOVE
Remove Crew Cab rear Door Check Bracket on Crew Cab for all Models
1. Use a torx head tool (Item 1) and remove two torx head bolts (Item 2) to remove the crew cab rear door
check bracket (Item 3) from the crew cab B - pillar (Item 4), driver side shown.
1. TORX HEAD TOOL 4. CREW CAB B - PILLAR

2. TORX HEAD BOLT
3. CREW CAB REAR DOOR CHECK
BRACKET
Figure 49 Crew Cab Rear Door Check Bracket
2. Repeat procedure to remove passenger side crew cab rear door check bracket.
4.13. CAB DOOR CHECK LINK

Remove Front Cab Door Check Link on Standard Cab, Extended Cab and Crew Cab for all Models
1. Remove front cab door trim panel, refer to CAB DOOR TRIM PANEL (See CAB DOOR TRIM PANEL,
page 56). If front cab door is equipped with electric windows and locks, refer to Remove Front Cab Door
Trim Panel with Electric Windows and Locks. If front cab door is equipped with manual windows and locks,
refer to Remove Front Cab Door Trim Panel with Manual Door Window and Locks.
2. Remove front cab door inner door panel water shield, refer to CAB DOOR INNER DOOR PANEL WATER
SHIELD (See CAB DOOR INNER DOOR PANEL WATER SHIELD, page 64). For removing front cab
door inner door panel water shield, refer to Remove Front Cab Door Inner Door Panel Water Shield on
Standard Cab, Extended Cab and Crew Cab for all Models.
53
REMOVE CAB DOOR CHECK LINK
3. Remove two hex nuts (Item 1) and remove the front cab door check link (Item 2) from the front cab door
1. HEX NUT 3. FRONT CAB DOOR

2. FRONT CAB DOOR CHECK LINK
Figure 50 Front Cab Door Check Link
4. Repeat procedure to remove passenger side front cab door check link.
Remove Rear Door Check Link on Crew Cab for all Models
1. Remove rear cab door trim panel, refer to CAB DOOR TRIM PANEL (See CAB DOOR TRIM PANEL, page
56). If crew cab rear door is equipped with electric windows and locks, refer to Remove Rear Cab Door
Trim Panel with Electric Windows and Locks. If crew cab rear door is equipped with manual windows and
locks, refer to Remove Rear Cab Door Trim Panel with Manual Door Window and Locks.
2. Remove crew cab rear door inner door panel water shield, refer to CAB DOOR INNER DOOR PANEL
WATER SHIELD (See CAB DOOR INNER DOOR PANEL WATER SHIELD, page 64). For removing rear
cab door inner door panel water shield, refer to Remove Rear Cab Door Inner Door Panel Water Shield
on Crew Cab for all Models.
54
CAB DOOR CHECK LINK REMOVE
3. Remove two hex nuts (Item 1) and remove the crew cab rear door check link (Item 2) from the crew cab
rear door (Item 3), driver side shown.
1. HEX NUT 3. CREW CAB REAR DOOR

2. CREW CAB REAR DOOR CHECK
LINK
Figure 51 Crew Cab Rear Door Check Link
4. Repeat procedure to remove passenger side crew cab rear door check link.
55
REMOVE CAB DOOR TRIM PANEL
4.14. CAB DOOR TRIM PANEL

Remove Front Cab Door Trim Panel with Electric Door Window and Locks on Standard Cab, Extended
Cab and Crew Cab for all Models
1. TORX HEAD SCREW 5. MAP POCKET

2. INNER DOOR PULL CUP 6. SMALL BLUNT SCREWDRIVER
3. FRONT CAB DOOR TRIM PANEL 7. PUSH-IN FASTENER
4. TORX HEAD SCREW
Figure 52 Front Cab Door Trim Panel Fasteners
1. Remove two torx head screws (Item 1, view arrow A) and remove inner door pull cup (Item 2, view arrow
A) from the front cab door trim panel (Item 3, view arrow A), driver side shown.
2. Remove two torx head screws (Item 4) recessed in map pocket (Item 5) of front cab door trim panel
3. Using a small blunt screwdriver (Item 6, view arrow B), push the center portion in slightly until they click,
on each of the eight push-in fasteners (Item 7, view arrow B). Remove each push-in fastener from front
cab door trim panel (Item 3), driver side shown.
56
CAB DOOR TRIM PANEL REMOVE
NOTE – If the center of the push-in fasteners (Item 7) is pushed in too far, the center portion will fall
inside the front cab door. Once the front cab door trim panel (Item 3) is removed from the front cab door,
the center portion of the push-in fasteners can be retrieved, driver side shown.
4. Lift front cab door trim panel (Item 1) up and away from front cab door (Item 2), driver side shown.
1. FRONT CAB DOOR TRIM PANEL 2. FRONT CAB DOOR

Figure 53 Front Cab Door Trim Panel
57
5. With the front cab door trim panel (Item 1) being held away from the front cab door (Item 2), disconnect
electrical connectors (Item 3) from electric window and door lock switch (Item 4). If so equipped,
disconnect electrical connector (Item 5) from electric mirror switch. Lay front cab door trim panel on a
padded surface and save for installation, driver side shown.
1. FRONT CAB DOOR TRIM PANEL 4. ELECTRIC WINDOW AND DOOR

2. FRONT CAB DOOR LOCK SWITCH
3. ELECTRICAL CONNECTOR 5. ELECTRICAL CONNECTOR
Figure 54 Front Cab Door Trim Panel Electrical Connectors
6. Repeat procedure to remove passenger side front cab door trim panel with electric door window and locks.
Remove Front Cab Door Trim Panel with Manual Door Window and Locks on Standard Cab, Extended
A) from the front cab door trim panel (Item 3, view arrow A), driver side shown.
2. Remove two torx head screws (Item 4) recessed in map pocket (Item 5) of front cab door trim panel
3. Push front cab door trim panel (Item 1, Figure 60) (See Figure 60, page 65) in at the window regulator
handle shaft. Using the proper removal tool, remove retaining clip (Item 13, Figure 60) (See Figure 60,
page 65) securing window regulator handle (Item 6) to the window regulator handle shaft. Remove window
regulator handle from window regulator handle shaft. Lay retaining clip and window regulator handle out of
the way and save for installation, driver side shown.
58
on each of the eight push-in fasteners (Item 8, view arrow B). Remove each push-in fastener from front
NOTE – If the center of the push-in fasteners (Item 8) are pushed in to far, the center portion will fall
inside the front cab door. Once the front cab door trim panel (Item 3) is removed from the front cab door,

2. INNER DOOR PULL CUP 6. WINDOW REGULATOR HANDLE
3. FRONT CAB DOOR TRIM PANEL 7. SMALL BLUNT SCREWDRIVER
4. TORX HEAD SCREW 8. PUSH-IN FASTENER
Figure 55 Front Cab Door Trim Panel Fasteners and Window Regulator Handle
59
5. Lift front cab door trim panel (Item 1) up and away from front cab door (Item 2). Lay front cab door trim
panel on a padded surface to protect painted surfaces and save for installation, driver side shown.
6. Repeat procedure to remove passenger side front cab door trim panel with manual door window and locks.
Remove Crew Cab Rear Cab Door Trim Panel with Electric Door Window and Locks on Crew Cab for
all Models

2. INNER DOOR PULL CUP 6. SMALL BLUNT SCREWDRIVER
3. REAR CAB DOOR TRIM PANEL 7. PUSH-IN FASTENER
4. TORX HEAD SCREW
Figure 56 Rear Cab Door Trim Panel Fasteners
60
A) from the rear cab door trim panel (Item 3, view arrow A), driver side shown.
2. Remove two torx head screws (Item 4) recessed in map pocket (Item 5) of rear cab door trim panel
on each of the eight push-in fasteners (Item 7, view arrow B). Remove each push-in fastener from rear
NOTE – If the center of the push-in fasteners (Item 7) is pushed in too far, the center portion will fall
inside the rear cab door. Once the rear cab door trim panel (Item 3) is removed from the rear cab door,
4. Lift rear cab door trim panel (Item 1) up and away from rear cab door (Item 2), driver side shown.
1. REAR CAB DOOR TRIM PANEL 2. REAR CAB DOOR

Figure 57 Rear Cab Door Trim Panel
61
5. With the rear cab door trim panel (Item 1) being held away from the rear cab door (Item 2), disconnect
electrical connectors (Item 3) from electric window and door lock switch (Item 4). Lay rear cab door trim
panel on a padded surface and save for installation, driver side shown.
1. REAR CAB DOOR TRIM PANEL 4. ELECTRIC WINDOW AND DOOR

2. REAR CAB DOOR LOCK SWITCH
3. ELECTRICAL CONNECTOR
Figure 58 Rear Cab Door Trim Panel Electrical Connectors
6. Repeat procedure to remove passenger side rear cab door trim panel with electric door window and
locks, driver side shown.
Remove Crew Cab Rear Cab Door Trim Panel with Manual Door Window and Locks on Crew Cab for
all Models
A) from the rear cab door trim panel (Item 3, view arrow A), driver side shown.
2. Remove two torx head screws (Item 4) recessed in map pocket (Item 5) of rear cab door trim panel
3. Push rear cab door trim panel (Item 1, Figure 61) (See Figure 61, page 66) in at the window regulator
handle shaft. Using the proper removal tool, remove retaining clip (Item 13, Figure 61) (See Figure 61,
page 66) securing window regulator handle (Item 6) to the window regulator handle shaft. Remove window
regulator handle from window regulator handle shaft. Lay retaining clip and window regulator handle out of
the way and save for installation, driver side shown.
62
on each of the eight push-in fasteners (Item 8, view arrow B). Remove each push-in fastener from rear
NOTE – If the center of the push-in fasteners (Item 8) are pushed in to far, the center portion will fall
inside the rear cab door. Once the rear cab door trim panel (Item 3) is removed from the rear cab door,

2. INNER DOOR PULL CUP 6. WINDOW REGULATOR HANDLE
3. REAR CAB DOOR TRIM PANEL 7. SMALL BLUNT SCREWDRIVER
4. TORX HEAD SCREW 8. PUSH-IN FASTENER
Figure 59 Rear Cab Door Trim Panel Fasteners and Window Regulator Handle
63
REMOVE CAB DOOR INNER DOOR PANEL WATER SHIELD
5. Lift rear cab door trim panel (Item 1) up and away from rear cab door (Item 2). Lay rear cab door trim panel
on a padded surface to protect painted surfaces and save for installation, driver side shown.
6. Repeat procedure to remove passenger side rear cab door trim panel with manual door window and locks.
4.15. CAB DOOR INNER DOOR PANEL WATER SHIELD

Remove Front Cab Door Inner Panel Water Shield on Standard Cab, Extended Cab and Crew Cab for
all Models
page 56). If front cab door is equipped with electric door window and locks, refer to Remove Front Cab
Door Trim Panel with Electric Door Window and Locks. If front cab door is equipped with manual door
window and locks, refer to Remove Front Cab Door Trim Panel with Manual Door Window and Locks.
2. Once the front cab door trim panel (Item 1) is removed. Before removing front cab door inner door panel
water shield (Item 2), note how it is positioned on the front cab door (Item 3), so that it can be installed
properly during the install procedure. Carefully remove the front cab door inner door panel water shield
from the front cab door, driver side shown. Lay out of the way and save for installation unless damaged
and being replaced.
64
CAB DOOR INNER DOOR PANEL WATER SHIELD REMOVE
1. FRONT CAB DOOR TRIM PANEL 8. CAB DOOR ACCESS OPENING

2. FRONT CAB DOOR INNER 9. BLUNT TIP FLAT BLADE SCREW
DOOR PANEL WATER SHIELD DRIVER
3. FRONT CAB DOOR 10. WINDOW REGULATOR ARM
4. CAB DOOR GLASS 11. CAB DOOR WINDOW SLIDE
5. ELECTRIC WINDOW SWITCH BLOCK
PANEL 12. CAB DOOR WINDOW SLIDE
6. WINDOW REGULATOR HANDLE RAIL
7. WINDOW REGULATOR HANDLE 13. RETAINING CLIP
SHAFT
Figure 60 Front Cab Door Inner Door Panel Water Shield
3. Repeat procedure to remove passenger side front cab door inner door panel water shield.
65
REMOVE CAB DOOR INNER DOOR PANEL WATER SHIELD
Remove Rear Cab Door Inner Panel Water Shield on Crew Cab for all Models
56). If rear cab door is equipped with electric door window and locks, refer to Remove Rear Cab Door Trim
Panel with Electric Door Window and Locks. If rear cab door is equipped with manual door window and
1. REAR CAB DOOR TRIM PANEL 8. CAB DOOR ACCESS OPENING

2. REAR CAB DOOR INNER DOOR 9. BLUNT TIP FLAT BLADE SCREW
PANEL WATER SHIELD DRIVER
3. REAR CAB DOOR 10. WINDOW REGULATOR ARM
4. CAB DOOR GLASS 11. CAB DOOR WINDOW SLIDE
5. ELECTRIC WINDOW SWITCH BLOCK
PANEL 12. CAB DOOR WINDOW SLIDE
6. WINDOW REGULATOR HANDLE RAIL
7. WINDOW REGULATOR HANDLE 13. RETAINING CLIP
SHAFT
Figure 61 Rear Cab Door Inner Door Panel Water Shield
66
CAB DOOR WINDOW SLIDE BLOCK REMOVE
2. Once the rear cab door trim panel (Item 1) is removed. Before removing rear cab door inner door panel
water shield (Item 2), note how it is positioned on the rear cab door (Item 3), so that it can be installed
properly during the install procedure. Carefully remove the rear cab door inner door panel water shield
from the rear cab door, driver side shown. Lay out of the way and save for installation unless damaged
and being replaced.
3. Repeat procedure to remove passenger side rear cab door inner door panel water shield.
4.16. CAB DOOR WINDOW SLIDE BLOCK

Remove Front Cab Door Window Slide Block on Standard Cab, Extended Cab and Crew Cab for
all Models
NOTE – It is not necessary to remove the front cab door glass to remove the front cab door window slide
block.
1. If vehicle is equipped with electric door window, lower cab door glass (Item 4) to the bottom of front
cab door (Item 3) before disconnecting electric window switch panel (Item 5) during front cab door trim
panel (Item 1) removal.
4. If vehicle is equipped with manual door window, temporarily place the window regulator handle (Item 6)
on the window regulator handle shaft (Item 7) and lower cab door glass (Item 4) to the bottom of front
cab door (Item 3), driver side shown.
5. Working through the cab door access opening (Item 8), using a blunt tip flat blade screw driver (Item 9),
carefully pry window regulator arm (Item 10) from the cab door window slide block (Item 11) in the cab
door window slide rail (Item 12), driver side shown.
6. Working through the cab door access opening, using a small flat blade screw driver (Item 1), carefully
brake off the plastic retaining tab (Item 2) used to keep the cab door window slide block (Item 3) from
sliding off the cab door window slide rail (Item 4), driver side shown.
7. Once the plastic retaining tab (Item 2) is removed , slide the cab door window slide block (Item 3) from the
cab door window slide rail (Item 4), driver side shown.
67
REMOVE CAB DOOR WINDOW SLIDE BLOCK
1. FLAT BLADE SCREW DRIVER 4. CAB DOOR WINDOW SLIDE

2. PLASTIC RETAINING TAB RAIL
3. CAB DOOR WINDOW SLIDE
BLOCK
Figure 62 Front Cab Door Window Slide Block
8. Repeat procedure to remove passenger side front cab door window slide block.
Remove Rear Cab Door Window Slide Block on Crew Cab for all Models
NOTE – It is not necessary to remove the rear cab door glass to remove the rear cab door window slide
block.
1. If vehicle is equipped with electric door window, lower cab door glass (Item 4) to the bottom of rear cab
door (Item 3) before disconnecting electric window switch panel (Item 5) during rear cab door trim panel
(Item 1) removal.
3. Remove rear cab door inner door panel water shield, refer to CAB DOOR INNER DOOR PANEL WATER
SHIELD (See CAB DOOR INNER DOOR PANEL WATER SHIELD, page 64). For removing rear cab
door inner door panel water shield, refer to Remove Rear Cab Door Inner Door Panel Water Shield
68
CAB DOOR WINDOW SLIDE BLOCK REMOVE
on the window regulator handle shaft (Item 7) and lower cab door glass (Item 4) to the bottom of rear
6. Working through the cab door access opening, using a small flat blade screw driver (Item 1), carefully
brake off the plastic retaining tab (Item 2) used to keep the cab door window slide block (Item 3) from
sliding off the cab door window slide rail (Item 4), driver side shown.
7. Once the plastic retaining tab (Item 2) is removed , slide the cab door window slide block (Item 3) from the
cab door window slide rail (Item 4), driver side shown.
1. FLAT BLADE SCREW DRIVER 4. CAB DOOR WINDOW SLIDE

2. PLASTIC RETAINING TAB RAIL
3. CAB DOOR WINDOW SLIDE
BLOCK
Figure 63 Rear Cab Door Window Slide Block
8. Repeat procedure to remove passenger side rear cab door window slide block.
69
REMOVE CAB DOOR GLASS
4.17. CAB DOOR GLASS

Remove Front Cab Door Glass on Standard Cab, Extended Cab and Crew Cab for all Models
1. If vehicle is equipped with electric door window, lower cab door glass (Item 4) to the bottom of front cab
door before disconnecting electric window switch panel (Item 5) during front cab door trim panel removal.
70
CAB DOOR GLASS REMOVE
6. Remove front cab door glass seal and run channel by first pulling left side of front cab door glass seal and
run channel (Item 1) from front cab door (Item 2). Then pull the top of front cab door glass seal and run
channel (Item 3) down from the front cab door, driver side shown.
1. LEFT SIDE OF FRONT CAB 3. TOP OF FRONT CAB DOOR

DOOR GLASS SEAL AND RUN GLASS SEAL AND RUN
CHANNEL CHANNEL
2. FRONT CAB DOOR
Figure 64 Front Cab Door Glass Seal and Run Channel
71
7. Pull right side of front cab door glass seal and run channel (Item 1) from the front cab door (Item 2), driver
side shown. Lay it out of the way and save for installation, if not damaged.
1. RIGHT SIDE OF FRONT CAB 2. FRONT CAB DOOR

DOOR GLASS SEAL AND RUN
CHANNEL
72
8. Pull front cab door glass seal and inner belt (Item 1) from inner lower flange of front cab door (Item 2). Also
pull front cab door glass seal and outer belt (Item 3) from outer lower flange of front cab door, driver side
shown. Lay them both out of the way and save for installation, if not damaged.
9. Lift front cab door glass (Item 4) up to cab door glass opening of front cab door (Item 2), driver side shown.
Modular door hardware assembly removed for clarity.
1. FRONT CAB DOOR GLASS SEAL 3. FRONT CAB DOOR GLASS SEAL
AND INNER BELT AND OUTER BELT
2. FRONT CAB DOOR 4. FRONT CAB DOOR GLASS
Figure 66 Front Cab Door Glass Seal and Inner and Outer Belt
73
10. From outside front cab door (Item 1), pull front cab door glass (Item 2) up and out of front cab door glass
opening (Item 3), driver side shown. Lay front cab door glass out of the way and save for installation,
if not damaged.

2. FRONT CAB DOOR GLASS OPENING
Figure 67 Front Cab Door Glass
11. Repeat procedure to remove passenger side front cab door glass.
Remove Rear Cab Door Glass on Crew Cab for all Models
door before disconnecting electric window switch panel (Item 5) during rear cab door trim panel removal.
74
on the window regulator handle shaft (Item 7) and lower cab door glass (Item 4) to the bottom of rear
6. Remove rear cab door glass seal and run channel by first pulling left side of rear cab door glass seal and
run channel (Item 1) from rear cab door (Item 2). Then pull the top of rear cab door glass seal and run
channel (Item 3) down from the rear cab door, driver side shown.
1. LEFT SIDE OF REAR CAB 3. TOP OF REAR CAB DOOR

DOOR GLASS SEAL AND RUN GLASS SEAL AND RUN
CHANNEL CHANNEL
2. REAR CAB DOOR
Figure 68 Rear Cab Door Glass Seal and Run Channel
75
7. Pull right side of rear cab door glass seal and run channel (Item 1) from the rear cab door (Item 2), driver
side shown. Lay it out of the way and save for installation, if not damaged.
1. RIGHT SIDE OF REAR CAB 2. REAR CAB DOOR

CHANNEL
76
8. Pull rear cab door glass seal and inner belt (Item 1) from inner lower flange of rear cab door (Item 2). Also
pull rear cab door glass seal and outer belt (Item 3) from outer lower flange of rear cab door, driver side
shown. Lay them both out of the way and save for installation, if not damaged.
9. Lift rear cab door glass (Item 4) up to cab door glass opening of rear cab door (Item 2), driver side shown.
Modular door hardware assembly removed for clarity.
1. REAR CAB DOOR GLASS SEAL 3. REAR CAB DOOR GLASS SEAL
2. REAR CAB DOOR 4. REAR CAB DOOR GLASS
Figure 70 Rear Cab Door Glass Seal and Inner and Outer Belt
77
REMOVE MODULAR DOOR HARDWARE ASSEMBLY
10. From outside rear cab door (Item 1), pull rear cab door glass (Item 2) up and out of rear cab door glass
opening (Item 3), driver side shown. Lay front cab door glass out of the way and save for installation,
if not damaged.

2. REAR CAB DOOR GLASS OPENING
Figure 71 Rear Cab Door Glass
11. Repeat procedure to remove passenger side rear cab door glass.
4.18. MODULAR DOOR HARDWARE ASSEMBLY

Remove Front Cab Door Modular Door Hardware Assembly on Standard Cab, Extended Cab and
The front cab door modular door hardware assembly (Item 1) consists of the window regulator assembly
(Item 2), front window run channel (Item 3), rear window run channel (Item 4), inner cab door handle (Item
5), outer cab door handle (Item 6) and door latch (Item 7). This assembly is installed and removed as
a module, driver side shown.
78
MODULAR DOOR HARDWARE ASSEMBLY REMOVE
1. If vehicle is equipped with electric door window, lower cab door glass (Item 4) to the bottom of front cab
door before disconnecting electric window switch panel (Item 5) during front cab door trim panel (Item
1) removal.
4. Remove front cab door glass, refer to CAB DOOR GLASS (See CAB DOOR GLASS, page 70).
5. Once the front cab door trim panel, front cab door inner door panel water shield and front cab door glass
have been removed per steps 2, 3 and 4 above, the front cab door modular door hardware assembly (Item
1) can be removed by removing all mounting hardware associated with all of its components as follows.
6. Remove three torx head bolts (Item 8) securing door latch assembly (Item 7) to front cab door (Item
7. Using a flat blade screw driver (Item 10), covered with a cloth rag to protect the painted surface of the front
cab door (Item 9), remove outer cab door handle trim bezel (Item 11), driver side shown.
NOTE – The plastic tabs that hold the outer cab door handle trim bezel (Item 11) will likely break off
during removal. A new outer cab door handle trim bezel will likely be needed if service to the cab door
requires removing it.
8. Remove four torx pan head screws (Item 12) securing outer cab door handle (Item 6) to front cab door
9. Remove four torx head bolts (Item 13) securing front cab door modular door hardware assembly (Item
1) to front cab door (Item 9), driver side shown.
10. Once the four torx head bolts (Item 13) have been removed, slide mounting guide pin (Item 14) of front
cab door modular door hardware assembly (Item 1) out of front cab door (Item 9) and slide front cab door
modular door hardware assembly to the right to get it out from behind front cab door, then lift it up and pull
the bottom out and drop it down out of the front cab door access opening, driver side shown.
79
1. FRONT CAB DOOR MODULAR 8. TORX HEAD BOLTS

DOOR HARDWARE ASSEMBLY 9. FRONT CAB DOOR
2. WINDOW REGULATOR 10. FLAT BLADE SCREW DRIVER
ASSEMBLY 11. OUTER CAB DOOR HANDLE
3. FRONT WINDOW RUN CHANNEL TRIM BEZEL
4. REAR WINDOW RUN CHANNEL 12. TORX PAN HEAD SCREWS
5. INNER CAB DOOR HANDLE 13. TORX HEAD BOLTS
6. OUTER CAB DOOR HANDLE 14. MOUNTING GUIDE PIN
7. DOOR LATCH ASSEMBLY 15. MOUNTING GUIDE PIN HOLE
Figure 72 Front Cab Door Modular Door Hardware Assembly
80
11. Disconnect wiring harness connector (Item 1) from the electric window motor (Item 2), driver side shown.
12. Once the front cab door modular door hardware assembly (Item 3) is free of the front cab door (Item 4),
reach behind front cab door modular door hardware assembly and squeeze together push-in fasteners four
places (Item 5) and push them through the front cab door modular door hardware assembly. Disconnect
wiring harness connector (Item 6) from the door latch assembly (Item 7), driver side shown. Position wiring
harness out of the way and remove front cab door modular door hardware assembly. Inner cab door
handle (Item 5, Figure 72) (See Figure 72, page 80) removed for clarity. Lay front cab door modular door
hardware assembly on a suitable work surface and save for installation.
1. WIRING HARNESS CONNECTOR 5. PUSH-IN FASTENER

2. ELECTRIC WINDOW MOTOR LOCATIONS
3. FRONT CAB DOOR MODULAR 6. WIRING HARNESS CONNECTOR
DOOR HARDWARE ASSEMBLY 7. DOOR LATCH ASSEMBLY
4. FRONT CAB DOOR
Figure 73 Front Cab Door Wiring Harness
13. Repeat procedure to remove passenger side front cab door modular door hardware assembly.
81
Remove Rear Cab Door Modular Door Hardware Assembly on Crew Cab for all Models
The rear cab door modular door hardware assembly (Item 1) consists of the window regulator assembly
(Item 2), front window run channel (Item 3), rear window run channel (Item 4), inner cab door handle (Item
5), outer cab door handle (Item 6) and door latch (Item 7). This assembly is installed and removed as
door before disconnecting electric window switch panel (Item 5) during rear cab door trim panel removal.
4. Remove rear cab door glass, refer to CAB DOOR GLASS (See CAB DOOR GLASS, page 70).
5. Once the rear cab door trim panel, rear cab door inner door panel water shield and rear cab door glass
have been removed per steps 2, 3 and 4 above, the rear cab door modular door hardware assembly (Item
1) can be removed by removing all mounting hardware associated with all of its components as follows.
6. Remove three torx head bolts (Item 8) securing door latch assembly (Item 7) to rear cab door (Item
7. Using a flat blade screw driver (Item 10), covered with a cloth rag to protect the painted surface of the rear
cab door (Item 9), remove outer cab door handle trim bezel (Item 11), driver side shown.
NOTE – The plastic tabs that hold the outer cab door handle trim bezel (Item 11) will likely break off
during removal. A new outer cab door handle trim bezel will likely be needed if service to the cab door
requires removing it.
8. Remove four torx pan head screws (Item 12) securing outer cab door handle (Item 6) to rear cab door
9. Remove four torx head bolts (Item 13) securing rear cab door modular door hardware assembly (Item
1) to rear cab door (Item 9), driver side shown.
10. Once the four torx head bolts (Item 13) have been removed, slide mounting guide pin (Item 14) of rear
cab door modular door hardware assembly (Item 1) out of rear cab door (Item 9) and slide rear cab door
modular door hardware assembly to the right to get it out from behind rear cab door, then lift it up and pull
the bottom out and drop it down out of the rear cab door access opening, driver side shown.
82
1. REAR CAB DOOR MODULAR 8. TORX HEAD BOLTS

DOOR HARDWARE ASSEMBLY 9. REAR CAB DOOR
2. WINDOW REGULATOR 10. FLAT BLADE SCREW DRIVER
ASSEMBLY 11. OUTER CAB DOOR HANDLE
3. FRONT WINDOW RUN CHANNEL TRIM BEZEL
4. REAR WINDOW RUN CHANNEL 12. TORX PAN HEAD SCREWS
5. INNER CAB DOOR HANDLE 13. TORX HEAD BOLTS
6. OUTER CAB DOOR HANDLE 14. MOUNTING GUIDE PIN
7. DOOR LATCH ASSEMBLY 15. MOUNTING GUIDE PIN HOLE
Figure 74 Rear Cab Door Modular Door Hardware Assembly
11. Disconnect wiring harness connector (Item 1) from the electric window motor (Item 2), driver side shown.
12. Once the rear cab door modular door hardware assembly (Item 3) is free of the rear cab door (Item 4),
reach behind rear cab door modular door hardware assembly and squeeze together push-in fasteners
three places (Item 5) and push them through the rear cab door modular door hardware assembly.
Disconnect wiring harness connector (Item 6) from the door latch assembly (Item 7), driver side shown.
Position wiring harness out of the way and remove rear cab door modular door hardware assembly. Lay
rear cab door modular door hardware assembly on a suitable work surface and save for installation.
83
1. WIRING HARNESS CONNECTOR 5. PUSH-IN FASTENER

2. ELECTRIC WINDOW MOTOR LOCATIONS
3. REAR CAB DOOR MODULAR 6. WIRING HARNESS CONNECTOR
DOOR HARDWARE ASSEMBLY 7. DOOR LATCH ASSEMBLY
4. REAR CAB DOOR
Figure 75 Rear Cab Door Wiring Harness
13. Repeat procedure to remove passenger side rear cab door modular door hardware assembly.
84
CAB DOOR VENT WINDOW REMOVE
4.19. CAB DOOR VENT WINDOW

Remove Front Cab Door Vent Window on Standard Cab, Extended Cab and Crew Cab for all Models
85
1. FRONT CAB DOOR VENT 2. TORX HEAD SCREW
WINDOW 3. VENT WINDOW LATCH PIVOT
REMOVE CAB DOOR VENT WINDOW HINGE
4. CAB DOOR VENT WINDOW 7. LOWER CAB DOOR VENT

FRAME WINDOW MOUNTING PIN
5. UPPER CAB DOOR VENT 8. LOWER CAB DOOR VENT
WINDOW HINGE WINDOW HINGE
6. UPPER CAB DOOR VENT 9. FRONT CAB DOOR
WINDOW MOUNTING PIN
Figure 76 Front Cab Door Vent Window
1. Open front cab door vent window (Item 1). Remove two torx head screws (Item 2) from vent window latch
pivot (Item 3) and cab door vent window frame (Item 4), driver side shown.
2. With front cab door vent window (Item 1) still open, swing it out away from cab door vent window opening
until the upper cab door vent window hinge (Item 5, View in Circle A) is accessible. Use a flat blade screw
driver and carefully push the upper cab door vent window hinge up off the upper cab door vent window
mounting pin (Item 6, View in Circle A). Once the cab door vent window is free at the top, lift lower cab
door vent window mounting pin (Item 7, View in Circle B) out of the lower cab door vent window hinge
(Item 8, View in Circle B) and remove from front cab door (Item 9), driver side shown. Lay it out of the
way and save for installation, unless damaged and being replaced.
3. Repeat procedure to remove passenger side front cab door vent window.
4.20. CAB DOOR VENT WINDOW HINGE

Remove Front Cab Door Vent Window Hinge on Standard Cab, Extended Cab and Crew Cab for all
Models
1. Remove front cab door vent window, refer to CAB DOOR VENT WINDOW (See CAB DOOR VENT
WINDOW, page 85).
2. Once the front cab door vent window is removed. Remove two torx head screws (Item 1) and remove cab
door vent window hinge (Item 2) from the cab door vent window frame (Item 3), driver side shown. Lay it
86
CAB DOOR VENT WINDOW HINGE REMOVE
1. TORX HEAD SCREW 5. CAB DOOR VENT WINDOW

2. CAB DOOR VENT WINDOW OPENING
HINGE 6. FRONT CAB DOOR
3. CAB DOOR VENT WINDOW 7. CAB DOOR VENT WINDOW
FRAME HINGE LOCATING PIN
4. CAB DOOR VENT WINDOW
SEAL
Figure 77 Front Cab Door Vent Window Hinge and Seal
3. Repeat procedure to remove passenger side front cab door vent window hinge.
87
REMOVE CAB DOOR VENT WINDOW SEAL
4.21. CAB DOOR VENT WINDOW SEAL

Remove Front Cab Door Vent Window Seal on Standard Cab, Extended Cab and Crew Cab for all Models
1. Remove cab door vent window, refer to CAB DOOR VENT WINDOW (See CAB DOOR VENT WINDOW,
page 85).
2. Once the front cab door vent window is removed. Pull cab door vent window seal (Item 4) from cab door
vent window opening (Item 5) of the front cab door (Item 6), driver side shown. Lay it out of the way and
save for installation, unless damaged and being replaced.
3. Repeat procedure to remove passenger side front cab door vent window seal.
4.22. CAB DOOR LOCK CYLINDER

Remove Cab Door Lock Cylinder on Front Cab Door of Standard Cab or Extended Cab Models and on
Front and Rear Cab Doors of Crew Cab Models
The cab door lock cylinder (Item 7) on the front doors of standard cab or extended cab models and front and
rear doors of crew cab models are key coded the same as the ignition switch on instrument panel, so that one
key operates both the ignition switch and door locks.
1. Using a flat blade screw driver (Item 1) covered with a cloth rag to protect the painted surface of the cab
door (Item 2), remove outer cab door handle trim bezel (Item 3), driver side shown.
NOTE – The plastic tabs that hold the outer cab door handle trim bezel (Item 3) will likely break off during
removal. A new outer cab door handle trim bezel will likely be needed if service to the cab door requires
removing it.
2. Using a flat blade screw driver (Item 4) remove retaining clip (Item 5) from behind outer door handle (Item
6) and remove cab door lock cylinder (Item 7) from the cavity in outer door handle, driver side shown.
88
CAB DOOR LOCK CYLINDER REMOVE
1. FLAT BLADE SCREW DRIVER 4. FLAT BLADE SCREW DRIVER

2. CAB DOOR 5. RETAINING CLIP
3. CAB DOOR HANDLE TRIM 6. OUTER CAB DOOR HANDLE
BEZEL 7. CAB DOOR LOCK CYLINDER
Figure 78 Cab Door Lock Cylinder on Standard Cab or Extended Cab Front Doors and Crew Cab
Front and Rear Doors
3. Repeat procedure to remove passenger side cab door lock cylinder from front or rear cab doors.
89
REMOVE CAB DOOR WINDOW ELECTRIC MOTOR
4.23. CAB DOOR WINDOW ELECTRIC MOTOR

Remove Front Cab Door Window Electric Motor on Standard Cab, Extended Cab and Crew Cab for
all Models
1. WIRING HARNESS CONNECTOR 5. MOUNTING STUDS

2. CAB DOOR WINDOW ELECTRIC 6. GEAR
MOTOR 7. SHAFT BUSHING
3. HEX NUT
4. MODULAR DOOR HARDWARE
ASSEMBLY
Figure 79 Front Cab Door Window Electric Motor on Standard or Extended Cab Models and Crew
Cab Models
90
CAB DOOR WINDOW ELECTRIC MOTOR REMOVE
3. Disconnect wiring harness connector (Item 1) from connector on cab door window electric motor (Item
4. Remove three hex nuts (Item 3) securing cab door window electric motor (Item 2) to modular door
hardware assembly (Item 4). Using a flat blade screw driver carefully pry the cab door window electric
motor away from modular door hardware assembly, driver side shown. Lay it out of the way and save for
installation, unless damaged and being replaced.
5. Repeat procedure to remove passenger side front cab door window electric motor.
Remove Rear Cab Door Window Electric Motor on Crew Cab for all Models
3. Disconnect wiring harness connector (Item 1) from connector on cab door window electric motor (Item
4. Remove three hex nuts (Item 3) securing cab door window electric motor (Item 2) to modular door
hardware assembly (Item 4). Using a flat blade screw driver, carefully pry the cab door window electric
motor away from modular door hardware assembly, driver side shown. Lay it out of the way and save for
91
REMOVE CAB DOOR WINDOW REGULATOR ARM ASSEMBLY
1. WIRING HARNESS CONNECTOR 5. MOUNTING STUDS

2. CAB DOOR WINDOW ELECTRIC 6. GEAR
MOTOR 7. SHAFT BUSHING
3. HEX NUT
4. MODULAR DOOR HARDWARE
ASSEMBLY
Figure 80 Rear Cab Door Window Electric Motor on Crew Cab Models
5. Repeat procedure to remove passenger side rear cab door window electric motor.
4.24. CAB DOOR WINDOW REGULATOR ARM ASSEMBLY

Remove Front Cab Door Window Regulator Arm Assembly on Standard Cab, Extended Cab and
92
CAB DOOR WINDOW REGULATOR ARM ASSEMBLY REMOVE
3. Remove front cab door window electric motor, refer to CAB DOOR WINDOW ELECTRIC MOTOR (See
CAB DOOR WINDOW ELECTRIC MOTOR, page 90). For removing front cab door window electric
motor, refer to Remove Front Cab Door Window Electric Motor on Standard Cab, Extended Cab and
Crew Cab for all Models.
cab door (Item 3).
6. Slide cab door glass (Item 4) to the top of front cab door (Item 3) and support it there.
7. Remove hex bolt (Item 1) from inner cab door handle (Item 2), driver side shown.
8. Slide inner cab door handle (Item 2) to the right enough to pull both retaining tabs (Item 3) out of the
modular door hardware assembly (Item 4), driver side shown.
1. HEX BOLT 4. MODULAR DOOR HARDWARE

2. INNER CAB DOOR HANDLE ASSEMBLY
3. RETAINING TABS
Figure 81 Inner Cab Door Handle
9. Rotate inner cab door handle (Item 1) so the bottom of it rest above the window regulator assembly
coil spring (Item 2), driver side shown.
93
WARNING
Be sure to use an appropriate tool and use care when removing the window regulator
assembly coil spring from behind the retaining tab on the modular door hardware
assembly per step 10 below, to prevent bodily injury since the window regulator
assembly coil spring will be in the loaded position during removal.
10. Using an appropriate tool, release window regulator assembly coil spring (Item 2) from the retaining tab
(Item 3) on the modular door hardware assembly (Item 4) and release the tension on the window regulator
assembly coil spring, driver side shown.
11. Remove window regulator assembly coil spring (Item 2) from the window regulator arm assembly shaft
1. INNER CAB DOOR HANDLE 4. MODULAR DOOR HARDWARE

2. WINDOW REGULATOR ASSEMBLY
ASSEMBLY COIL SPRING 5. WINDOW REGULATOR ARM
3. RETAINING TAB ASSEMBLY SHAFT
Figure 82 Cab Door Window Regulator Arm Assembly and Coil Spring
94
CAB DOOR WINDOW REGULATOR ARM ASSEMBLY REMOVE
12. Once the window regulator assembly coil spring (Item 2, Figure 82) (See Figure 82, page 94) is removed.
Use a flat blade screw driver (Item 1) in the slot of the window regulator arm assembly shaft (Item 2), rotate
it counter clockwise and remove the window regulator arm assembly shaft from the window regulator arm
(Item 3). Remove window regulator arm from behind the modular door hardware assembly (Item 4), driver
side shown. Lay window regulator assembly coil spring, window regulator arm assembly shaft and window
regulator arm out of the way and save for installation, unless damaged and being replaced.
1. FLAT BLADE SCREW DRIVER 3. WINDOW REGULATOR ARM

2. WINDOW REGULATOR ARM 4. MODULAR DOOR HARDWARE
ASSEMBLY SHAFT ASSEMBLY
Figure 83 Window Regulator Arm and Window Regulator Arm Assembly Shaft
13. Repeat procedure to remove passenger side front cab door window regulator arm and window regulator
arm assembly shaft.
95
Remove Rear Cab Door Window Regulator Arm Assembly on Crew Cab for all Models
3. Remove rear cab door window electric motor, refer to CAB DOOR WINDOW ELECTRIC MOTOR (See
CAB DOOR WINDOW ELECTRIC MOTOR, page 90). For removing rear cab door window electric motor,
refer to Remove Rear Cab Door Window Electric Motor on Crew Cab for all Models.
4. If vehicle is equipped with manual door window, temporarily place the window regulator handle (Item
6) on the window regulator handle shaft (Item 7) and lower cab door glass (Item 4) to the bottom of
rear cab door (Item 3).
6. Slide cab door glass (Item 4) to the top of rear cab door (Item 3) and support it there.
7. Remove hex bolt (Item 1) from inner cab door handle (Item 2), driver side shown.
9. Rotate inner cab door handle (Item 1) so the bottom of it rest above the window regulator assembly
coil spring (Item 2), driver side shown.
WARNING
Be sure to use an appropriate tool and use care when removing the window regulator
assembly coil spring from behind the retaining tab on the modular door hardware
assembly per step 10 below, to prevent bodily injury since the window regulator
assembly coil spring will be in the loaded position during removal.
10. Using an appropriate tool, release window regulator assembly coil spring (Item 2) from the retaining tab
(Item 3) on the modular door hardware assembly (Item 4) and release the tension on the window regulator
assembly coil spring, driver side shown.
11. Remove window regulator assembly coil spring (Item 2) from the window regulator arm assembly shaft
96
OUTER CAB DOOR HANDLE REMOVE
12. Once the window regulator assembly coil spring (Item 2, Figure 82) (See Figure 82, page 94) is removed.
Use a flat blade screw driver (Item 1) in the slot of the window regulator arm assembly shaft (Item 2), rotate
it counter clockwise and remove the window regulator arm assembly shaft from the window regulator arm
(Item 3). Remove window regulator arm from behind the modular door hardware assembly (Item 4), driver
side shown. Lay window regulator assembly coil spring, window regulator arm assembly shaft and window
regulator arm out of the way and save for installation, unless damaged and being replaced.
13. Repeat procedure to remove passenger side rear cab door window regulator arm and window regulator
arm assembly shaft.
4.25. OUTER CAB DOOR HANDLE

Remove Front Cab Door Outer Cab Door Handle on Standard Cab, Extended Cab and Crew Cab for
all Models
3. Remove front cab door modular door hardware assembly, refer to MODULAR DOOR HARDWARE
ASSEMBLY (See MODULAR DOOR HARDWARE ASSEMBLY, page 78). For removing front cab door
modular door hardware assembly, refer to Remove Front Cab Door Modular Door Hardware Assembly on
97
REMOVE OUTER CAB DOOR HANDLE
4. With the front cab door modular door hardware assembly (Item 1, Figure 72) (See Figure 72, page 80)
removed and placed on a suitable work surface. Remove outer cab door handle (Item 1) from window
run channel (Item 2) by pressing the locking tab (Item 3) in and slide the hanger support bracket (Item 4)
out of the window run channel, driver side shown.
1. OUTER CAB DOOR HANDLE 3. LOCKING TAB

2. WINDOW RUN CHANNEL 4. HANGER SUPPORT BRACKET
Figure 84 Outer Cab Door Handle, Rear Window Run Channel and Hanger Support Bracket
98
5. Slide the control rod (Item 1) coming from the outer cab door handle (Item 2) out of the lock lever (Item 3)
of the cab door latch (Item 4), driver side shown.
6. Rotate outer cab door handle (Item 2) and slide it off the control rod (Item 5) coming from the cab door
latch (Item 4), driver side shown. Lay it out of the way and save for installation, unless damaged and
being replaced.
1. CONTROL ROD 4. CAB DOOR LATCH

2. OUTER CAB DOOR HANDLE 5. CONTROL ROD
3. LOCK LEVER
Figure 85 Outer Cab Door Handle and Control Rods
99
REMOVE OUTER CAB DOOR HANDLE
7. If it is necessary to replace the outer cab door handle (Item 1), rotate hanger support bracket (Item 2)
counter clockwise, lining up the slot (Item 3) in the hanger support bracket with the T-shaped locking tab
(Item 4) on the outer cab door handle and lift it off, driver side shown. Lay it out of the way and save for
1. OUTER CAB DOOR HANDLE 3. SLOT

2. HANGER SUPPORT BRACKET 4. T-SHAPED LOCKING TAB
Figure 86 Outer Cab Door Handle and Hanger Support Bracket
8. Remove front cab door lock cylinder, refer to CAB DOOR LOCK CYLINDER (See CAB DOOR LOCK
CYLINDER, page 88). For removing front cab door lock cylinder, refer to Remove Cab Door Lock
Cylinder on Front Cab Door of Standard Cab or Extended Cab Models and Front and Rear Cab Doors
of Crew Cab Models.
100
9. Remove door lock control rod (Item 1) from door lock cylinder lever (Item 2) on outer cab door handle (Item
3), driver side shown. Lay it out of the way and save for installation, unless damaged and being replaced.
10. Remove door lock cylinder lever (Item 2) from outer cab door handle (Item 3), driver side shown. Lay it out
of the way and save for installation, unless damaged and being replaced.
1. DOOR LOCK CONTROL ROD 3. OUTER CAB DOOR HANDLE

2. DOOR LOCK CYLINDER LEVER
Figure 87 Outer Cab Door Handle and Door Lock Control Rod
11. Repeat procedure to remove passenger side outer cab door handle on front cab door of standard cab,
extended cab and crew cab for all models.
Remove Rear Cab Door Outer Cab Door Handle on Crew Cab for all Models
3. Remove rear cab door modular door hardware assembly, refer to MODULAR DOOR HARDWARE
ASSEMBLY (See MODULAR DOOR HARDWARE ASSEMBLY, page 78). For removing rear cab door
modular door hardware assembly, refer to Remove Rear Cab Door Modular Door Hardware Assembly
101
REMOVE CAB DOOR LATCH
4. With the rear cab door modular door hardware assembly (Item 1, Figure 74) (See Figure 74, page 83)
5. Slide the control rod (Item 1) coming from the outer cab door handle (Item 2) out of the lock lever (Item 3)
6. Rotate outer cab door handle (Item 2) and slide it off the control rod (Item 5) coming from the cab door
latch (Item 4), driver side shown. Lay it out of the way and save for installation, unless damaged and
being replaced.
7. If it is necessary to replace the outer cab door handle (Item 1), rotate hanger support bracket (Item 2)
counter clockwise, lining up the slot (Item 3) in the hanger support bracket with the T-shaped locking tab
(Item 4) on the outer cab door handle and lift it off, driver side shown. Lay it out of the way and save for
8. Remove rear cab door lock cylinder, refer to CAB DOOR LOCK CYLINDER (See CAB DOOR LOCK
CYLINDER, page 88). For removing rear cab door lock cylinder, refer to Remove Cab Door Lock Cylinder
on Front Cab Door of Standard Cab or Extended Cab Models and Front and Rear Cab Doors of Crew
Cab Models.
9. Remove door lock control rod (Item 1) from door lock cylinder lever (Item 2) on outer cab door handle (Item
3), driver side shown. Lay it out of the way and save for installation, unless damaged and being replaced.
10. Remove door lock cylinder lever (Item 2) from outer cab door handle (Item 3), driver side shown. Lay it out
of the way and save for installation, unless damaged and being replaced.
11. Repeat procedure to remove passenger side outer cab door handle on rear cab door of crew cab models.
4.26. CAB DOOR LATCH

Remove Front Cab Door Latch on Standard Cab, Extended Cab and Crew Cab for all Models
102
CAB DOOR LATCH REMOVE
removed and placed on a suitable work surface. Remove cab door latch (Item 1) from window run channel
(Item 2) by pressing the locking tab (Item 3) in and slide the hanger support bracket (Item 4) out of the
window run channel, driver side shown.
1. CAB DOOR LATCH 3. LOCKING TAB

2. WINDOW RUN CHANNEL 4. HANGER SUPPORT BRACKET
Figure 88 Cab Door Latch and Hanger Support Bracket
103
REMOVE CAB DOOR LATCH
5. Remove cab door latch (Item 1) from inner cab door handle control rods (Items 2 and 3) by rotating the cab
door latch down around inner cab door handle control rods and slide it off control rods, driver side shown.
Lay it out of the way and save for installation, unless damaged and being replaced.
1. CAB DOOR LATCH 3. INNER CAB DOOR HANDLE

2. INNER CAB DOOR HANDLE CONTROL ROD
CONTROL ROD
Figure 89 Cab Door Latch and Inner Cab Door Handle Control Rods
6. Repeat procedure to remove passenger side front cab door latch.
Remove Rear Cab Door Latch on Crew Cab for all Models
104
INNER CAB DOOR HANDLE REMOVE
removed and placed on a suitable work surface. Remove cab door latch (Item 1) from window run channel
(Item 2) by pressing the locking tab (Item 3) in and slide the hanger support bracket (Item 4) out of the
window run channel, driver side shown.
5. Remove cab door latch (Item 1) from inner cab door handle control rods (Items 2 and 3) by rotating the cab
door latch down around inner cab door handle control rods and slide it off control rods, driver side shown.
Lay it out of the way and save for installation, unless damaged and being replaced.
6. Repeat procedure to remove passenger side rear cab door latch.
4.27. INNER CAB DOOR HANDLE

Remove Front Cab Door Inner Cab Door Handle on Standard Cab, Extended Cab and Crew Cab for
all Models
removed and placed on a suitable work surface. Remove front cab door outer cab door handle and
front cab door latch as follows.
5. Remove front cab door outer cab door handle, refer to OUTER CAB DOOR HANDLE (See OUTER CAB
DOOR HANDLE, page 97). For removing front cab door outer cab door handle, refer to Remove Front
Cab Door Outer Cab Door Handle on Standard Cab, Extended Cab and Crew Cab for all Models.
6. Remove front cab door latch, refer to CAB DOOR LATCH (See CAB DOOR LATCH, page 102). For
removing front cab door latch, refer to Remove Front Cab Door Latch on Standard Cab, Extended Cab
and Crew Cab for all Models.
105
REMOVE INNER CAB DOOR HANDLE
7. With the modular door hardware assembly (Item 1) laying on it's front, remove inner cab door handle
control rod (Item 2) with the spring (Item 3) from retaining clip (Item 4), driver side shown.
1. MODULAR DOOR HARDWARE 3. SPRING

ASSEMBLY 4. RETAINING CLIP
2. INNER CAB DOOR HANDLE 5. INNER CAB DOOR HANDLE
CONTROL ROD CONTROL ROD
Figure 90 Inner Cab Door Handle and Control Rods
8. With the modular door hardware assembly (Item 4) laying on it's back, remove hex bolt (Item 1) from
inner cab door handle (Item 2), driver side shown.
modular door hardware assembly (Item 4). Lift inner cab door handle up and over the window regulator
assembly and slide it to the right until the inner cab door handle control rods (Items 2 and 5, Figure 90)
(See Figure 90, page 106) clear the opening in the front cab door modular door hardware assembly, driver
side shown. Lay inner cab door handle with inner cab door handle control rods out of the way and save for
106
INNER CAB DOOR HANDLE REMOVE
10. Once inner cab door handle (Item 1) is removed from front cab door modular door hardware assembly,
remove inner cab door handle control rod (Item 2) from inner cab door handle, then remove inner cab door
handle control rod (Item 3) with the spring (Item 4) from slotted hole of inner cab door handle, driver side
shown. Lay them out of the way and save for installation, unless damaged and being replaced.
1. INNER CAB DOOR HANDLE 3. INNER CAB DOOR HANDLE

CONTROL ROD 4. SPRING
Figure 91 Inner Cab Door Handle and Control Rods
11. Repeat procedure to remove passenger side front cab door inner cab door handle.
Remove Rear Cab Door Inner Cab Door Handle on Crew Cab for all Models
107
REMOVE CAB DOOR WINDOW RUN CHANNELS
removed and placed on a suitable work surface. Remove rear cab door outer cab door handle and
rear cab door latch as follows.
5. Remove rear cab door outer cab door handle, refer to OUTER CAB DOOR HANDLE (See OUTER CAB
DOOR HANDLE, page 97). For removing rear cab door outer cab door handle, refer to Remove Rear Cab
Door Outer Cab Door Handle on Crew Cab for all Models.
6. Remove rear cab door latch, refer to CAB DOOR LATCH (See CAB DOOR LATCH, page 102). For
removing rear cab door latch, refer to Remove Rear Cab Door Latch on Crew Cab for all Models.
7. With the modular door hardware assembly (Item 1) laying on it's front, remove inner cab door handle
control rod (Item 2) with the spring (Item 3) from retaining clip (Item 4), driver side shown.
8. With the modular door hardware assembly (Item 4) laying on it's back, remove hex bolt (Item 1) from
inner cab door handle (Item 2), driver side shown.
modular door hardware assembly (Item 4). Lift inner cab door handle up and over the window regulator
assembly and slide it to the right until the inner cab door handle control rods (Items 2 and 5, Figure 90)
(See Figure 90, page 106) clear the opening in the modular door hardware assembly, driver side shown.
Lay inner cab door handle with inner cab door handle control rods out of the way and save for installation,
unless damaged and being replaced.
10. Once inner cab door handle (Item 1) is removed from modular door hardware assembly, remove inner cab
door handle control rod (Item 2) from inner cab door handle, then remove inner cab door handle control
rod (Item 3) with the spring (Item 4) from slotted hole of inner cab door handle, driver side shown. Lay
them out of the way and save for installation, unless damaged and being replaced.
11. Repeat procedure to remove passenger side rear cab door inner cab door handle.
4.28. CAB DOOR WINDOW RUN CHANNELS

Remove Front Cab Door Window Run Channels on Standard Cab, Extended Cab and Crew Cab for
all Models
108
CAB DOOR WINDOW RUN CHANNELS REMOVE
5. Remove cab door latch (Item 1) from window run channel (Item 2) by pressing the locking tab (Item 3) in
and slide the hanger support bracket (Item 4) out of the window run channel, driver side shown.
6. With the modular door hardware assembly (Item 1) laying on it's back. Using a flat blade screw driver (Item
2), push in locking tab (Item 3) at the top of the window run channel (Item 4) on the right, and slide window
run channel to the left out of the modular door hardware assembly, driver side shown.
7. Using a flat blade screw driver, push in locking tab (Item 5) at the bottom of the window run channel (Item
4) on the right, and slide window run channel to the left out of the modular door hardware assembly
(Item 1), driver side shown. Lay window run channel out of the way and save for installation, unless
damaged and being replaced.
8. To remove the window run channel (Item 6) on the left, use a flat blade screw driver and push in locking
tab (Item 7) at the top of the window run channel, and slide window run channel to the right out of the
6) on the left, and slide window run channel to the right out of the modular door hardware assembly
10. Repeat procedure to remove passenger side front cab door window run channels.
109
REMOVE CAB DOOR WINDOW RUN CHANNELS
1. MODULAR DOOR HARDWARE 5. LOCKING TAB

ASSEMBLY 6. WINDOW RUN CHANNEL
2. FLAT BLADE SCREW DRIVER 7. LOCKING TAB
3. LOCKING TAB 8. LOCKING TAB
4. WINDOW RUN CHANNEL
Figure 92 Cab Door Window Run Channels
110
CAB DOOR WINDOW RUN CHANNELS REMOVE
Remove Rear Cab Door Window Run Channels on Crew Cab for all Models
5. Remove cab door latch (Item 1) from window run channel (Item 2) by pressing the locking tab (Item 3) in
and slide the hanger support bracket (Item 4) out of the window run channel, driver side shown.
6. With the modular door hardware assembly (Item 1) laying on it's back. Using a flat blade screw driver (Item
2), push in locking tab (Item 3) at the top of the window run channel (Item 4) on the right, and slide window
run channel to the left out of the modular door hardware assembly, driver side shown.
4) on the right, and slide window run channel to the left out of the modular door hardware assembly
8. To remove the window run channel (Item 6) on the left, use a flat blade screw driver and push in locking
tab (Item 7) at the top of the window run channel, and slide window run channel to the right out of the
6) on the left, and slide window run channel to the right out of the modular door hardware assembly
10. Repeat procedure to remove passenger side rear cab door window run channels.
111
REMOVE CAB DOOR ELECTRIC WINDOW AND DOOR LOCK SWITCH
4.29. CAB DOOR ELECTRIC WINDOW AND DOOR LOCK SWITCH

Remove Front Cab Door Electric Window and Door Lock Switch on Standard Cab, Extended Cab
and Crew Cab for all Models
1. FRONT CAB DOOR ELECTRIC 3. SWITCH BUTTONS

WINDOW AND DOOR LOCK 4. SPRING RETAINING CLIP
SWITCH 5. CAB DOOR TRIM PANEL
2. REMOVAL TOOL 6. WIRING HARNESS CONNECTOR
Figure 93 Front Cab Door Electric Window and Door Lock Switch
1. Remove driver side front cab door electric window and door lock switch (Item 1) by inserting removal tools
(Item 2) into the holes at each end of the front cab door electric window and door lock switch. Insert
removal tools at a slight angle toward the switch buttons (Item 3) to ensure that the tips of the removal
tools are located properly on the spring retaining clips (Item 4), driver side shown.
2. Once removal tools (Item 2) are inserted properly in the holes at each end of the front cab door electric
window and door lock switch (Item 1). Pull removal tools, in direction of arrows, out away from the switch
buttons (Item 3), to release the spring retaining clips (Item 4) and lift the front cab door electric window
and door lock switch (Item 1) out of the cab door trim panel (Item 5). Remove both removal tools, driver
side shown.
112
CAB DOOR ELECTRIC WINDOW AND DOOR LOCK SWITCH REMOVE
3. Once the front cab door electric window and door lock switch (Item 1) is lifted out of the cab door trim
panel (Item 5), disconnect both wiring harness connectors (Item 6) from front cab door electric window and
door lock switch, driver side shown. Lay it out of the way and save for installation, unless damaged and
being replaced.
4. Repeat procedure to remove passenger side front cab door electric window and door lock switch.
Remove Rear Cab Door Electric Window and Door Lock Switch on Crew Cab for all Models
1. REAR CAB DOOR ELECTRIC 3. SWITCH BUTTONS

WINDOW AND DOOR LOCK 4. SPRING RETAINING CLIP
SWITCH 5. CAB DOOR TRIM PANEL
2. REMOVAL TOOL 6. WIRING HARNESS CONNECTOR
Figure 94 Rear Cab Door Electric Window and Door Lock Switch
113
REMOVE CAB DOOR ELECTRIC MIRROR SWITCH
1. Remove driver side rear cab door electric window and door lock switch (Item 1) by inserting removal tools
(Item 2) into the holes at each end of the rear cab door electric window and door lock switch. Insert
removal tools at a slight angle toward the switch buttons (Item 3) to ensure that the tips of the removal
tools are located properly on the spring retaining clips (Item 4), driver side shown.
2. Once removal tools (Item 2) are inserted properly in the holes at each end of the rear cab door electric
window and door lock switch (Item 1). Pull removal tools, in direction of arrows, out away from the switch
buttons (Item 3), to release the spring retaining clips (Item 4) and lift the rear cab door electric window
and door lock switch (Item 1) out of the cab door trim panel (Item 5). Remove both removal tools, driver
side shown.
3. Once the rear cab door electric window and door lock switch (Item 1) is lifted out of the cab door trim panel
(Item 5), disconnect both wiring harness connectors (Item 6) from rear cab door electric window and
door lock switch, driver side shown. Lay it out of the way and save for installation, unless damaged and
being replaced.
4. Repeat procedure to remove passenger side rear cab door electric window and door lock switch.
4.30. CAB DOOR ELECTRIC MIRROR SWITCH

Remove Front Cab Door Electric Mirror Switch on Standard Cab, Extended Cab and Crew Cab for
all Models
1. Remove driver side front cab door electric mirror switch (Item 1) by carefully sliding a flat blade screw
driver under the edge of the electric mirror switch and gently pry it out of the front cab door trim panel
2. Once the front cab door electric mirror switch (Item 1) is lifted out of the front cab door trim panel (Item 2),
disconnect wiring harness connector (Item 3) from electric mirror switch, driver side shown. Lay it out of
the way and save for installation, unless damaged and being replaced.
114
SEATS REMOVE
1. FRONT CAB DOOR ELECTRIC 4. FRONT CAB DOOR ELECTRIC

MIRROR SWITCH WINDOW AND DOOR LOCK
2. FRONT CAB DOOR TRIM PANEL SWITCH
3. WIRING HARNESS CONNECTOR
Figure 95 Front Cab Door Electric Mirror Switch
4.31. SEATS
Remove Passenger Bucket Seat on Standard Cab, Extended Cab and Crew Cab for all Models
1. Remove four hex nuts and washers (Item 1) from threaded mounting studs of passenger bucket seat
(Item 2). If so equipped, disconnect air line (Item 3) from passenger bucket seat at the quick disconnect
connector (Item 4). Lay air line out of the way. It is recommended that when installing seats back into
a vehicle, that all new mounting hardware be used to ensure that the proper torquing requirements can
be met.
2. Remove hex flanged bolt (Item 5, view arrow B) and remove outer seat belt (Item 6, view arrow B) from
seat belt mounting bracket (Item 7, view arrow B). Lay hex flanged bolt and seat belt out of the way
and save for installation.
3. Remove hex flanged bolt (Item 8, view arrow A) and remove inner seat belt (Item 9, view arrow A)
from seat belt mounting bracket (Item 10, view arrow A). Lay hex flanged bolt and seat belt out of the
4. Lift passenger bucket seat (Item 2) off threaded mounting studs and remove passenger bucket seat from
inside cab. Lay passenger seat out of the way and save for installation.
115
REMOVE SEATS
1. HEX NUT AND WASHER 2. PASSENGER BUCKET SEAT
116
SEATS REMOVE
3. AIR LINE 8. HEX FLANGED BOLT

4. QUICK DISCONNECT 9. INNER SEAT BELT
CONNECTOR 10. SEAT BELT MOUNTING
5. HEX FLANGED BOLT BRACKET
6. OUTER SEAT BELT 11. TORX HEAD SCREWS
7. SEAT BELT MOUNTING 12. CAB DOOR OPENING SCUFF
BRACKET PLATE
Figure 96 Passenger Bucket Seat
5. Repeat procedure to remove driver side bucket seat.

Remove Fixed Passenger Seat on Standard Cab, Extended Cab and Crew Cab for all Models
1. Remove four hex nuts and washers (Item 1) from threaded mounting studs (Item 2) of fixed passenger seat
(Item 3). It is recommended that when installing seats back into a vehicle, that all new mounting hardware
be used to ensure that the proper torquing requirements can be met.
2. Lift fixed passenger seat (Item 3) off threaded mounting studs (Item 2) and remove fixed passenger seat
from inside cab. Lay fixed passenger seat out of the way and save for installation.
117
REMOVE SEATS
1. HEX NUT AND WASHER 5. TWO MAN FIXED BENCH SEAT

2. FIXED PASSENGER SEAT AND WITH TOOL BOX
TWO MAN FIXED BENCH SEAT 6. FLOOR MAT
MOUNTING STUDS 7. DRIVER SEAT MOUNTING
3. FIXED PASSENGER SEAT STUDS
4. TWO MAN FIXED BENCH SEAT
WITHOUT TOOL BOX
Figure 97 Fixed Passenger Seat and Two Man Fixed Bench Seat (With and Without Tool Box)
118
SEATS REMOVE
Remove Two Man Fixed Bench Seat without Tool Box on Standard Cab, Extended Cab and Crew
Cab for all Models
1. Remove four hex nuts and washers (Item 1) from threaded mounting studs (Item 2) of two man fixed bench
seat without tool box (Item 4). It is recommended that when installing seats back into a vehicle, that all
new mounting hardware be used to ensure that the proper torquing requirements can be met.
2. Pull seat belts through upper and lower seat and lift two man fixed bench seat without tool box (Item 4) off
threaded mounting studs (Item 2) and remove two man fixed bench seat without tool box from inside cab.
Lay two man fixed bench seat without tool box out of the way and save for installation.
Remove Two Man Fixed Bench Seat with Tool Box on Standard Cab, Extended Cab and Crew Cab for
all Models
1. Remove four hex nuts and washers (Item 1) from threaded mounting studs (Item 2) of two man fixed bench
seat with tool box (Item 5). It is recommended that when installing seats back into a vehicle, that all new
mounting hardware be used to ensure that the proper torquing requirements can be met.
2. Pull seat belts through upper and lower seat and lift two man fixed bench seat with tool box (Item 5) off
threaded mounting studs (Item 2) and remove two man fixed bench seat with tool box from inside cab. Lay
two man fixed bench seat with tool box out of the way and save for installation.
Remove Full Width Rear Bench Seat on Extended Cab and Crew Cab for all Models
1. Remove four hex nuts with washers (Item 1) from threaded mounting studs (Item 2) of full width rear bench
seat (Item 3). It is recommended that when installing seats back into a vehicle, that all new mounting
hardware be used to ensure that the proper torquing requirements can be met.
2. Pull seat belts (Item 4) through upper and lower seat and lift full width rear bench seat (Item 3) off threaded
mounting studs (Item 2) and remove full width rear bench seat from inside cab. Lay full width rear bench
seat out of the way and save for installation.
119
REMOVE SEATS
1. HEX NUT WITH WASHER 6. REAR FLOOR MAT

2. FULL WIDTH REAR BENCH 7. DRIVER SIDE SEAT MOUNTING
SEAT MOUNTING STUDS STUDS
3. FULL WIDTH REAR BENCH 8. PASSENGER SIDE SEAT AND
SEAT TWO MAN FIXED BENCH SEAT
4. SEAT BELT MOUNTING STUDS
5. FRONT FLOOR MAT
Figure 98 Full Width Rear Bench Seat
120
CAB DOOR OPENING SCUFF PLATE AND SEAT BELT RETRACTOR COVER REMOVE
4.32. CAB DOOR OPENING SCUFF PLATE AND SEAT BELT RETRACTOR COVER
Remove Cab Door Opening Scuff Plate and Seat Belt Retractor Cover on Standard Cab, Extended Cab
NOTE – This procedure applies to all front door openings for all cabs and models and rear door openings
for crew cab models.
1. Remove four torx head screws (Item 1) securing cab door opening scuff plate (Item 2) to cab floor,
passenger side shown. Lay torx head screws out of the way and save for installation.
2. Remove push-in fastener (Item 3) securing seat belt retractor cover (Item 4) to seat belt retractor assembly
(Item 5), passenger side shown. Lay push-in fastener and cab door opening scuff plate and seat belt
retractor cover out of the way and save for installation.
3. Repeat procedure to remove driver side cab door opening scuff plate and seat belt retractor cover.
1. TORX HEAD SCREW 4. SEAT BELT RETRACTOR COVER

2. CAB DOOR OPENING SCUFF 5. SEAT BELT RETRACTOR
PLATE ASSEMBLY
3. PUSH-IN FASTENER
Figure 99 Cab Door Opening Scuff Plate and Seat Belt Retractor Cover on Standard Cab, Extended
121
REMOVE EXTENDED CAB BUNK/STORAGE UNIT
4.33. EXTENDED CAB BUNK/STORAGE UNIT

Remove Bunk/Storage Unit on Extended Cab for all Models
1. PROTECTIVE PLATE 5. HEX FLANGED NUT

2. SEAT MOUNTING STUDS 6. TORX HEAD BOLT
3. BUNK MATTRESS 7. SEAT BELT
4. BUNK/STORAGE UNIT
Figure 100 Bunk/Storage Unit on Extended Cab for all Models
1. Remove passenger bucket seat, fixed passenger seat and/or fixed passenger bench seat, refer to SEATS
(See SEATS, page 115).
2. Once the passenger side seat is removed, if so equipped, remove protective plate (Item 1) from both rear
seat mounting studs (Item 2) in cab floor. Lay it out of the way and save for installation.
3. Remove bunk mattress (Item 3) from bunk/storage unit (Item 4). Lay it out of the way and save for
installation.
122
SIDE AND CORNER INTERIOR TRIM PANEL REMOVE
4. Remove four hex flanged nuts (Item 5), two each end, securing bunk/storage unit (Item 4) to cab floor.
Lay them out of the way and save for installation.
5. Remove two torx head bolts (Item 6) securing seat belts (Item 7) to cab floor. Lay them out of the way
6. Slide driver side seat all the way forward to allow removal of bunk/storage unit (Item 4).
7. Lift bunk/storage unit (Item 4) off the four threaded studs in cab floor. Turn bunk/storage unit on it's side
and remove from cab through passenger side door opening. Lay it out of the way and save for installation.
4.34. SIDE AND CORNER INTERIOR TRIM PANEL

Remove Side and Corner Interior Trim Panel on Standard Cab for all Models
1. TORX HEAD BOLT 4. PUSH-IN FASTENER

2. SHOULDER BELT 5. PASSENGER SIDE SIDE AND
3. PUSH-IN FASTENER REMOVAL CORNER INTERIOR TRIM
TOOL PANEL
Figure 101 Passenger Side Side and Corner Interior Trim Panel on Standard Cab
2. Remove passenger side cab door opening scuff plate and seat belt retractor cover, refer to CAB DOOR
OPENING SCUFF PLATE AND SEAT BELT RETRACTOR COVER (See CAB DOOR OPENING SCUFF
PLATE AND SEAT BELT RETRACTOR COVER, page 121).
123
REMOVE SIDE AND CORNER INTERIOR TRIM PANEL
3. Remove torx head bolt (Item 1) securing shoulder belt (Item 2) to the cab, passenger side shown. Lay the
torx head bolt and shoulder belt out of the way on the cab floor and save for installation.
4. Using push-in fastener removal tool (Item 3), remove seven push-in fasteners (Item 4), passenger side
shown. Lay them out of the way and save for installation.
5. Remove passenger side side and corner interior trim panel (Item 5) from the cab. Lay it out of the way and
save for installation unless damaged and being replaced.
6. Repeat procedure to remove driver side side and corner interior trim panel on standard cab.
Remove Side and Corner Interior Trim Panel on Extended Cab for all Models
2. If so equipped, remove bunk/storage unit from behind front seats, refer to EXTENDED CAB
BUNK/STORAGE UNIT (See EXTENDED CAB BUNK/STORAGE UNIT, page 122).
124
SIDE AND CORNER INTERIOR TRIM PANEL REMOVE
5. Using push-in fastener removal tool (Item 3), remove nine push-in fasteners (Item 4), passenger side

TOOL PANEL
Figure 102 Passenger Side Side and Corner Interior Trim Panel on Extended Cab
7. Repeat procedure to remove driver side side and corner interior trim panel on extended cab.
Remove Side and Corner Interior Trim Panel on Crew Cab for all Models
1. Remove full width rear bench seat, refer to SEATS (See SEATS, page 115).
125
REMOVE SIDE AND CORNER INTERIOR TRIM PANEL
4. Using push-in fastener removal tool (Item 3), remove seven push-in fasteners (Item 4), passenger side

TOOL PANEL
Figure 103 Passenger Side Side and Corner Interior Trim Panel on Crew Cab
6. Repeat procedure to remove driver side side and corner interior trim panel on crew cab.
126
EXTENDED CAB REAR SIDE WINDOW REMOVE
4.35. EXTENDED CAB REAR SIDE WINDOW

Remove Rear Side Window on Extended Cab for all Models
1. Remove passenger bucket seat, fixed passenger seat or fixed passenger bench seat, and if so equipped,
full width rear bench seat. Refer to SEATS (See SEATS, page 115).
2. If so equipped, remove bunk/storage unit from behind front seats, refer to EXTENDED CAB
4. Open rear side window latch (Item 1) and remove rear side window seal (Item 2) by pulling it off the rear
side window fence (Item 3).
5. Remove passenger side side and corner interior trim panel, refer to SIDE AND CORNER INTERIOR
TRIM PANEL (See SIDE AND CORNER INTERIOR TRIM PANEL, page 123). Remove Side and Corner
Interior Trim Panel on Extended Cab for all Models.
6. From inside the cab, remove two hex flanged bolts (Item 4) from rear side window latch (Item 1) at the
rear of the rear side window (Item 5).
7. From inside the cab, remove two hex flanged nuts (Item 6) from threaded studs (Item 7) at the front
of window opening for rear side window (Item 5).
8. From outside the cab, carefully pull threaded studs (Item 7) of rear side window (Item 5) out of mounting
holes in rear side window fence (Item 3) removing rear side window from cab and place it on a padded
work surface to protect it.
127
REMOVE EXTENDED CAB REAR SIDE WINDOW
1. REAR SIDE WINDOW LATCH 6. HEX FLANGED NUT

2. REAR SIDE WINDOW SEAL 7. THREADED STUDS
3. REAR SIDE WINDOW FENCE 8. REAR SIDE WINDOW SEAL
4. HEX FLANGED BOLT SEAM
5. REAR SIDE WINDOW
Figure 104 Extended Cab Rear Side Window on Extended Cab for all Models
9. Repeat procedure to remove driver side rear side window on extended cab for all models.
128
EXTENDED CAB REAR SIDE WINDOW REMOVE
Remove Rear Side Window Latch from Rear Side Window on Extended Cab for all Models
1. With the rear side window (Item 1) laying on a padded work surface latch side up.
2. Remove rear side window latch (Item 2) from the latch mounting pedestal (Item 3) on the rear side window
by rotating rear side window latch clockwise until the latch bar (Item 4) is in line with latch mounting
pedestal slot (Item 5) and lift the latch out. Lay rear side window latch out of the way and save for
3. This procedure is the same to remove driver or passenger side rear side window latch on extended
cab for all models.
1. REAR SIDE WINDOW 4. LATCH BAR

2. REAR SIDE WINDOW LATCH 5. LATCH MOUNTING PEDESTAL
3. REAR SIDE WINDOW SLOT
MOUNTING PEDESTAL
Figure 105 Extended Cab Rear Side Window Latch on Extended Cab for all Models
129
REMOVE REAR INTERIOR TRIM PANEL
4.36. REAR INTERIOR TRIM PANEL

Remove Rear Interior Trim Panel on Standard Cab, Extended Cab and Crew Cab for all Models
NOTE – The step below shows removing both driver and passenger side side and corner interior trim
panels before removing rear interior trim panel. It is possible to remove the rear interior trim panel by
removing one or the other of the side and corner interior trim panels then follow the steps below.
1. Remove passenger and driver side side and corner interior trim panel, refer to SIDE AND CORNER
INTERIOR TRIM PANEL (See SIDE AND CORNER INTERIOR TRIM PANEL, page 123).
2. Using push-in fastener removal tool (Item 1), remove five push-in fasteners (Item 2) across the top of the
rear interior trim panel (Item 3). Lay them out of the way and save for installation.
3. Remove rear interior trim panel (Item 3) from the cab. Lay it out of the way and save for installation
1. PUSH-IN FASTENER REMOVAL 2. PUSH-IN FASTENER

TOOL 3. REAR INTERIOR TRIM PANEL
Figure 106 Rear Interior Trim Panel
4.37. HEADER CONSOLE PANEL

Remove Header Console Panel on Standard Cab, Extended Cab and Crew Cab for all Models
130
HEADER CONSOLE PANEL REMOVE
installation.
3. Remove sun visor and clip, refer to SUN VISOR AND CLIP (See SUN VISOR AND CLIP, page 27).
1. COURTESY LIGHT 6. TORX HEAD SCREW

2. HEADER CONSOLE PANEL 7. RETAINING CLIP
3. WIRING HARNESS CONNECTOR 8. MOUNTING HOOK
4. TORX HEAD SCREW 9. PLASTIC ALIGNMENT TAB
5. TORX HEAD SCREW
Figure 107 Header Console Panel
131
REMOVE HEADER CONSOLE PANEL
4. Pull courtesy light (Item 1) out of header console panel (Item 2). Disconnect wiring harness connector (Item
3) from courtesy light. Lay it out of the way and save for installation unless damaged and being replaced.
5. Once the courtesy light (Item 1) is removed from header console panel (Item 2). Remove two torx head
screws (Item 4) inside cavity for courtesy light. Lay them out of the way and save for installation.
6. Remove two torx head screws (Item 5) near driver side speaker in header console panel (Item 2). Lay it
7. Remove two torx head screws (Item 6) near passenger side speaker in header console panel (Item
2). Lay it out of the way and save for installation.
8. Carefully pull two retaining clips (Item 7) of the header console panel (Item 2), one near each sun visor
clip, out of the header. Drop the header console panel down and slide three mounting hooks (Item 8) away
from windshield to remove the mounting hooks from the slots in the header. Lower header console panel
down and lay it across the dash panel.
9. Disconnect wiring harness connector (Item 1) from electronic control panel (Item 2) pig tail connector
(Item 3), if so equipped.
10. Disconnect wiring harness connector (Item 4) from driver side speaker (Item 5).
11. Disconnect wiring harness connector (Item 6) from passenger side speaker (Item 7).
12. If so equipped, pull off six retaining clips with ty-wraps (Item 8) securing the wiring harness (Item 9)
to the header console panel (Item 10).
13. Remove header console panel (Item 10) from the cab. Lay it out of the way and save for installation,
132
HEADER CONSOLE PANEL REMOVE
1. WIRING HARNESS CONNECTOR 6. WIRING HARNESS CONNECTOR

2. ELECTRONIC CONTROL PANEL 7. PASSENGER SIDE SPEAKER
3. PIG TAIL CONNECTOR 8. RETAINING CLIP WITH TY-WRAP
4. WIRING HARNESS CONNECTOR 9. WIRING HARNESS
5. DRIVER SIDE SPEAKER 10. HEADER CONSOLE PANEL
Figure 108 Header Console Panel Electrical Connections
133
REMOVE HEADLINER TRIM PANEL
4.38. HEADLINER TRIM PANEL

Remove Headliner Trim Panel on Standard Cab for all Models

TOOL 7. HEADLINER TRIM PANEL
2. PUSH-IN FASTENER 8. COAT HOOK
3. PASSENGER SIDE SIDE AND 9. COAT HOOK COVER
CORNER INTERIOR TRIM 10. COAT HOOK LEVER
PANEL 11. PUSH-IN FASTENER
4. PUSH-IN FASTENER 12. PUSH-IN FASTENER
5. DRIVER SIDE SIDE AND 13. PUSH-IN FASTENER
CORNER INTERIOR TRIM
PANEL
Figure 109 Headliner Trim Panel on Standard Cab for all Models
1. Remove header console panel, refer to HEADER CONSOLE PANEL (See HEADER CONSOLE PANEL,
page 130).
134
HEADLINER TRIM PANEL REMOVE
2. Using push-in fastener removal tool (Item 1), remove two push-in fasteners (Item 2) at the top of passenger
side side and corner interior trim panel (Item 3). Lay them out of the way and save for installation.
3. Using push-in fastener removal tool (Item 1), remove two push-in fasteners (Item 4) at the top of driver
4. Using push-in fastener removal tool (Item 1), remove two push-in fasteners (Item 6) at the back of
headliner trim panel (Item 7). Lay them out of the way and save for installation.
5. Remove coat hook (Item 8) at the back of headliner trim panel (Item 7) by pulling coat hook cover (Item 9)
down. With the coat hook cover down out of the way, push coat hook lever (Item 10) down and remove
coat hook. Lay it out of the way and save for installation.
6. Using push-in fastener removal tool (Item 1), remove push-in fastener (Item 11) from above passenger
side door opening in headliner trim panel (Item 7). Lay it out of the way and save for installation.
7. Using push-in fastener removal tool (Item 1), remove push-in fastener (Item 12) from above driver side
door opening in headliner trim panel (Item 7). Lay it out of the way and save for installation.
8. Using push-in fastener removal tool (Item 1), remove push-in fastener (Item 13) from above windshield in
the center of the headliner trim panel (Item 7), support the front of the headliner trim panel after removing
push-in fastener. Lay it out of the way and save for installation.
9. Once all the push-in fasteners (Items 2, 4, 6, 11, 12 and 13) and coat hook (Item 8) have been removed,
Lower front of headliner trim panel (Item 7) at the windshield. Slide headliner trim panel forward and
carefully pull it out from behind passenger and driver side side and corner interior trim panels (Items
3 and 5) and remove from cab. Lay it out of the way and save for installation, unless damaged and
being replaced.
Remove Front Headliner Trim Panel on Extended Cab for all Models
page 130).
2. Using push-in fastener removal tool (Item 1), remove push-in fastener (Item 2) from above passenger side
door opening in front headliner trim panel (Item 3). Lay it out of the way and save for installation.
3. Using push-in fastener removal tool (Item 1), remove push-in fastener (Item 4) from the front of passenger
side side and corner interior trim panel (Item 5). Lay it out of the way and save for installation.
4. Using push-in fastener removal tool (Item 1), remove push-in fastener (Item 6) from above driver side door
opening in front headliner trim panel (Item 3). Lay it out of the way and save for installation.
5. Using push-in fastener removal tool (Item 1), remove push-in fastener (Item 7) from the front of driver side
side and corner interior trim panel (Item 8). Lay it out of the way and save for installation.
6. Using push-in fastener removal tool (Item 1), remove five push-in fasteners (Item 9) at the back of front
headliner trim panel (Item 3) securing front headliner trim panel and rear headliner trim panel (Item 11) to
cab roof. Lay them out of the way and save for installation.
135

TOOL 8. DRIVER SIDE SIDE AND
2. PUSH-IN FASTENER CORNER INTERIOR TRIM
3. FRONT HEADLINER TRIM PANEL
5. PASSENGER SIDE SIDE AND 11. REAR HEADLINER TRIM PANEL
CORNER INTERIOR TRIM 12. PUSH-IN FASTENER
136
15. COAT HOOK 17. COAT HOOK LEVER

16. COAT HOOK COVER 18. COURTESY LIGHT
Figure 110 Front and Rear Headliner Trim Panel on Extended Cab for all Models
the center of the front headliner trim panel (Item 3), support the front of the front headliner trim panel after
removing push-in fastener. Lay push-in fastener out of the way and save for installation.
8. Once all the push-in fasteners (Items 2, 4, 6, 7, 9 and 10) have been removed. Lower front of front
headliner trim panel (Item 3) at the windshield. Slide front headliner trim panel forward and carefully pull it
out from under rear headliner trim panel (Item 11) and remove it from cab. Lay it out of the way and save
for installation, unless damaged and being replaced.
Remove Rear Headliner Trim Panel on Extended Cab for all Models
1. Using push-in fastener removal tool (Item 1), remove four push-in fasteners (Items 4 and 12) at the top
of passenger side side and corner interior trim panel (Item 5). Lay them out of the way and save for
installation.
2. Using push-in fastener removal tool (Item 1), remove four push-in fasteners (Items 7 and 13) at the top of
driver side side and corner interior trim panel (Item 8). Lay them out of the way and save for installation.
3. Using push-in fastener removal tool (Item 1), remove two push-in fasteners (Item 14) at the back of rear
4. Remove coat hook (Item 15) at the back of rear headliner trim panel (Item 11) by pulling coat hook cover
(Item 16) down. With the cover down out of the way, push coat hook lever (Item 17) down and remove coat
hook. Lay it out of the way and save for installation.
5. Using push-in fastener removal tool (Item 1), remove five push-in fasteners (Item 9) securing front
headliner trim panel (Item 3) and rear headliner trim panel (Item 11) to cab roof. Lay push-in fasteners
6. Once all the push-in fasteners (Items 4, 7, 9, 12, 13 and 14) and coat hook (Item 15) have been removed.
Slide front of rear headliner trim panel (Item 11) forward and carefully pull it out from behind passenger
and driver side side and corner interior trim panels (Items 5 and 8).
7. Lower rear headliner trim panel (Item 11) down from cab roof and disconnect electrical connector from
courtesy light (Item 18) and remove rear headliner trim panel from cab. Lay it out of the way and save for
Remove Front Headliner Trim Panel on Crew Cab for all Models
page 130).
2. Using push-in fastener removal tool (Item 1), remove push-in fastener (Item 2) from above passenger side
door opening in front headliner trim panel (Item 3). Lay it out of the way and save for installation.
137
3. Using push-in fastener removal tool (Item 1), remove push-in fastener (Item 4) from the front of passenger
side B - pillar trim panel (Item 5). Lay it out of the way and save for installation.
4. Using push-in fastener removal tool (Item 1), remove push-in fastener (Item 6) from above driver side door
opening in front headliner trim panel (Item 3). Lay it out of the way and save for installation.
5. Using push-in fastener removal tool (Item 1), remove push-in fastener (Item 7) from the front of driver side
B - pillar trim panel (Item 8). Lay it out of the way and save for installation.
6. Using push-in fastener removal tool (Item 1), remove five push-in fasteners (Item 9) at the back of front
headliner trim panel (Item 3) securing front headliner trim panel and rear headliner trim panel (Item 11) to
cab roof. Lay them out of the way and save for installation.
the center of the front headliner trim panel (Item 3), support the front of the front headliner trim panel after
removing push-in fastener. Lay push-in fastener out of the way and save for installation.
8. Once all the push-in fasteners (Items 2, 4, 6, 7, 9 and 10) have been removed. Lower front of front
headliner trim panel (Item 3) at the windshield. Slide front headliner trim panel forward and carefully pull it
out from under rear headliner trim panel (Item 11) and passenger and driver side B - pillar trim panels
(Items 5 and 8) and remove it from cab. Lay it out of the way and save for installation, unless damaged
and being replaced.
138

TOOL 7. PUSH-IN FASTENER
2. PUSH-IN FASTENER 8. DRIVER SIDE B-PILLAR TRIM
3. FRONT HEADLINER TRIM PANEL
5. PASSENGER SIDE B-PILLAR 11. REAR HEADLINER TRIM PANEL
TRIM PANEL 12. PUSH-IN FASTENER
139
13. PUSH-IN FASTENER 18. COAT HOOK

14. PASSENGER SIDE SIDE 19. COAT HOOK COVER
AND CORNER INTERIOR TRIM 20. COAT HOOK LEVER
16. PUSH-IN FASTENER 23. COURTESY LIGHT
17. DRIVER SIDE SIDE AND
CORNER INTERIOR TRIM
PANEL
Figure 111 Front and Rear Headliner Trim Panel on Crew Cab for all Models
Remove Rear Headliner Trim Panel on Crew Cab for all Models
1. Using push-in fastener removal tool (Item 1), remove push-in fastener (Item 12) from the rear of passenger
side B - pillar trim panel (Item 5). Lay it out of the way and save for installation.
2. Using push-in fastener removal tool (Item 1), remove two push-in fasteners (Item 13) at the top of
passenger side side and corner interior trim panel (Item 14). Lay them out of the way and save for
installation.
3. Using push-in fastener removal tool (Item 1), remove push-in fastener (Item 15) from the rear of driver side
B - pillar trim panel (Item 8). Lay it out of the way and save for installation.
4. Using push-in fastener removal tool (Item 1), remove two push-in fasteners (Item 16) at the top of driver
5. Remove coat hook (Item 18) at the back of rear headliner trim panel (Item 11) by pulling coat hook cover
(Item 19) down. With the cover down out of the way, push coat hook lever (Item 20) down and remove coat
hook. Lay it out of the way and save for installation.
6. Using push-in fastener removal tool (Item 1), remove two push-in fasteners (Item 21) at the back of rear
7. Using push-in fastener removal tool (Item 1), remove five push-in fasteners (Item 9) securing front
headliner trim panel (Item 3) and rear headliner trim panel (Item 11) to cab roof. Lay push-in fasteners
8. Using push-in fastener removal tool (Item 1), remove two push-in fasteners (Item 22) securing rear
headliner trim panel (Item 11) to cab roof. Lay push-in fasteners out of the way and save for installation.
9. Once all the push-in fasteners (Items 9, 12, 13, 15, 16, 21 and 22) and coat hook (Item 18) have been
removed. Slide front of rear headliner trim panel (Item 11) forward and carefully pull it out from behind
passenger and driver side B - pillar trim panels (Items 5 and 8) and passenger and driver side side
and corner interior trim panels (Items 14 and 17).
10. Lower rear headliner trim panel (Item 11) down from cab roof and disconnect electrical connector from
courtesy light (Item 23) and remove rear headliner trim panel from cab. Lay it out of the way and save for
140
CREW CAB B - PILLAR TRIM PANEL REMOVE
4.39. CREW CAB B - PILLAR TRIM PANEL

Remove B - Pillar Trim Panel on Crew Cab for all Models
1. To remove the B - pillar trim panel on crew cab models, refer to CAB DOORS (See CAB DOORS, page
38). Refer to Remove Rear Cab Door on Crew Cab for all Models.
4.40. CAB DOOR OPENING WEATHER SEALS

Remove Front Cab Door Opening Weather Seals on Standard Cab, Extended Cab and Crew Cab for
all Models
A primary rubber weather seal (Item 1) and secondary rubber weather seal (Item 3) provides a weather tight
seal around cab door when door is closed.
1. Remove cab door opening scuff plate and seat belt retractor cover. Refer to CAB DOOR OPENING
SCUFF PLATE AND SEAT BELT RETRACTOR COVER (See CAB DOOR OPENING SCUFF PLATE
AND SEAT BELT RETRACTOR COVER, page 121).
2. Carefully pull primary rubber weather seal (Item 1) off of the cab door opening weather seal flange (Item 2)
all the way around cab door opening, driver side shown. Lay it out of the way and save for installation,
3. Carefully pull secondary rubber weather seal (Item 3) off of the cab door opening weather seal flange (Item
4) across the top and front of cab door opening, driver side shown. Lay it out of the way and save for
4. Repeat procedure to remove passenger side primary rubber weather seal and secondary rubber weather
seal on front cab door opening.
141
REMOVE CAB DOOR OPENING WEATHER SEALS
1. PRIMARY RUBBER WEATHER 3. SECONDARY RUBBER

SEAL WEATHER SEAL
2. CAB DOOR OPENING WEATHER 4. CAB DOOR OPENING WEATHER
SEAL FLANGE SEAL FLANGE
Figure 112 Front Cab Door Opening Weather Seals
Remove Rear Cab Door Opening Weather Seals on Crew Cab for all Models
1. Remove cab door opening scuff plate and seat belt retractor cover. Refer to CAB DOOR OPENING
SCUFF PLATE AND SEAT BELT RETRACTOR COVER (See CAB DOOR OPENING SCUFF PLATE
AND SEAT BELT RETRACTOR COVER, page 121).
2. Carefully pull primary rubber weather seal (Item 1) off of the cab door opening weather seal flange (Item 2)
all the way around cab door opening, driver side shown. Lay it out of the way and save for installation,
3. Carefully pull secondary rubber weather seal (Item 3) off of the cab door opening weather seal flange (Item
4) across the top of cab door opening, driver side shown. Lay it out of the way and save for installation,
4. Repeat procedure to remove passenger side primary rubber weather seal and secondary rubber weather
seal on rear cab door opening of crew cab models.
142
WINDSHIELD WIPER ARM AND BLADE ASSEMBLY REMOVE
1. PRIMARY RUBBER WEATHER 3. SECONDARY RUBBER

SEAL WEATHER SEAL
2. CAB DOOR OPENING WEATHER 4. CAB DOOR OPENING WEATHER
SEAL FLANGE SEAL FLANGE
Figure 113 Rear Cab Door Opening Weather Seals
4.41. WINDSHIELD WIPER ARM AND BLADE ASSEMBLY

Remove Windshield Wiper Arm and Blade Assembly on Standard Cab, Extended Cab and Crew Cab for
all Models
1. Unlatch hood on both sides and tilt hood to fully open position.
2. To remove driver side windshield wiper arm and blade assembly (Item 1), first remove washer hose (Item
2) from “T” fitting (Item 3). Note position of windshield wiper arm and blade assembly on wiper pivot post
(Item 4) for installation before removing it. Lift up on lock lever (Item 5) securing windshield wiper arm and
blade assembly to wiper pivot post and pull it off. Lay driver side windshield wiper arm and blade assembly
with washer hose out of the way and save for installation, unless damaged and being replaced.
3. To remove passenger side windshield wiper arm and blade assembly (Item 6), first remove washer hose
(Item 7) from fitting (Item 8). Note position of windshield wiper arm and blade assembly on wiper pivot post
(Item 9) for installation before removing it. Lift up on lock lever (Item 10) securing windshield wiper arm
and blade assembly to wiper pivot post and pull it off. Lay passenger side windshield wiper arm and blade
assembly with washer hose out of the way and save for installation, unless damaged and being replaced.
143
REMOVE CAB COWL TRAY
1. DRIVER SIDE WINDSHIELD 6. PASSENGER SIDE WINDSHIELD

WIPER ARM AND BLADE WIPER ARM AND BLADE
ASSEMBLY ASSEMBLY
2. WASHER HOSE 7. WASHER HOSE
3. “T” FITTING 8. FITTING
4. WIPER PIVOT POST 9. WIPER PIVOT POST
5. LOCK LEVER 10. LOCK LEVER
Figure 114 Windshield Wiper Arm and Blade Assembly
4.42. CAB COWL TRAY

Remove Cab Cowl Tray on Standard Cab, Extended Cab and Crew Cab for all Models before September
2000
144
CAB COWL TRAY REMOVE
1. WASHER HOSE 3. RUBBER SEAL

2. COWL TRAY 4. ANTENNA
145
5. HEX FLANGED BOLT 11. HEX FLANGED NUT

6. MOUNTING BRACKET 12. HEX FLANGED NUT
7. TORX PAN HEAD SCREW 13. MOUNTING STUD
8. PLASTIC BRACKET 14. EVAPORATOR BOX
9. HEX FLANGED BOLT 15. U-SHAPED SPEED NUT
10. CENTER MOUNTING BRACKET 16. WIPER PIVOT POST
Figure 115 Cab Cowl Tray on Standard Cab, Extended Cab and Crew Cab for all Models before
September 2000
2. Remove both driver and passenger side windshield wiper arm and blade assembly. Refer to WINDSHIELD
WIPER ARM AND BLADE ASSEMBLY (See WINDSHIELD WIPER ARM AND BLADE ASSEMBLY,
page 143).
3. Remove washer hose (Item 1, view arrow A) from under cowl tray (Item 2, view arrow A) on driver side.
4. Slide rubber seal (Item 3, view arrow E) off antenna (Item 4, view arrow E) on passenger side.
5. Remove hex flanged bolt (Item 5, view arrow D) from mounting bracket (Item 6, view arrow D) under cowl
tray (Item 2, view arrow D) on passenger side.
6. Remove torx pan head screw (Item 7, view arrow C) from plastic bracket (Item 8, view arrow C) at the front
of cowl tray (Item 2, view arrow C) on passenger side.
7. Remove hex flanged bolt (Item 9, section A - A) from center mounting bracket (Item 10, section A - A)
at the center of cowl tray (Item 2, section A - A).
8. Remove hex flanged nut (Item 11, view arrow B) from under cowl tray (Item 2, view arrow B) on driver side.
9. Remove hex flanged nut (Item 12, view arrow D) from under cowl tray (Item 2, view arrow D) on passenger
side.
10. Once all mounting hardware securing cowl tray (Item 2) have been removed, slide the holes in the cowl
tray forward off the mounting studs (Item 13) and over both driver and passenger side wiper pivot posts
(Item 16).
11. Lift cowl tray (Item 2) up over the antenna (Item 4) and lay it out of the way and save for installation.
Remove Cab Cowl Tray on Standard Cab, Extended Cab and Crew Cab for all Models after September
2000
146

147

6. MOUNTING BRACKET 12. HEX FLANGED NUT
7. TORX PAN HEAD SCREW 13. MOUNTING STUD
8. PLASTIC BRACKET 14. EVAPORATOR BOX
9. HEX FLANGED BOLT 15. U-SHAPED SPEED NUT
10. CENTER MOUNTING BRACKET 16. WIPER PIVOT POST
Figure 116 Cab Cowl Tray on Standard Cab, Extended Cab and Crew Cab for all Models after
September 2000
page 143).
5. Remove hex flanged bolt (Item 5, view arrow D) from mounting bracket (Item 6, view arrow D) under cowl
tray (Item 2, view arrow D) on passenger side.
side.
10. Once all mounting hardware securing cowl tray (Item 2) have been removed, slide the holes in the cowl
tray forward off the mounting studs (Item 13) and over both driver and passenger side wiper pivot posts
(Item 16).
Remove Cab Cowl Tray on Standard Cab, Extended Cab and Crew Cab for all Models after February
2002
148

149
REMOVE WINDSHIELD WIPER ASSEMBLY
5. TORX PAN HEAD SCREW 12. WASHER BOTTLE VENT HOSE

6. COWL TRAY CENTER 13. VENT HOSE PUSH-IN
MOUNTING BRACKET FASTENER
7. HEX FLANGED BOLT 14. WIPER PIVOT POST
8. CENTER MOUNTING BRACKET 15. PLASTIC BRACKET OF
9. HEX FLANGED NUT EVAPORATOR BOX
10. HEX FLANGED NUT 16. EVAPORATOR BOX
11. MOUNTING STUD
Figure 117 Cab Cowl Tray on Standard Cab, Extended Cab and Crew Cab for all Models after February
2002
page 143).
side.
9. Remove washer bottle vent hose (Item 12, view arrow B) from driver side of cowl tray (Item 2, view arrow
B) by pulling vent hose push-in fastener (Item 13, view arrow B) out of the cowl tray.
10. Once the washer bottle vent hose and all mounting hardware securing cowl tray (Item 2) have been
removed, slide the holes in the cowl tray forward off the mounting studs (Item 11) and over both driver
and passenger side wiper pivot posts (Item 14).
4.43. WINDSHIELD WIPER ASSEMBLY

Remove Windshield Wiper Assembly on Standard Cab, Extended Cab and Crew Cab for all Models
150
WINDSHIELD WIPER ASSEMBLY REMOVE
1. WIRING HARNESS CONNECTOR 7. HEX FLANGED NUT

2. WINDSHIELD WIPER MOTOR 8. WINDSHIELD WIPER ASSEMBLY
CONNECTOR 9. MOUNTING STUD
3. HEX FLANGED NUT 10. HEX FLANGED NUT
4. WINDSHIELD WIPER MOTOR 11. MOUNTING STUD
MOUNTING BRACKET 12. TY-WRAP
5. MOUNTING STUD 13. WIRING HARNESS
6. WINDSHIELD WIPER MOTOR
Figure 118 Windshield Wiper Assembly
page 143).
151
REMOVE ELECTRIC WINDSHIELD WIPER MOTOR
3. Remove the cab cowl tray. Refer to CAB COWL TRAY (See CAB COWL TRAY, page 144).
4. Disconnect wiring harness connector (Item 1) from windshield wiper motor connector (Item 2).
5. Remove two hex flanged nuts (Item 3, view arrow A) securing windshield wiper motor mounting bracket
(Item 4, view arrow A) to mounting studs (Item 5) just below the windshield wiper motor (Item 6, view arrow
A) at the center of the cab cowl. Lay them out of the way and save for installation.
6. Remove hex flanged nut (Item 7, view arrow B) securing windshield wiper assembly (Item 8, view arrow B)
to mounting stud (Item 9) on driver side of the cab cowl. Lay it out of the way and save for installation.
7. Remove hex flanged nut (Item 10, view arrow C) securing windshield wiper assembly (Item 8, view arrow C)
to mounting stud (Item 11) on passenger side of the cab cowl. Lay it out of the way and save for installation.
8. If required, cut ty-wrap (Item 12, view arrow A) securing wiring harness (Item 13, view arrow A) to
windshield wiper motor (Item 6, view arrow A) and/or wiper motor mounting bracket (Item 4).
9. Remove windshield wiper assembly (Item 8) from the four mounting studs (Items 5, 9 and 11) on the cab
cowl. Lay it out of the way and save for installation, unless damaged and being replaced.
4.44. ELECTRIC WINDSHIELD WIPER MOTOR

Remove Electric Windshield Wiper Motor on Standard Cab, Extended Cab and Crew Cab for all Models
The windshield wiper system consists of a single unitized 12 volt electric motor that operates the wiper arms
through linkage (Figure 119) (See Figure 119, page 153).
Since the wiper motor is of unitized construction, there is no need for motor rebuild or adjustments. There are
no serviceable parts; the complete assembly is replaced.
CAUTION
1. With ignition key in ON position, cycle wiper arm to the end of the sweep cycle (wiper blade by left side of
windshield). Turn key to OFF position.
152
ELECTRIC WINDSHIELD WIPER MOTOR REMOVE
1. HEX RETAINING NUT 7. HEX FLANGED BOLT

2. WIPER DRIVE ARM 8. WIPER ARM
3. ELECTRIC WIPER MOTOR 9. WIPER BLADE
4. LOCK WASHER 10. WIPER PIVOT POST
5. WIPER LINKAGE
6. WIPER MOTOR MOUNTING
BRACKET
Figure 119 Electric Windshield Wiper Motor
3. Disconnect wiring harness connector (Item 1) from windshield wiper motor connector (Item 2).
4. If required, cut ty-wrap (Item 12, view arrow A) securing wiring harness (Item 13, view arrow A) to
windshield wiper motor (Item 6) and/or windshield wiper motor mounting bracket (Item 4).
NOTE – Windshield wipers and cowl tray have been removed in part of Figure 119 to show the windshield
wiper assembly located under the cowl tray.
Refer toFigure 119 for Items in parentheses.
153
REMOVE WINDSHIELD WASHER BOTTLE AND/OR PUMP MOTOR
5. Remove hex retaining nut (Item 1, view arrow A and view arrow B) securing wiper drive arm (Item 2, view
arrow A) to electric wiper motor (Item 3, view arrow A). Remove wiper drive arm and lock washer (Items
2 and 4, view arrow A) from electric wiper motor shaft. Lay wiper drive arm and wiper linkage (Items 2
and 5, view arrow A) on the wiper motor mounting bracket (Item 6, view arrow A). Lay hex retaining nut
and lock washer aside and save for installation.
6. With the wiper drive arm (Item 2, view arrow A) and wiper linkage (Item 5, view arrow A) out of the way.
Remove three hex flanged bolts (Item 7, view arrow A) securing electric wiper motor (Item 3, view arrow A)
to the wiper motor mounting bracket (Item 6, view arrow A) and remove electric wiper motor. Save hex
flanged bolts and electric wiper motor for installation, unless damaged and being replaced.
4.45. WINDSHIELD WASHER BOTTLE AND/OR PUMP MOTOR

Remove Windshield Washer Bottle and/or Pump Motor on Standard Cab, Extended Cab and Crew
Cab for all Models
Refer to Figure 120 for all models before July 2001 or Figure 121 (See Figure 121, page 156) for all models after
July 2001 or Figure 122 (See Figure 122, page 157) for all models after June 2002 for Items in parentheses.
NOTE – If the pump motor is removable and is being replaced, it is necessary to remove the washer
bottle before removing the pump motor.
2. Remove two hex flanged bolts (Item 1) securing washer bottle (Item 2) with pump motor (Item 3) to washer
bottle bracket (Item 4). Save hex flanged bolts for installation. Remove washer bottle from washer bottle
bracket and lay it forward to access the pump motor.
3. Since two different types of washer bottles and pump motors (Items 2 and 3) may be found on vehicles,
always check Parts Catalog before removing pump motor (Item 3) from washer bottle (Item 2).
4. Disconnect wiring harness connector (Item 5) from pump motor (Item 3).
5. Use a suitable container to catch washer fluid and empty all the washer fluid from washer bottle (Item 2).
Remove washer hose (Item 6) from pump motor outlet fitting (Item 7).
6. If pump motor (Item 3) is being replaced, carefully pull pump motor from washer bottle (Item 2).
7. If washer bottle (Item 2) is being replaced, disconnect wiring harness connector (Item 8) from washer bottle
wiring harness connector (Item 9) coming from low fluid sensor (Item 10) in washer bottle.
8. Remove washer bottle (Item 2) from vehicle.
154
WINDSHIELD WASHER BOTTLE AND/OR PUMP MOTOR REMOVE
1. HEX FLANGED BOLT 7. PUMP MOTOR OUTLET FITTING

2. WASHER BOTTLE 8. WIRING HARNESS CONNECTOR
3. PUMP MOTOR 9. WASHER BOTTLE WIRING
4. WASHER BOTTLE BRACKET HARNESS CONNECTOR
5. WIRING HARNESS CONNECTOR 10. LOW FLUID SENSOR
6. WASHER HOSE
Figure 120 Washer Bottle and Pump Motor on Standard Cab, Extended Cab and Crew Cab for
all Models before July 2001
155
REMOVE WINDSHIELD WASHER BOTTLE AND/OR PUMP MOTOR

6. WASHER HOSE
Figure 121 Washer Bottle and Pump Motor on Standard Cab, Extended Cab and Crew Cab for all
Models after July 2001
156
WINDSHIELD WASHER BOTTLE AND/OR PUMP MOTOR REMOVE

6. WASHER HOSE
Figure 122 Washer Bottle and Pump Motor on Standard Cab, Extended Cab and Crew Cab for
all Models after June 2002
157
REMOVE ENGINE COVER AND CUP HOLDER
4.46. ENGINE COVER AND CUP HOLDER

Remove Cup Holder on Standard Cab, Extended Cab and Crew Cab for all Models
2. If so equipped, remove cup holder and ashtray (Item 4) as follows.
3. Using a flat blade screw driver, carefully slide it between the center dash panel (Item 1) and center dash
panel trim bezel (Item 2). Carefully pry the center dash panel trim bezel out of the center dash panel. Lay it
4. Remove two torx head screws (Item 3) from the front of center dash panel (Item 1) and slide cup holder
and ashtray (Item 4) rearward to unhook cup holder and ashtray from underneath center dash panel. Lay it
1. CENTER DASH PANEL 3. TORX HEAD SCREW

2. CENTER DASH PANEL TRIM 4. CUP HOLDER AND ASHTRAY
BEZEL
Figure 123 Cup Holder and Ashtray
Remove Engine Cover on Standard Cab, Extended Cab and Crew Cab for all Models
1. On a vehicle with automatic transmission and hydraulic brakes, remove four hex flanged bolts (Item 1)
and remove hydraulic hand brake lever (Item 2) from cab floor. Lay it out of the way on the cab floor
158
ENGINE COVER AND CUP HOLDER REMOVE
1. HEX FLANGED BOLT 5. FLOOR MAT

2. HYDRAULIC HAND BRAKE 6. HEX FLANGED BOLT
LEVER 7. HEX FLANGED BOLT
3. HEX FLANGED BOLT 8. HEX FLANGED BOLT
4. ENGINE COVER 9. HEX FLANGED BOLT
Figure 124 Hydraulic Hand Brake Lever and Engine Cover
159
REMOVE ENGINE COVER AND CUP HOLDER
2. On a vehicle with standard transmission and air brakes, remove rubber boot (Item 1) from the cab floor
around the gear shift lever (Item 2).
3. Hold rubber boot (Item 1) up and remove allen screw (Item 3) securing gear shift lever (Item 2) to
transmission shift lever shaft (Item 4). Remove gear shift lever and rubber boot from transmission shift
lever shaft. Lay them out of the way on the cab floor and save for installation.
1. RUBBER BOOT 4. TRANSMISSION SHIFT LEVER

2. GEAR SHIFT LEVER SHAFT
3. ALLEN SCREW
Figure 125 Gear Shift Lever and Rubber Boot
160
CAB REMOVE
4. Remove two hex flanged bolts (Item 3) at the top of the engine cover (Item 4). Lay them out of the way
5. Pull driver side floor mat (Item 5, view circle A) back away from bottom edge of the engine cover (Item 4,
view circle A). Remove two hex flanged bolts (Item 6, view circle A) from driver side of the engine cover.
Lay them out of the way and save for installation.
6. Pull floor mat (Item 5, view circle B) back away from bottom edge across the front of the engine cover
(Item 4, view circle B). Remove hex flanged bolt (Item 7, view circle B) from the engine cover. Lay it
7. Pull floor mat (Item 5, view circle C) back away from bottom edge across the front of the engine cover
(Item 4, view circle C). Remove hex flanged bolt (Item 8, view circle C) from the engine cover. Lay it
8. Pull passenger side floor mat (Item 5, view circle D and E) back away from bottom edge of the engine
cover (Item 4, view circle D and E). Remove two hex flanged bolts (Item 9, view circle D and E) from
passenger side of the engine cover. Lay them out of the way and save for installation.
9. Carefully pull engine cover (Item 4) out from under dash panel, lift bottom front edge of engine cover over
transmission shift lever shaft (Item 4, Figure 125) (See Figure 125, page 160), if so equipped, and pull
it completely out from under dash panel. Remove engine cover from inside cab. Lay it out of the way
4.47. CAB
General Procedures for Cab Removal
The removal of the cab from chassis can be performed provided an overhead crane and cab lifting fixture
are available. Removal procedures may vary for various models depending on the type of equipment and
accessories.
NOTE – Refer to the correct sections in the Master Service Manual for the component being removed
and replaced.
1. The following steps may be used as a guide.
2. Block wheels of truck and engage parking brake.
3. Tilt or remove hood.
4. Disconnect battery ground cable.
5. Drain cooling system and disconnect heater hose.
6. Disconnect steering shaft at gear.
7. Disconnect accelerator linkage and cruise control, if so equipped.
8. Disconnect electrical connections and ground wire.
9. Disconnect clutch linkage.
161
REMOVE CAB
10. Disconnect brake system (air or hydraulic).
WARNING
To prevent personal injury, whenever any component is serviced or removed from the
air system, be sure the air system is drained and be sure to set the parking brake and/or
block the vehicle to prevent the vehicle from moving while the service is being performed.
11. Disconnect air conditioning lines (if so equipped). Refer to GROUP 16 - CAB in the Master Service
Manual for the proper procedure.
WARNING
Refrigerant must be recovered from the air conditioning system before any components
of the system are removed or replaced. Removing components while pressure is in the
system will cause personal injury or death.
WARNING
Always use approved refrigerant recycling equipment when working with R-134a.
Federal and state laws require that refrigerant be recovered and recycled to help protect
the environment.
WARNING
Do not vent refrigerant into the atmosphere. The use of R-12 is a worldwide
environmental concern. Because of the absence of chlorine in the molecular structure
of R-134a, the use of R-134a refrigerant will not have any harmful effects on the ozone
layer of the atmosphere. Because there is not enough evidence to determine the “
greenhouse ” effect of R-134a, recycling of R-134a is recommended. Effective November
1995, recovery and recycling of R-134a will be required by law.
12. Remove shift lever from transmission.
13. Detach exhaust system from cab if system is vertical type.
14. Detach any other connections between the cab and frame, if required.
15. Install cab lifting fixture. Make sure fixture is padded to prevent damage to cab.
NOTE – Use an overhead crane and cab lifting fixture when removing the cab from the chassis. Pad the
lifting fixture to prevent damage to the cab assembly.
16. Partially lift cab so cab weight will be supported on lifting fixture.
Remove Cab with Low Mount Front Cab Mounting and Low Mount Rear Cab Mounting for 4100, 4200,
4300 and 4400 Standard Cab and Extended Cab Models
1. To remove cabs with Low Mount Front Cab Mounting and Low Mount Rear Cab Mounting for 4200, 4300
and 4400 Standard Cab and Extended Cab Models. Remove cab to frame mounting bolts and nuts at front
162
CAB REMOVE
and rear mounting locations. Refer to (Figure 126) (See Figure 126, page 163) for Cab with Low Mount
Front Cab Mounting for 4100, 4200, 4300 and 4400 Standard Cab and Extended Cab Models and (Figure
127) (See Figure 127, page 165) for Cab with Low Mount Rear Cab Mounting for 4100, 4200, 4300 and
4400 Standard Cab and Extended Cab Models.
Cab with Low Mount Front Cab Mounting for 4100, 4200, 4300 and 4400 Standard Cab and Extended
Cab Models
1. Remove the hex flanged nut (Item 1) and remove cab mount safety retainer (Item 2) from under cab
chassis mounting bracket (Item 3), driver side shown. Save hex flanged nut and cab mount safety
retainer for installation.
2. Pull hex flanged bolt (Item 4) out of front cab mounting bracket (Item 5), driver side shown. Save hex
flanged bolt for installation.
3. Repeat procedure to remove passenger side cab mounting hardware.
1. HEX FLANGED NUT 5. FRONT CAB MOUNTING

2. CAB MOUNT SAFETY RETAINER BRACKET
3. CAB CHASSIS MOUNTING 6. FRONT CAB MOUNTING
BRACKET ISOLATOR
163
REMOVE CAB
8. HEX FLANGED BOLT

Figure 126 Low Mount Front Cab Mounting for 4100, 4200, 4300 and 4400 Standard Cab and Extended
Cab Models
164
CAB REMOVE
Cab with Low Mount Rear Cab Mounting for 4100, 4200, 4300 and 4400 Standard Cab and Extended
Cab Models
1. Remove hex flanged nut (Item 1) and remove rear cab rebound isolator (Item 2) from under rear cab
chassis crossmember (Item 3). Repeat procedure to remove the other hex flanged nut (Item 1) and rear
cab rebound isolator (Item 2).
2. The two carriage bolts (Item 4) are secured in place at the bottom of the cab underbody sill (Item 5) which
is part of the cab floor with retaining clips (Item 6). The carriage bolts will remain with cab underbody sill
and cab floor when cab is lifted off the chassis.
1. HEX FLANGED NUT 5. CAB UNDERBODY SILL

2. REAR CAB REBOUND ISOLATOR 6. RETAINING CLIP
3. REAR CAB CHASSIS 7. REAR CAB COMPRESSION
CROSSMEMBER ISOLATOR
4. CARRIAGE BOLT
Figure 127 Low Mount Rear Cab Mounting for 4100, 4200, 4300 and 4400 Standard Cab and Extended
Cab Models
CAUTION
Inspect all cab to frame attaching points to be sure they are disconnected or damage can
result.
3. Using an overhead crane and cab lifting fixture, carefully lift cab from chassis. If removing cab from
overhead crane, set it on a suitable surface to protect painted surfaces.
165
REMOVE CAB
Remove Low Mount Front Cab Mounting Isolators for 4100, 4200, 4300 and 4400 Standard Cab and
Extended Cab before January 2003
1. Once the cab is lifted from the chassis, if it is necessary to replace the front cab mounting isolator (Item 6),
driver side shown. Remove as follows.
2. Remove two hex flanged nuts (Item 7) from two hex flanged bolts (Item 8) and remove both hex flanged
bolts. Remove front cab mounting isolator (Item 6) from cab chassis mounting bracket (Item 3), driver
side shown. Save front cab mounting isolator, hex flanged nuts and hex flanged bolts for installation,
3. Repeat procedure to remove passenger side front cab mounting isolator.
Remove Low Mount Rear Cab Carriage Bolts and Compression Isolators for 4100, 4200, 4300 and 4400
Standard Cab and Extended Cab Models before January 2003
1. Once the cab is lifted from the chassis, the rear cab compression isolators (Item 7) can be lifted off
the cab chassis crossmember (Item 3). Save rear cab compression isolators for installation, unless
2. The two carriage bolts (Item 4) are secured in place at the bottom of the cab underbody sill (Item 5) which
and cab floor when cab is lifted off the cab chassis crossmember (Item 3).
3. If it is necessary to replace the two carriage bolts (Item 4), thread retaining clips (Item 6) off the two
carriage bolts. From inside the cab, lift the rear of the floor mat at the rear cab panel below the rear window
and pull the two carriage bolts out of cab underbody sill (Item 5) and cab floor.
Remove Cab with Low Mount Front Cab Mounting for all Crew Cabs and 4100, 4200, 4300 and 4400
Standard Cab and Extended Cab Models after January 2003 and Low Mount Rear Cab Air Suspension
Mounting for all Crew Cab Models
1. To remove cabs with Low Mount Front Cab Mounting for all Crew Cabs and 4100, 4200, 4300 and 4400
Mounting for all Crew Cabs. Remove cab to frame mounting bolts and nuts at front and rear mounting
locations. Refer to (Figure 128) (See Figure 128, page 167) for Cab with Low Mount Front Cab Mounting
for all Crew Cabs and 4100, 4200, 4300 and 4400 Standard Cab and Extended Cab Models after January
2003 and (Figure 129) (See Figure 129, page 168) for Cab with Low Mount Rear Cab Air Suspension
Mounting for all Crew Cab Models.
166
CAB REMOVE
Cab with Low Mount Front Cab Mounting for all Crew Cabs and 4100, 4200, 4300 and 4400 Standard
Cab and Extended Cab Models after January 2003
1. Remove the hex flanged nut (Item 1) from the threaded stud (Item 2) of the cab chassis mounting bracket
(Item 3) sticking through the front cab mounting bracket (Item 4), driver side shown. Save hex flanged
nut for installation.

2. THREADED STUD BRACKET
3. CAB CHASSIS MOUNTING
BRACKET
Figure 128 Low Mount Front Cab Mounting for all Crew Cabs and 4100, 4200, 4300 and 4400 Standard
Cab and Extended Cab Models after January 2003
167
REMOVE CAB
Cab with Low Mount Rear Cab Air Suspension Mounting for all Crew Cab Models
1. Remove two hex flanged nuts (Item 1) from the two carriage bolts (Item 2) under the top plate of the rear
cab air suspension assembly (Item 3).
2. The two carriage bolts (Item 2) are secured in place to the bottom of the cab underbody sill (Item 4) which
and cab floor when cab is lifted off the rear cab air suspension assembly (Item 3).
1. HEX FLANGED NUT 5. RETAINING CLIP

2. CARRIAGE BOLT 6. HEX FLANGED NUT
3. REAR CAB AIR SUSPENSION 7. HEX FLANGED BOLT
ASSEMBLY 8. FRAME RAIL CROSSMEMBER
4. CAB UNDERBODY SILL
Figure 129 Low Mount Rear Cab Air Suspension Mounting for all Crew Cab Models
CAUTION
result.
168
CAB REMOVE
Remove Low Mount Rear Cab Air Suspension for all Crew Cab Models
1. Once the cab is lifted from the rear cab air suspension assembly (Item 3), if it is necessary to remove
the cab air suspension assembly to replace it, follow steps below.
2. If it is necessary to replace the rear cab air suspension assembly (Item 3), remove four hex flanged nuts
(Item 6) from the four hex flanged bolts (Item 7). Remove the four hex flanged bolts from the mounting
holes in the rear cab air suspension assembly.
3. Disconnect the air line connection to the rear cab air suspension assembly (Item 3), remove rear cab air
suspension assembly from the frame rail crossmember (Item 8).
Remove Low Mount Rear Cab Air Suspension Mounting Carriage Bolts for all Crew Cab Models
1. Once the cab is lifted from the rear cab air suspension assembly (Item 3). The two carriage bolts (Item
2) are secured to the cab underbody sill (Item 4) which is part of the cab floor with retaining clips (Item
5). The carriage bolts will remain with cab underbody sill and cab floor when cab is lifted off the rear
cab air suspension assembly.
Remove Cab with Mid High Front Cab Mounting and Mid High Rear Cab Air Suspension Mounting for
4400 Model for City Tractor Applications
1. To remove cabs with Mid High Mount Front Cab Mounting and Mid High Mount Rear Cab Air Suspension
Mounting for 4400 Model for City Tractor Applications. Remove cab to frame mounting hex flanged nuts at
front and rear mounting locations. Refer to (Figure 130) (See Figure 130, page 170) for Cab with Mid
High Mount Front Cab Mounting for 4400 Model for City Tractor Applications and (Figure 131) (See
Figure 131, page 171) for Cab with Mid High Mount Rear Cab Air Suspension Mounting for 4400 Model
for City Tractor Applications.
169
REMOVE CAB
Cab with Mid High Front Cab Mounting and Mid High Rear Cab Air Suspension Mounting for 4400
Model for City Tractor Applications
1. Remove the hex flanged nut (Item 1) from the threaded stud (Item 2) of the cab chassis mounting bracket
(Item 3) sticking through the front cab mounting bracket (Item 4), driver side shown. Save hex flanged
nut for installation.

2. THREADED STUD BRACKET
3. CAB CHASSIS MOUNTING
BRACKET
Figure 130 Mid High Front Cab Mounting for 4400 Model for City Tractor Applications
170
CAB REMOVE
3. Remove two hex flanged nuts (Item 1) from the two carriage bolts (Item 2) under the top plate of the
rear air suspension assembly (Item 3).
4. The two carriage bolts (Item 2) are secured to the cab underbody sill (Item 4) with cab mount retaining
clips (Item 5). The carriage bolts will remain with cab underbody sill when cab is lifted off the rear cab air
suspension assembly (Item 3).
1. HEX FLANGED NUT 5. CAB MOUNT RETAINING CLIP

2. CARRIAGE BOLT 6. HEX FLANGED NUT
3. REAR CAB AIR SUSPENSION 7. HEX FLANGED BOLT
ASSEMBLY 8. FRAME RAIL CROSSMEMBER
4. CAB UNDERBODY SILL
Figure 131 Mid High Rear Cab Air Suspension Mounting for 4400 Model for City Tractor Applications
CAUTION
result.
Remove Mid High Mount Rear Cab Air Suspension for 4400 Model for City Tractor Applications
1. Once the cab is lifted from the rear cab air suspension assembly (Item 3), if it is necessary to remove
the cab air suspension assembly to replace it, follow steps below.
2. If it is necessary to replace the rear cab air suspension assembly (Item 3), remove four hex flanged nuts
(Item 6) from the four hex flanged bolts (Item 7). Remove the four hex flanged bolts from the mounting
holes in the rear cab air suspension assembly.
171
REMOVE CAB
3. Disconnect the air line connection to the rear cab air suspension assembly (Item 3), remove rear cab air
suspension assembly from the frame rail crossmember (Item 8).
Remove Mid High Mount Rear Cab Air Suspension Mounting Carriage Bolts for 4400 Model for City
Tractor Applications
1. Once the cab is lifted from the rear cab air suspension assembly (Item 3). The two carriage bolts (Item
2) are secured to the cab underbody sill (Item 4) which is part of the cab floor with retaining clips (Item
5). The carriage bolts will remain with cab underbody sill and cab floor when cab is lifted off the rear
cab air suspension assembly.
172
ONE PIECE ENCAPSULATED WINDSHIELD INSTALL
5. INSTALL
5.1. ONE PIECE ENCAPSULATED WINDSHIELD
There are two types of urethane adhesive that may be used to install one piece encapsulated windshields on
the vehicles covered in the service manual.
It is recommended to use the two part U216 urethane adhesive that comes in the Essex windshield installation
kit (Figure 132) (See Figure 132, page 174). The use of this urethane adhesive allows for a 30 minute drive
away time for the customer.
An optional one part U400HV urethane adhesive may be used when installing a one piece encapsulated
windshield, but the cure time is based on time, temperature and humidity and the cure table for U400HV
urethane adhesive. This requires a much longer drive away time for the customer.
Install One Piece Encapsulated Windshield using Two Part U216 Urethane Adhesive (adhesive A and
curative B) on Standard Cab, Extended Cab and Crew Cab for all Models
The 4100, 4200, 4300 and 4400 model vehicles come standard with a one piece encapsulated windshield
(Figure 7) (See Figure 7, page 9).
IMPORTANT – To install a one piece encapsulated windshield you will need to have the INTERNATIONAL®
Bonded Windshield Tool Kit ZTSE4470. This kit has a tool box that includes the tools required to remove
and install bonded windshields. To order, call toll free in U. S. and Canada 1–800–520–2584 or Fax
1–800–578–7375. NOTE - The INTERNATIONAL® Bonded Windshield Tool Kit ZTSE4470 is no longer
available through the INTERNATIONAL® tool supplier. For materials that are available contact
To install a one piece encapsulated windshield, you will also need the Essex windshield installation kit (Figure
132) (See Figure 132, page 174). The kit includes:
• U413 window fence primer

• U401 window glass prep
• U402 window glass primer
• U216 adhesive (two tubes, adhesive A and curative B)
• Application mixing head
• Applicator nozzle
173
INSTALL ONE PIECE ENCAPSULATED WINDSHIELD
1. U413 WINDOW FENCE PRIMER 5. U216–CURATIVE B TUBE

2. U401 WINDOW GLASS PREP 6. APPLICATION MIXING HEAD
3. U402 WINDOW GLASS PRIMER 7. APPLICATOR NOZZLE
4. U216–ADHESIVE A TUBE
Figure 132 Essex Windshield Installation Kit
These materials must be used on or before expiration date marked on container. U413 Window Fence Primer,
U401 Window Glass Prep and U402 Window Glass Primer have a 6 month shelf life. U216 Urethane adhesive
A and Curative B tubes have a 9 month shelf life.
In addition to the items supplied in the Essex windshield installation kit (Figure 132) (See Figure 132, page
174) above, you will need the following materials:
• Essex GC800 glass cleaner

• White or brown paper towels
• Applicator nozzles supplied by Essex to puncture U216 adhesive (two tubes, adhesive A and curative B)
NOTE – For the windshield, use only laminated safety glass (AS—1 per ANSI Z26.1–Latest revision) and
Navistar TMS-9522 (SAE J1203).
WARNING
Wear protective work gloves when handling the windshield. Also wear appropriate
protective gloves when using any of the Betaseal system chemicals from the Essex
windshield installation kit.
NOTE – Before installing new windshield, wipe off any water remaining around windshield fence and
surrounding cab area with a lint free cloth.
174
1. Dry fit new windshield on vehicle to make sure the windshield fits windshield opening properly before
applying U216 adhesive. Once the windshield is positioned properly in the windshield opening, place a
piece of tape as a reference mark across the center upper portion of windshield and cab. Use a utility knife
and cut the tape between the cab and windshield.
2. Remove new windshield from vehicle and place it on a suitable padded work stand to prepare it for
installation.
3. Remove urethane adhesive (Item 1) from windshield fence (Item 2) around windshield opening with a
gasket chisel (Item 3). A thin layer of old urethane adhesive of 2 to 3 mm thick (Item 4) may be left on
windshield fence. Try to keep a consistent thickness of old urethane adhesive around the perimeter of
the windshield fence.
1. URETHANE ADHESIVE 4. OLD URETHANE ADHESIVE (2

2. WINDSHIELD FENCE TO 3 MM THICK ALLOWED)
3. GASKET CHISEL
Figure 133 Removing Urethane Adhesive from Windshield Fence
175
4. Clean dirt and any water left from spraying around windshield during removal, off windshield fence (Item 1)
with a brush or clean, lint free cloth (Item 2) before installing new windshield.
1. WINDSHIELD FENCE 2. BRUSH

Figure 134 Cleaning Windshield Fence
5. Take U413 window fence primer from Essex windshield installation kit (Item 1, Figure 132) (See Figure
132, page 174). Shake U413 window fence primer (Item 1) for at least one minute. Remove cover (Item
2) from container.
1. U413 WINDOW FENCE PRIMER, 2. COVER

U401 WINDOW GLASS PREP OR
U402 WINDOW GLASS PRIMER
Figure 135 Preparation of Window Fence Primer, Window Glass Prep or Window Glass Primer
176
6. Apply U413 window fence primer (Item 1) with a clean, dry applicator (Item 2) to cover scratches and
bare metal on windshield fence (Item 3). DO NOT apply U413 window fence primer over old urethane
adhesive left on windshield fence.
1. U413 WINDOW FENCE PRIMER 3. WINDSHIELD FENCE

2. APPLICATOR
Figure 136 Applying Window Fence Primer to Windshield Fence
7. Allow U413 window fence primer to dry for 6 to 10 minutes minimum after application.
8. With new windshield on a padded work stand, prepare windshield for installation as follows:
9. Using a razor blade if necessary, and plastic scrubbing pad, remove any windshield encapsulation flash
from bonding surface of new windshield. Clean new windshield thoroughly with Essex glass cleaner
GC800. Dry thoroughly with paper towels. Make sure windshield is completely clean and dry before
proceeding (Figure 137).
Figure 137 Cleaning Windshield for Glass Prep, Glass Primer and Adhesive Application
177
10. Once the new windshield has been cleaned, take U401 window glass prep from Essex windshield
installation kit (Item 2, Figure 132) (See Figure 132, page 174). Shake U401 window glass prep (Item
1) for at least one minute. Remove cover (Item 2) from container.
NOTE – Read completely through Step 11 below to ensure the correct application and removal of the
glass prep U401.
11. Apply U401 window glass prep (Item 1) with a clean, dry applicator (Item 2) to bonding surface only on
new windshield (Item 3). If applied to clear glass surface, glass will haze. Immediately wipe glass prep off
by following eight to ten inches behind the applicator with a white or brown paper towel (Item 4). DO NOT
use a cloth shop towel. After completing first application of glass prep, repeat glass prep application and
removal process. This is a clear liquid.
1. U401 WINDOW GLASS PREP 4. WHITE OR BROWN PAPER

2. APPLICATOR TOWEL
3. NEW WINDSHIELD
Figure 138 Application of Glass Prep to Windshield
12. Once U401 window glass prep has been applied and wiped off new windshield, take U402 window glass
primer from Essex windshield installation kit (Item 3, Figure 132) (See Figure 132, page 174). Shake U402
window glass primer (Item 1) for at least one minute. Remove cover (Item 2) from container.
178
13. Apply U402 window glass primer (Item 1) with a clean, dry applicator (Item 2) to bonding surface on
new windshield (Item 3).
1. U402 WINDOW GLASS PRIMER 3. NEW WINDSHIELD

2. APPLICATOR
Figure 139 Application of Glass Primer to Windshield
14. Allow U402 window glass primer to dry to a tack free condition for 6 to 10 minutes minimum after
application.
CAUTION
Once the windshield has been primed, ensure there is no contact with bonding surface
as oil from skin will affect bonding performance. If the windshield is not bonded properly,
the cab strength and safety would be compromised. If contact with bonding surface has
occurred, repeat the cleaning process and reapply U402 window glass primer and allow
it to dry for 6 to 10 minutes before applying U216 adhesive.
15. Remove Essex U216 adhesive (two tubes, adhesive A and curative B) from Essex windshield installation
kit (Items 4 and 5, Figure 132) (See Figure 132, page 174).
179
16. Using the pull tab or a screwdriver (Item 1), if pull tab not supplied, pry out bottom cover (Item 2) from both
adhesive A and curative B adhesive tubes (Item 3).
1. SCREWDRIVER 3. ADHESIVE TUBE

2. BOTTOM COVER
Figure 140 Removing Bottom Cover from Adhesive Tubes
180
17. Use one applicator nozzle (Item 1) supplied separately by Essex to puncture adhesive A tube (Item 2).
Use the other applicator nozzle (Item 1) supplied separately by Essex to puncture curative B tube (Item 2).
DO NOT use the same applicator nozzle to puncture both tubes; this keeps from contaminating the other
tube before installing application mixing head (Item 6, Figure 132) (See Figure 132, page 174). Be sure to
push applicator nozzle all the way in to ensure adhesive tubes are fully opened.
1. APPLICATOR NOZZLE 2. ADHESIVE A TUBE OR

CURATIVE B TUBE
Figure 141 Puncturing both Adhesive Tubes
18. Once both adhesive A and curative B adhesive tubes (Item 2) have been prepared for use, remove
application mixing head (Item 6, Figure 132) (See Figure 132, page 174) from Essex windshield installation
kit.
181
19. Install both adhesive A and curative B adhesive tubes (Item 1) on mixing head (Item 2).
1. ADHESIVE A AND CURATIVE B 2. MIXING HEAD

ADHESIVE TUBES
Figure 142 Installing both Adhesive Tubes to Mixing Head
182
20. Once both adhesive A and curative B adhesive tubes (Item 1) are installed on mixing head (Item 2),
remove applicator nozzle (Item 7, Figure 132) (See Figure 132, page 174) from Essex windshield
installation kit. Install applicator nozzle (Item 3) on mixing head (Item 2). Cut tab (Item 4) off applicator
nozzle. Measure and mark a 3/8 inch wide by 5/8 inch long with a 1/8 inch wide dimension at the base of
the new notch (Item 5) to replace the current V-notch on the applicator nozzle. Use a utility knife and cut
out new notch to allow for proper adhesive application.
1. ADHESIVE A AND CURATIVE B 5. CUT 3/8 INCH WIDE AND

ADHESIVE TUBES 5/8 INCH LONG NOTCH INTO
2. MIXING HEAD APPLICATOR NOZZLE
3. APPLICATOR NOZZLE
4. CUT TAB OFF APPLICATOR
NOZZLE
Figure 143 Installing Applicator Nozzle on Mixing Head and Cutting Tab Off
183
21. Before loading adhesive tubes with mixing head and applicator nozzle (Item 1) into betagun (Item 2), pull
trigger and run plungers (Item 3) all the way back to allow for adhesive tubes to be loaded. Open front
cover (Item 4) on betagun and install adhesive tubes with mixing head and applicator nozzle into betagun.
1. ADHESIVE TUBES WITH MIXING 2. BETAGUN

HEAD AND APPLICATOR 3. PLUNGERS
NOZZLE 4. FRONT COVER
Figure 144 Loading Adhesive into Betagun
184
22. Once adhesive tubes with mixing head and applicator nozzle (Item 1) have been installed into betagun
(Item 2), close front cover (Item 3). Run plungers (Item 4) forward on betagun until plungers are in position
to apply adhesive. Stop when adhesive reaches applicator nozzle.

HEAD AND APPLICATOR 3. FRONT COVER
NOZZLE 4. PLUNGERS
Figure 145 Running Plungers Forward on Betagun
23. Using a standard caulking gun (Item 1), apply a small bead of U400HV one part urethane adhesive (Item
2) to the weld seams at the top and bottom of the windshield fence (Item 3) on both sides.
1. STANDARD CAULKING GUN 3. WINDSHIELD FENCE

2. U400HV ONE PART URETHANE
ADHESIVE
Figure 146 Using a Standard Caulking Gun to Apply U400HV Adhesive
NOTE – Application of adhesive bead on new windshield shall be 0 to 2 mm from encapsulation edge
and be at least 5/8 to 3/4 inch (16 to 19 mm) high and 3/8 to 1/2 inch (10 to 13 mm) wide maximum.
185
IMPORTANT – If U216 two part adhesive runs out before getting all the way around the windshield, it is
acceptable to fill in the gap left (6 inches or less) with U400HV one part urethane adhesive using a standard
caulking gun. It is recommended that because of the short time frame in which to install the windshield, to
have a tube of U400HV one part urethane adhesive loaded into a caulking gun and ready to use, so that the
time will not run out to get the windshield installed onto the vehicle. Use a utility knife and cut out notch in the
applicator nozzle on the U400HV Urethane adhesive tube to allow for proper adhesive application, measure
and mark a 3/8 inch wide by 5/8 inch long with a 1/8 inch wide dimension at the base of the notch (Item 5) on
the applicator nozzle. Refer to (Figure 143) (See Figure 143, page 183).
24. Hold betagun (Item 1) and applicator nozzle (Item 2) as close to a 90 degree angle as possible and start
at the outer edge of locating tab on bottom edge of windshield at either driver or passenger side. Going
toward the corner, pull trigger to apply a uniform bead of adhesive (Item 3) all the way around windshield.
The harder you pull the trigger the faster the adhesive will extrude. Use this variable speed control to slow
down as you apply adhesive around the corners. Overlap adhesive at the seam slightly, and use a plastic
or wood tongue depressor (Item 4) to smooth or even out adhesive as required before installing windshield.
1. BETAGUN 4. PLASTIC OR WOOD TONGUE

2. APPLICATOR NOZZLE DEPRESSOR
3. ADHESIVE
Figure 147 Using Betagun to Apply Adhesive
25. Once adhesive has been applied on windshield it MUST be installed within 5 to 7 minutes maximum.
Adhesive starts curing immediately and will not provide an adequate bond if not installed within the 5 to
7 minute time frame.
186
26. With the aid of an assistant install windshield (Figure 148) as follows:
Figure 148 Installing Windshield
27. If the vehicle has a sunshade, position new windshield (Item 1) under sunshade being careful not to
touch windshield on cab. Align tape mark (Item 2) on windshield with tape mark on top of cab and
align windshield locator tabs (Item 3) on new windshield with cab locator post (Item 4) at the bottom of
windshield opening on cab.
1. NEW WINDSHIELD 3. WINDSHIELD LOCATOR TAB

2. TAPE MARK 4. CAB LOCATOR POST
Figure 149 Positioning Windshield Locator Tabs on Cab Locator Darts
187
28. On vehicles without a sunshade, align the piece of tape (Item 1) at the top of the windshield with tape (Item
2) above windshield opening on the cab, then position windshield locator tabs (Item 3, Figure 149) (See
Figure 149, page 187) on cab locator post (Item 4, Figure 149) (See Figure 149, page 187). While holding
windshield locator tabs in place on cab locator posts, push windshield (Item 3) back against windshield
fence (Item 4). Check windshield encapsulation rubber trim (Item 5) to make sure it is positioned properly
around windshield opening.
1. TAPE AT TOP OF WINDSHIELD 4. WINDSHIELD FENCE

2. TAPE ABOVE WINDSHIELD 5. WINDSHIELD ENCAPSULATION
OPENING ON CAB RUBBER TRIM
3. WINDSHIELD
Figure 150 Pushing Windshield into Place
29. With the aid of an assistant, gently push on windshield all around outer edge to set it properly against
windshield fence. There are tabs built into the windshield to keep it from being pushed in too far (Figure
151).
Figure 151 Pushing Windshield Back Against Windshield Fence
188
30. Remove both pieces of tape (Items 1 and 2) from windshield and cab.
31. If the unit is equipped with an exterior sunshade (Item 1) remove piece of tape (Item 2) from bottom side of
each sunshade mounting bracket (Item 3) used to protect sunshade mounting bracket paint while cutting
out windshield. If sunshade was removed, install sunshade. Refer to SUNSHADE (See SUNSHADE, page
228), for 4100, 4200, 4300 and 4400 models as required.
32. Position driver side A pillar trim panel (Item 1) in place at the cab A pillar (Item 3), align A pillar trim panel
retaining clips (Item 9) with the mounting holes in the cab A pillar and push in to secure.
33. Position passenger side A pillar trim panel (Item 5) in place inside cab, align A pillar trim panel retaining
clips with the mounting holes in the cab A pillar and push in to secure. Then position passenger side grab
handle (Item 6) in place on the passenger side A pillar trim panel and install two hex flanged bolts (Item 4)
to secure grab handle. Tighten the two hex bolts (Item 4) to 77 to 95 lbf-in (8.7 to 10.7 N•m).
34. Install windshield wiper arms and blades. Refer to WINDSHIELD WIPER ARM AND BLADE ASSEMBLY,
Install (See WINDSHIELD WIPER ARM AND BLADE ASSEMBLY, page 282).
35. Test operation of windshield wipers and washer, then clean windshield and surrounding area.
36. Close hood and latch hood on both sides.
IMPORTANT – The quick curing time of U216 two part urethane adhesive allows the vehicle to be driven 30
minutes after completing windshield installation. If the vehicle is equipped with AIR BAGS, the U216 two part
urethane adhesive should be allowed to cure for 60 minutes before driving. Even if U400HV one part urethane
adhesive has to be used to fill in a gap of 6 inches or less during the application of U216 two part urethane
adhesive the cure time before the vehicle can be driven will be the same as above. If more than 6 inches of
U400HV one part urethane adhesive is used, you will need to use the area on the Form Bonded Windshield
Replacement Report (Figure 205) (See Figure 206, page 305) to record Time, Temperature and Humidity
and follow the cure table for U400HV.
Install One Piece Encapsulated Windshield using One Part U400HV Urethane Adhesive on Standard
Cab, Extended Cab and Crew Cab for all Models
Although it is recommended to use the two part U216 urethane adhesive that comes in the Essex windshield
installation kit (Figure 132) (See Figure 132, page 174). The optional one part U400HV urethane adhesive
may be used when installing a one piece encapsulated windshield.
To install a one piece encapsulated windshield, you will also need the following items.

• U400HV adhesive (one tube)
• Standard caulking gun
189
These materials must be used on or before expiration date marked on container. U413 Window Fence Primer,
U401 Window Glass Prep and U402 Window Glass Primer have a 6 month shelf life. U400HV Urethane
adhesive tube has a 9 month shelf life.
When cutting the applicator nozzle on the U400HV Urethane adhesive tube, measure and mark a 3/8 inch
wide by 5/8 inch long with a 1/8 inch wide dimension at the base of the notch (Item 5) on the applicator nozzle.
Use a utility knife and cut out notch to allow for proper adhesive application. Refer to (Figure 143) (See
Figure 143, page 183)
IMPORTANT – When using U400HV one part urethane adhesive, you will need to use the area on the
Form Bonded Windshield Replacement Report (Figure 205) (See Figure 206, page 305) to record Time,
Temperature and Humidity and follow the cure table for U400HV. This is critical to when the vehicle can be
driven after completing the windshield installation.

NOTE – For the windshield, use only laminated safety glass (AS—1 per ANSI Z26.1–Latest revision) and
Navistar TMS-9522 (SAE J1203).
WARNING
Wear protective work gloves when handling the windshield. Also wear appropriate
protective gloves when using any of the Betaseal system chemicals from the Essex
windshield installation kit.
NOTE – Before installing new windshield, wipe off any water remaining around windshield fence and
surrounding cab area with a lint free cloth.
1. Dry fit new windshield on vehicle to make sure the windshield fits windshield opening properly before
applying U400HV adhesive. Once the windshield is positioned properly in the windshield opening, place a
piece of tape as a reference mark across the center upper portion of windshield and cab. Use a utility knife
and cut the tape between the cab and windshield.
2. Remove new windshield from vehicle and place it on a suitable padded work stand to prepare it for
installation.
3. Remove urethane adhesive (Item 1) from windshield fence (Item 2) around windshield opening with a
gasket chisel (Item 3). A thin layer of old urethane adhesive of 2 to 3 mm thick (Item 4) may be left on
windshield fence. Try to keep a consistent thickness of old urethane adhesive around the perimeter of
the windshield fence.
4. Clean dirt and any water left from spraying around windshield during removal, off windshield fence (Item 1)
with a brush or clean, lint free cloth (Item 2) before installing new windshield.
190
2) from container.
bare metal on windshield fence (Item 3). DO NOT apply U413 window fence primer over old urethane
adhesive left on windshield fence.
8. With new windshield on a padded work stand, prepare windshield for installation as follows:
9. Using a razor blade if necessary, and plastic scrubbing pad, remove any windshield encapsulation flash
from bonding surface of new windshield. Clean new windshield thoroughly with Essex glass cleaner
GC800. Dry thoroughly with paper towels. Make sure windshield is completely clean and dry before
proceeding (Figure 137). (See Figure 137, page 177)
10. Once the new windshield has been cleaned, take U401 window glass prep from Essex windshield
glass prep U401.
new windshield (Item 3). If applied to clear glass surface, glass will haze. Immediately wipe glass prep off
by following eight to ten inches behind the applicator with a white or brown paper towel (Item 4). DO NOT
use a cloth shop towel. After completing first application of glass prep, repeat glass prep application and
removal process. This is a clear liquid.
12. Once U401 window glass prep has been applied and wiped off new windshield, take U402 window glass
primer from Essex windshield installation kit (Item 3, Figure 132) (See Figure 132, page 174). Shake U402
window glass primer (Item 1) for at least one minute. Remove cover (Item 2) from container.
13. Apply U402 window glass primer (Item 1) with a clean, dry applicator (Item 2) to bonding surface on
new windshield (Item 3).
application.
191
CAUTION
Once the windshield has been primed, ensure there is no contact with bonding surface
as oil from skin will affect bonding performance. If the windshield is not bonded properly,
the cab strength and safety would be compromised. If contact with bonding surface has
occurred, repeat the cleaning process and reapply U402 window glass primer and allow
it to dry for 6 to 10 minutes before applying U400HV adhesive.
15. Using a standard caulking gun (Item 1), apply a small bead of U400HV one part urethane adhesive (Item
2) to the weld seams at the top and bottom of the windshield fence (Item 3) on both sides.
NOTE – Application of adhesive bead on new windshield shall be 0 to 2 mm from encapsulation edge
and be at least 5/8 to 3/4 inch (15 to 20 mm) high and 3/8 to 1/2 inch (8 to 12 mm) wide maximum.
1. CAULKING GUN 4. PLASTIC OR WOOD TONGUE

3. ADHESIVE
Figure 152 Using Caulking Gun to Apply Adhesive
16. Hold caulking gun (Item 1) and applicator nozzle (Item 2) as close to a 90 degree angle as possible and
start at the outer edge of locating tab on bottom edge of windshield at either driver or passenger side.
Going toward the corner, apply a uniform bead of adhesive (Item 3) all the way around windshield. Overlap
adhesive at the seam slightly, and use a plastic or wood tongue depressor (Item 4) to smooth or even out
adhesive as required before installing windshield.
192
17. Once adhesive has been applied on windshield. With the aid of an assistant install windshield (Figure 148)
(See Figure 148, page 187) as follows:
18. If the vehicle has a sunshade, position new windshield (Item 1) under sunshade being careful not to
touch windshield on cab. Align tape mark (Item 2) on windshield with tape mark on top of cab and
align windshield locator tabs (Item 3) on new windshield with cab locator post (Item 4) at the bottom of
windshield opening on cab.
19. On vehicles without a sunshade, align the piece of tape (Item 1) at the top of the windshield with tape (Item
2) above windshield opening on the cab, then position windshield locator tabs (Item 3, Figure 149) (See
Figure 149, page 187) on cab locator post (Item 4, Figure 149) (See Figure 149, page 187). While holding
windshield locator tabs in place on cab locator posts, push windshield (Item 3) back against windshield
fence (Item 4). Check windshield encapsulation rubber trim (Item 5) to make sure it is positioned properly
around windshield opening.
20. With the aid of an assistant, gently push on windshield all around outer edge to set it properly against
windshield fence. There are tabs built into the windshield to keep it from being pushed in too far (Figure
151) (See Figure 151, page 188).
21. Remove both pieces of tape (Items 1 and 2) from windshield and cab.
22. If the unit is equipped with an exterior sunshade (Item 1) remove piece of tape (Item 2) from bottom side of
each sunshade mounting bracket (Item 3) used to protect sunshade mounting bracket paint while cutting
out windshield. If sunshade was removed, install sunshade. Refer to SUNSHADE (See SUNSHADE, page
228), for 4100, 4200, 4300 and 4400 models as required.
23. Position driver side A pillar trim panel (Item 1) in place at the cab A pillar (Item 3), align A pillar trim panel
retaining clips (Item 9) with the mounting holes in the cab A pillar and push in to secure.
clips with the mounting holes in the cab A pillar and push in to secure. Then position passenger side grab
handle (Item 6) in place on the passenger side A pillar trim panel and install two hex flanged bolts (Item 4)
to secure grab handle. Tighten the two hex bolts (Item 4) to 77 to 95 lbf-in (8.7 to 10.7 N•m).
25. Install windshield wiper arms and blades. Refer to WINDSHIELD WIPER ARM AND BLADE ASSEMBLY,
Install (See WINDSHIELD WIPER ARM AND BLADE ASSEMBLY, page 282).
26. Test operation of windshield wipers and washer, then clean windshield and surrounding area.
27. Close hood and latch hood on both sides.
193
INSTALL REAR WINDOW GLASS ON VEHICLES WITHOUT VAN BODY
IMPORTANT – To allow for the correct curing time of U400HV one part urethane adhesive, you will need
to use the area on the Form Bonded Windshield Replacement Report (Figure 201) (See Figure 202, page 298)
to record Time, Temperature and Humidity and follow the cure table for U400HV.
5.2. REAR WINDOW GLASS ON VEHICLES WITHOUT VAN BODY

Install Rear Window Glass on Vehicles without Van Body on Standard Cab, Extended Cab and Crew
Cab for all Models
IMPORTANT – To install rear window glass you will need to have the INTERNATIONAL® Bonded Windshield
Tool Kit ZTSE4470. This kit has a tool box that includes the tools required to remove and install bonded rear
window glass. To order, call toll free in U. S. and Canada 1–800–520–2584 or Fax 1–800–578–7375. NOTE -
The INTERNATIONAL® Bonded Windshield Tool Kit ZTSE4470 is no longer available through the
INTERNATIONAL® tool supplier. For materials that are available contact INTERNATIONAL® service
parts.
To install rear window glass, you will also need the Essex windshield installation kit (Figure 132) (See Figure
132, page 174). The kit includes:

These materials must be used on or before expiration date marked on container. U413 Fence Primer, U401
Glass Prep and U402 Glass Primer have a 6 month shelf life. U216 Urethane adhesive A and Curative B
tubes have a 9 month shelf life.

NOTE – Use only heat treated glass (AS-2 per ANSI Z26.1-Latest revision).
WARNING
Wear protective work gloves when handling the rear window glass. Also wear
appropriate protective gloves when using any of the Betaseal system chemicals from
the Essex windshield installation kit.
NOTE – Before installing new rear window glass, wipe off any water remaining around rear window fence
and surrounding cab area with a lint free cloth.
194
REAR WINDOW GLASS ON VEHICLES WITHOUT VAN BODY INSTALL
1. Dry fit new rear window glass on vehicle to make sure the glass fits rear window opening properly before
applying U216 adhesive. Once the rear window glass is positioned properly in the rear window opening,
place a piece of tape as a reference mark across the top and bottom center portion of rear window glass
and cab. Use a utility knife and cut the tape between the cab and rear window glass.
2. Remove new rear window glass from vehicle and place it on a suitable padded work stand to prepare
it for installation.
3. Remove urethane adhesive (Item 1) from rear window fence (Item 2) around window opening with a
gasket chisel (Item 3). A thin layer of old urethane adhesive of 2 to 3 mm thick (Item 4) may be left
on window fence. Try to keep a consistent thickness of old urethane adhesive around the perimeter
of the window fence.
1. URETHANE ADHESIVE 4. OLD URETHANE ADHESIVE (2

2. REAR WINDOW FENCE TO 3 MM THICK ALLOWED)
3. GASKET CHISEL
Figure 153 Removing Urethane Adhesive from Rear Window Fence
4. Clean dirt and any water left from spraying around rear window glass during removal, off rear window
fence (Item 1) with a brush or clean, lint free cloth (Item 2) before installing new rear window glass.
1. REAR WINDOW FENCE 2. BRUSH
195
Figure 154 Cleaning Rear Window Fence
2) from container.
bare metal on rear window fence (Item 3). DO NOT apply U413 window fence primer over old urethane
adhesive left on rear window fence.
1. U413 WINDSHIELD FENCE 2. APPLICATOR

PRIMER 3. REAR WINDOW FENCE
Figure 155 Applying Window Fence Primer to Rear Window Glass Fence
8. With new rear window glass on a padded work stand, prepare rear window glass for installation as follows:
9. Using a razor blade if necessary, and plastic scrubbing pad, remove any encapsulation flash from bonding
surface of new rear window glass. Clean new rear window glass thoroughly with Essex glass cleaner
GC800. Dry thoroughly with paper towels. Make sure rear window glass is completely clean and dry
before proceeding (Figure 156).
196
Figure 156 Cleaning Rear Window Glass for Glass Prep, Glass Primer and Adhesive Application
10. Once the new rear window glass has been cleaned, take U401 window glass prep from Essex windshield
window glass prep U401.
1. U401 WINDOW GLASS PREP 4. WHITE OR BROWN PAPER

2. APPLICATOR TOWEL
3. NEW REAR WINDOW GLASS
Figure 157 Application of Glass Prep to Windshield
new rear window glass (Item 3). If applied to clear glass surface, glass will haze. Immediately wipe glass
prep off by following eight to ten inches behind the applicator with a white or brown paper towel (Item
197
4). DO NOT use a cloth shop towel. After completing first application of glass prep, repeat glass prep
application and removal process. This is a clear liquid.
12. Once U401 window glass prep has been applied and wiped off new rear window glass, take U402 window
glass primer from Essex windshield installation kit (Item 3, Figure 132) (See Figure 132, page 174). Shake
U402 window glass primer (Item 1) for at least one minute. Remove cover (Item 2) from container.
13. Apply U402 window glass primer (Item 1) with a clean, dry applicator (Item 2) to bonding surface on new
rear window glass (Item 3).
1. U402 WINDOW GLASS PRIMER 3. NEW REAR WINDOW GLASS

2. APPLICATOR
Figure 158 Application of Window Glass Primer to Rear Window Glass
application.
CAUTION
Once the rear window glass has been primed, ensure there is no contact with bonding
surface as oil from skin will affect bonding performance. If the rear window glass is not
bonded properly, the cab strength and safety would be compromised. If contact with
bonding surface has occurred, repeat the cleaning process and reapply U402 window
glass primer and allow it to dry for 6 to 10 minutes before applying U216 adhesive.
198
1. SCREWDRIVER 3. ADHESIVE TUBE

2. BOTTOM COVER
Figure 159 Removing Bottom Cover from Adhesive Tubes
199
1. APPLICATOR NOZZLE 2. ADHESIVE A TUBE OR

CURATIVE B TUBE
Figure 160 Puncturing both Adhesive Tubes
kit.
200
201
1. ADHESIVE A AND CURATIVE B 2. MIXING HEAD

ADHESIVE TUBES
Figure 161 Installing both Adhesive Tubes to Mixing Head
202
20. Once both adhesive A and curative B adhesive tubes (Item 1) are installed on mixing head (Item 2), remove
applicator nozzle (Item 7, Figure 132) (See Figure 132, page 174) from Essex windshield installation kit.
Install applicator nozzle (Item 3) on mixing head (Item 2). Cut tab (Item 4) off applicator nozzle.
1. ADHESIVE A AND CURATIVE B 3. APPLICATOR NOZZLE

ADHESIVE TUBES 4. CUT TAB OFF APPLICATOR
2. MIXING HEAD NOZZLE
Figure 162 Installing Applicator Nozzle on Mixing Head and Cutting Tab Off
203

HEAD AND APPLICATOR 3. PLUNGERS
NOZZLE 4. FRONT COVER
Figure 163 Loading Adhesive into Betagun
204

HEAD AND APPLICATOR 3. FRONT COVER
NOZZLE 4. PLUNGERS
Figure 164 Running Plungers Forward on Betagun
NOTE – Application of adhesive bead on new rear window glass shall be 0 to 2 mm from encapsulation
edge and be at least 5/8 to 3/4 inch (15 to 20 mm) high and 3/8 to 1/2 inch (8 to 12 mm) wide maximum.
205
23. Hold betagun (Item 1) and applicator nozzle (Item 2) as close to a 90 degree angle as possible and start at
the center of the bottom edge of rear window glass. Going across the bottom in either direction, pull trigger
to apply a uniform bead of adhesive (Item 3) all the way around rear window glass. The harder you pull the
trigger the faster the adhesive will extrude. Use this variable speed control to slow down as you apply
adhesive around the corners. Overlap adhesive at the seam slightly, and use a plastic or wood tongue
depressor (Item 4) to smooth or even out adhesive as required before installing rear window glass.
1. BETAGUN 4. PLASTIC OR WOOD TONGUE

3. ADHESIVE
Figure 165 Using Betagun to Apply Adhesive
24. Once adhesive has been applied on rear window glass it MUST be installed within 5 to 7 minutes
maximum. Adhesive starts curing immediately and will not provide an adequate bond if not installed within
the 5 to 7 minute time frame.
25. With the aid of an assistant install rear window glass as follows:
206
26. Align tape marks (Item 1) on top and bottom of rear window glass (Item 2) with tape marks (Item 3) on
top and bottom of window opening of cab (Item 4), also position lower window glass locator tabs (Item 5)
between window locators (Item 6) of lower window fence of cab. Make sure upper window glass spring clip
(Item 7) is inside top of window fence (Item 8).
1. TAPE MARK 6. WINDOW LOCATOR

2. NEW REAR WINDOW GLASS 7. UPPER WINDOW GLASS
3. TAPE MARK SPRING CLIP
4. CAB 8. WINDOW FENCE
5. LOWER WINDOW GLASS
LOCATOR TAB
Figure 166 Installing Rear Window Glass
27. With the aid of an assistant, gently push on rear window glass all around outer edge to set it properly
against window fence.
207
28. Once the rear window glass (Item 1) is set properly against the window fence, using tape (Item 2) tape
rear window glass to the back of the cab (Item 3).
1. REAR WINDOW GLASS 3. BACK OF CAB

2. TAPE
Figure 167 Taping Rear Window Glass in Place
29. Remove pieces of tape (Items 1 and 3, Figure 166) (See Figure 166, page 207) from top and bottom of
rear window glass and cab rear window opening that was used during installation rear window glass.
30. If removed during rear window glass removal, install the seats back into the cab. Refer to SEATS, Install
CAUTION
Be careful while putting the seats back into the cab, not to hit the rear window glass while
the adhesive is curing. This may cause rear window glass to not seal properly and could
cause leaking.
minutes after completing rear window glass installation. You will need to use the area on the Form Bonded
Windshield Replacement Report (Figure 205) (See Figure 206, page 305) to record Time, Temperature
and Humidity.
208
REAR WINDOW GLASS ON VEHICLES WITH VAN BODY INSTALL
5.3. REAR WINDOW GLASS ON VEHICLES WITH VAN BODY

Install Rear Window Glass on Vehicles with Van Body on Standard Cab, Extended Cab and Crew
Cab for all Models
IMPORTANT – To install rear window glass you will need to have the INTERNATIONAL® Bonded Windshield
Tool Kit ZTSE4470. This kit has a tool box that includes the tools required to remove and install bonded rear
window glass. To order, call toll free in U. S. and Canada 1–800–520–2584 or Fax 1–800–578–7375. NOTE -
The INTERNATIONAL® Bonded Windshield Tool Kit ZTSE4470 is no longer available through the
INTERNATIONAL® tool supplier. For materials that are available contact INTERNATIONAL® service
parts.
To install rear window glass, you will also need the Essex windshield installation kit (Figure 132) (See Figure
132, page 174). The kit includes:

These materials must be used on or before expiration date marked on container. U413 Fence Primer, U401
Glass Prep and U402 Glass Primer have a 6 month shelf life. U216 Urethane adhesive A and Curative B
tubes have a 9 month shelf life.
In addition to the items supplied in the kit listed above, you will need the following materials:

NOTE – Use only heat treated glass (AS-2 per ANSI Z26.1-Latest revision).
WARNING
Wear protective work gloves when handling the rear window glass. Also wear
appropriate protective gloves when using any of the Betaseal system chemicals from
the Essex windshield installation kit.
NOTE – Before installing new rear window glass, wipe off any water remaining around rear window fence
and surrounding cab area with a lint free cloth.
To install a rear window glass onto a vehicle with a van body, you will need to have the INTERNATIONAL®
Bonded Windshield Tool Kit ZTSE4470. This kit has two special suction cups (Item 1) and a slide rail (Item 2),
which will need to be assembled. (NOTE - The INTERNATIONAL® Bonded Windshield Tool Kit ZTSE4470
is no longer available through the INTERNATIONAL® tool supplier. For materials that are available
209
INSTALL REAR WINDOW GLASS ON VEHICLES WITH VAN BODY
contact INTERNATIONAL® service parts.) They are required to remove and install the bonded rear window
glass from between the cab and the van body.
1. Before preparing the rear window fence for installing rear window glass, dry fit new rear window glass
as follows.
2. Dry fit new rear window glass on vehicle to make sure the glass fits rear window opening properly before
applying U216 adhesive.
3. Carefully place rear window glass (Item 1) on the slide rail (Item 2) with the proper side facing the back
of the cab.
1. REAR WINDOW GLASS 2. SLIDE RAIL

Figure 168 Place Rear Window Glass on Slide Rail for Dry Fit
4. Slide rear window glass (Item 1) on the slide rail (Item 2) between the back of the cab and the van body.
Lean the top of rear window glass against the van body.
210
1. REAR WINDOW GLASS 2. SLIDE RAIL

Figure 169 Slide Rear Window Glass on Slide Rail for Dry Fit
5. Place two suction cups (Item 1) on the rear window glass (Item 2) as it sits on the slide rail between the
back of the cab and the van body. With the suction cup placed against the rear window glass, repeatedly
push plunger until the red line (Item 7, Figure 17) (See Figure 17, page 19) on the plunger is not visible.
1. SUCTION CUP 2. REAR WINDOW GLASS

Figure 170 Install Suction Cups on Rear Window Glass for Dry Fit
6. Place a piece of tape (Item 1) at the bottom center of the rear window opening on the back trim panel
(Item 2).
211
1. TAPE 2. BACK TRIM PANEL

Figure 171 Applying Tape on Back Trim Panel for Dry Fit of Rear Window Glass
7. Using the two suction cups (Item 1, Figure 172), lift the rear window glass (Item 2, Figure 172) off the
slide rail between the back of the cab and the van body. Position lower window glass locator tabs (Item 5)
between window locators (Item 6) of lower window fence of cab. Make sure upper window glass spring clip
(Item 7) is inside top of window fence (Item 8).

Figure 172 Install Rear Window Glass for Dry Fit
212
8. Using the two suction cups (Item 1), hold the rear window glass (Item 2) in the proper place in the rear
window opening.

Figure 173 Rear Window Glass Held in Place at Dry Fit
9. While holding the rear window glass (Item 1) in the proper place in the rear window opening. Use a
marker and mark a line (Item 2) in line with both right and left sides of the tape (Item 3). These lines will
help align the rear window glass during installation.
1. REAR WINDOW GLASS 3. TAPE

2. LINE ON REAR WINDOW GLASS
Figure 174 Mark Rear Window Glass at Dry Fit
10. Using the suction cups, tilt the top of rear window glass out. Lift the rear window glass off window glass
fence and place it in the slide rail. Lean the top of rear window glass against the van body.
213
11. Use the suction cups to slide the rear window glass down the slide rail enough to grab the rear window
glass from outside the cab.
12. Remove the suction cups from the rear window glass.
13. Remove new rear window glass from slide rail and place it on a suitable padded work stand to prepare
it for installation.
14. Remove urethane adhesive (Item 1) from rear window fence (Item 2) around window opening with a utility
knife (Item 3) and/or power knife with short inside cutting blade (Item 4). A thin layer of old urethane
adhesive of 2 to 3 mm thick may be left on window fence. Try to keep a consistent thickness of old
urethane adhesive around the perimeter of the window fence.
1. URETHANE ADHESIVE 4. POWER KNIFE WITH SHORT

2. REAR WINDOW FENCE INSIDE CUTTING BLADE
3. UTILITY KNIFE
Figure 175 Removing Urethane Adhesive from Rear Window Fence
214
15. Clean dirt and any water left from spraying around rear window glass during removal, off rear window
fence (Item 1) with a brush or clean, lint free cloth (Item 2) before installing new rear window glass.
16. Place strips of tape (Item 1) around the rear window opening (Item 2) to protect the painted surfaces
while applying U413 window fence primer from Essex windshield installation kit (Item 1, Figure 132)
(See Figure 132, page 174).
1. TAPE 2. REAR WINDOW OPENING

Figure 176 Taping Rear Window Opening
2) from container.
215
bare metal on rear window fence (Item 3). DO NOT apply U413 window fence primer over old urethane
adhesive left on rear window fence.
1. U413 WINDSHIELD FENCE 2. APPLICATOR

PRIMER 3. REAR WINDOW FENCE
Figure 177 Applying Window Fence Primer to Rear Window Glass Fence
216
19. Remove strips of tape (Item 1) from around the rear window opening (Item 2).
1. TAPE 2. REAR WINDOW OPENING

Figure 178 Remove Tape from Around Rear Window Opening
21. With new rear window glass on a padded work stand, prepare rear window glass for installation as follows:
22. Using a razor blade if necessary, and plastic scrubbing pad, remove any encapsulation flash from bonding
surface of new rear window glass. Clean new rear window glass thoroughly with Essex glass cleaner
GC800. Dry thoroughly with paper towels. Make sure rear window glass is completely clean and dry
before proceeding (Figure 156) (See Figure 156, page 197).
23. Once the new rear window glass has been cleaned, take U401 window glass prep from Essex windshield
217
window glass prep U401.
218
new rear window glass (Item 3). If applied to clear glass surface, glass will haze. Immediately wipe glass
prep off by following eight to ten inches behind the applicator with a white or brown paper towel (Item
4). DO NOT use a cloth shop towel. After completing first application of glass prep, repeat glass prep
application and removal process. This is a clear liquid.
25. Once U401 window glass prep has been applied and wiped off new rear window glass, take U402 window
glass primer from Essex windshield installation kit (Item 3, Figure 132) (See Figure 132, page 174). Shake
U402 window glass primer (Item 1) for at least one minute. Remove cover (Item 2) from container.
26. Apply U402 window glass primer (Item 1) with a clean, dry applicator (Item 2) to bonding surface on new
rear window glass (Item 3).
application.
CAUTION
Once the rear window glass has been primed, ensure there is no contact with bonding
surface as oil from skin will affect bonding performance. If the rear window glass is not
bonded properly, the cab strength and safety would be compromised. If contact with
bonding surface has occurred, repeat the cleaning process and reapply U402 window
glass primer and allow it to dry for 6 to 10 minutes before applying U216 adhesive.
kit.
219
33. Once both adhesive A and curative B adhesive tubes (Item 1) are installed on mixing head (Item 2), remove
applicator nozzle (Item 7, Figure 132) (See Figure 132, page 174) from Essex windshield installation kit.
Install applicator nozzle (Item 3) on mixing head (Item 2). Cut tab (Item 4) off applicator nozzle.
NOTE – Application of adhesive bead on new rear window glass shall be 0 to 2 mm from encapsulation
edge and be at least 5/8 to 3/4 inch (15 to 20 mm) high and 3/8 to 1/2 inch (8 to 12 mm) wide maximum.
36. Hold betagun (Item 1) and applicator nozzle (Item 2) as close to a 90 degree angle as possible and start at
the center of the bottom edge of rear window glass. Going across the bottom in either direction, pull trigger
to apply a uniform bead of adhesive (Item 3) all the way around rear window glass. The harder you pull the
trigger the faster the adhesive will extrude. Use this variable speed control to slow down as you apply
adhesive around the corners. Overlap adhesive at the seam slightly, and use a plastic or wood tongue
depressor (Item 4) to smooth or even out adhesive as required before installing rear window glass.
37. Once adhesive has been applied on rear window glass it MUST be installed within 5 to 7 minutes
maximum. Adhesive starts curing immediately and will not provide an adequate bond if not installed within
the 5 to 7 minute time frame.
38. Using the two suction cups (Item 1), place rear window glass (Item 2) onto slide rail, remove the one
suction cup nearest the cab and slide rear window glass down the slide rail using the other suction cup
(Item 1). Remove the other suction cup.
220

Figure 179 Place Rear Window Glass with Adhesive onto Slide Rail
39. From inside the cab, install the two suction cups (Item 1) onto the inside of the rear window glass (Item 2).
With the suction cup placed against the rear window glass, repeatedly push plunger until the red line (Item
7, Figure 17) (See Figure 17, page 19) on the plunger is not visible.

Figure 180 Install Suction Cups on Rear Window Glass
221
40. Using the two suction cups (Item 1, Figure 181) on the rear window glass (Item 2, Figure 181), lift the
rear window glass off the slide rail and using the alignment lines at the bottom of the glass, position lower
window glass locator tabs (Item 5) between window locators (Item 6) of lower window fence of cab. Once
the bottom of the rear window glass is in the proper position on the bottom of the rear window fence,
carefully pull the rear window glass into position at the top and make sure that the upper window glass
spring clip (Item 7) fits inside upper window fence (Item 8). Pull the rear window glass in against the rear
window fence as evenly as possible.

Figure 181 Install Rear Window Glass with Adhesive into Window Opening
222
41. Remove the two suction cups (Item 1) from the rear window glass (Item 2).

Figure 182 Remove Suction Cups from Rear Window Glass
42. Reach in between back of cab and van body, and from both sides, gently push on rear window glass all
around outer edge to set it properly against window fence.
223
43. Remove pin (Item 1) from slide rail (Item 2) and the hole in the block (Item 3) of the suction cup (Item 4), to
allow the slide rail to be removed from the suction cup, driver side shown.
1. PIN 3. BLOCK ON SUCTION CUP

Figure 184 Remove Pin from Slide Rail and Suction Cup Block on Driver Side
224
44. Remove pin (Item 1) from slide rail (Item 2) and the hole in the block (Item 3) of the suction cup (Item 4), to
allow the slide rail to be removed from the suction cup, passenger side shown.
1. PIN 3. BLOCK ON SUCTION CUP

Figure 185 Remove Pin from Slide Rail and Suction Cup Block on Passenger Side
45. Once both driver and passenger side pins (Item 1) have been removed from the slide rail (Item 2) and
the block (Item 3) on each suction cup (Item 4).
225
46. Remove the slide rail (Item 1) from between the cab and the back of the van body.
1. SLIDE RAIL
Figure 186 Remove Slide Rail from between the Cab and Van Body
226
47. Remove the suction cup on drive side (Item 1) and suction cup on passenger side (Item 2) from the
back of the van body.
1. SUCTION CUP ON DRIVER SIDE 2. SUCTION CUP ON PASSENGER

SIDE
Figure 187 Remove Suction Cups on Van Body
48. It is not necessary to disassemble the slide rail (Item 1) if there is space available to store it assembled,
once the job is completed.
49. If it is desired to store the slide rail (Item 2) back in the removal and installation kit. Remove four wing nuts
(Item 6) from underneath the bottom rail (Item 4) and remove four flat head screws (Item 5) from the two
top rails (Item 3). It can now be stored in the removal and installation kit
50. If removed during rear window glass removal, install the seats back into the cab. Refer to SEATS, Install
CAUTION
Be careful while putting the seats back into the cab, not to hit the rear window glass while
the adhesive is curing. This may cause rear window glass to not seal properly and could
cause leaking.
227
INSTALL HOOD SEAL
minutes after completing rear window glass installation. You will need to use the area on the Form Bonded
Windshield Replacement Report (Figure 205) (See Figure 206, page 305) to record Time, Temperature
and Humidity.
5.4. HOOD SEAL

Install Hood Seal on Standard Cab, Extended Cab and Crew Cab for all Models
1. Check hood seal (Item 1) for cracks and tears. If damaged, replace it.
2. Position hood seal (Item 1) with hood seal mounting groove over the flange of the cowl tray (Item 2). Push
hood seal down firmly onto cowl tray flange all the way across the cowl tray to secure it properly.
3. Close hood and fasten latches on both sides of hood.
5.5. SUNSHADE
Install Sunshade on Standard Cab, Extended Cab and Crew Cab for all Models
1. MOUNTING BRACKET 5. MOUNTING BOLTS

2. ELECTRICAL CONNECTOR 6. CLEARANCE LIGHT
3. GASKET 7. SCREWS
4. SUNSHADE
Figure 188 Sunshade
1. Apply Loctite Blue 242 to mounting bolts.
2. Connect electrical cable from cab to sunshade electrical connector (See Figure 188, page 228).
228
SUN VISOR AND CLIP INSTALL
3.
CAUTION
Do not allow sunshade to fall or hang from electrical cable before installing mounting
bolts. This can damage cable wires and result in inoperative clearance lights.
Install sunshade and three new gaskets on mounting bracket with three mounting bolts (See Figure 188, page
228). Tighten bolts to 18 to 21.4 N•m (13 to 16 Lbf-ft)
4. Install left, center, and right clearance lights, and secure with 6 screws (See Figure 188, page 228).
Tighten screws to 2.3 to 2.8 N•m (20 to 24.7 Lbf-in).
5.6. SUN VISOR AND CLIP

Install Sun Visor and Clip on Standard Cab, Extended Cab and Crew Cab for all Models
1. Position sun visor clip (Item 4) onto the header console panel (Item 3) and install the torx head screw (Item
6). Tighten to 20 to 24.7 lbf-in (2.3 to 2.8 N•m).
2. Position sun visor (Item 2) into the sun visor clip (Item 4) at the center of the header console panel (Item
3). Position sun visor in place on the header console panel and install three torx head screws (Item 1)
securing sun visor to header console panel. Tighten to 20 to 24.7 lbf-in (2.3 to 2.8 N•m).
5.7. IGNITION SWITCH AND IGNITION SWITCH CYLINDER

The ignition switch and door locks are coded the same so that one key operates ignition switch and door locks.
The code number is stamped and bar coded on a plastic bag that the ignition switch and door lock cylinders
are supplied in at the assembly plant. This plastic bag is to remain with the vehicle when it is delivered to the
customer. It is very important that this plastic bag be kept by the customer in a safe, secure place, so that if a
replacement key is required, the key can be replaced.
The code number does not appear on ignition switch body or door lock assembly.
Install Ignition Switch Cylinder on Standard Cab, Extended Cab and Crew Cab for all Models
If the original key is desired when replacing the ignition switch cylinder, code the new ignition switch
accordingly. Use the following steps:
1. Insert original key (Item 1) in new ignition switch cylinder (Item 2). Before insertion into ignition switch
body, file off tumblers that protrude from cylinder. Make certain that no burrs are left on tumblers, and
that all filings are blown out with compressed air.
229
INSTALL INSTRUMENT PANEL
1. ORIGINAL KEY 2. NEW IGNITION SWITCH

CYLINDER
Figure 189 Original Key in New Switch Cylinder
2. To re-install same ignition switch cylinder, or to install a new ignition switch cylinder (Item 1), apply a
small quantity of powdered graphite to tumblers, then insert ignition switch key (Item 3) into ignition
switch cylinder (Item 1) . Rotate ignition key and ignition switch cylinder counterclockwise to accessory
position and insert ignition switch cylinder back into ignition switch body (Item 2). Turn key to Off position
and remove key.
Install Ignition Switch on Standard Cab, Extended Cab and Crew Cab for all Models
1. Position ignition switch (Item 2) at dash panel and connect ignition switch connector (Item 1) to back
of ignition switch.
2. Position ignition switch (Item 2) up behind dash panel (Item 1) and insert it into dash panel opening.
3. With ignition switch (Item 3) pushed through dash panel (Item 1) and positioned properly, using a 1–1/8
inch thin wall socket, install mounting cap nut (Item 4) securing it to dash panel. Tighten snugly.
4. Install rubber trim (Item 2) around ignition switch (Item 3).
5.8. INSTRUMENT PANEL

Install Instrument Panel on Standard Cab, Extended Cab and Crew Cab for all Models
IMPORTANT – Always disconnect battery ground before servicing or installing instrument panel.
230
INSTRUMENT PANEL INSTALL
1. Install instrument panel (Item 2) by carefully lifting it over the steering wheel. This will allow for connecting
warning harness connectors and air ducts so the instrument panel can be installed into the vehicle. Lower
instrument panel forward and then downward against the cowl panel (Item 15).
2. Position the air brake control unit (Item 11) in the center dash panel (Item 7) and install four torx head
bolt assemblies (Item 10) and tighten.
3. Connect ignition switch connector (Item 1) onto the back of the ignition switch (Item 2).
4. Install six torx head bolt assemblies (Item 12) into the center dash panel (Item 7).
5. Install courtesy lights under the instrument panel on both driver and passenger side.
6. Install two hex bolt assemblies (Item 8) underneath steering column (Item 9) securing steering column
to instrument panel (Item 2).
7. If vehicle has a center flat dash panel and is equipped with automatic transmission shifter unit (Item 4)
follow step a below. If vehicle has a center wing dash panel and is equipped with automatic transmission
shifter unit (Item 4) follow step b below.
a. Position automatic transmission shifter unit at the automatic transmission shifter unit mounting bracket
(Item 6) at the left edge of the center dash panel (Item 7) of instrument panel (Item 2). Align the
first and third mounting holes nearest the automatic transmission shifter unit with the two holes in
the automatic transmission shifter unit mounting bracket and install two hex flanged bolts (Item 5).
Tighten to 14.5 to 17.7 lbf-ft (19.6 to 24 N•m).
b. Position automatic transmission shifter unit at the automatic transmission shifter unit mounting bracket
(Item 6) at the left edge of the center dash panel (Item 7) of instrument panel (Item 2). Align the
second and fourth mounting holes nearest the automatic transmission shifter unit with the two holes in
the automatic transmission shifter unit mounting bracket and install two hex flanged bolts (Item 5).
Tighten to 14.5 to 17.7 lbf-ft (19.6 to 24 N•m).
8. Install five hex bolt assemblies (Item 13) into five U-shaped speed nuts (Item 14) at the front edge of the
upper instrument panel (Item 2) and cowl panel (Item 15). Tighten to 84 to 106 lbf-in (9.5 to 12 N•m).
9. With passenger side door open, install two hex bolt assemblies (Item 1) under the right end of the
passenger side at the lower instrument panel (Item 2). Tighten to 15.5 to 19 lbf-ft (21 to 26 N•m).
10. With driver side door open, install two hex bolt assemblies (Item 1) under the left end of the driver side at
the lower instrument panel (Item 2). Tighten to 15.5 to 19 lbf-ft (21 to 26 N•m).
11. Position center dash panel trim bezel (Item 2) in place in the center dash panel (Item 1) and carefully push
the center dash panel trim bezel in place until in snaps in place.
231
INSTALL INSTRUMENT PANEL
12. Position driver side A pillar trim panel (Item 1) in place at the cab A pillar (Item 3), align A pillar trim
panel retaining clips (Item 9) with the mounting holes in the cab A pillar and push in until it snaps into
place to secure.
clips with the mounting holes in the cab A pillar (Item 8) and push in until it snaps into place to secure.
Then position passenger side grab handle (Item 6) in place on the passenger side A pillar trim panel and
install two hex flanged bolts (Item 4) to secure grab handle. Tighten the two hex bolts (Item 4) to 77
to 95 lbf-in (8.7 to 10.7 N•m).
14. To install fuse panel access cover (Item 3 , Figure 34) (See Figure 34, page 35), position the access cover
tabs (Item 1) at the bottom of the access cover (Item 2) into the access cover tab mounting holes (Item 3)
in the bottom of the instrument panel (Item 4). Rotate the access cover toward the instrument panel until
the access cover guides (Item 5) slide into slotted holes (Item 6). Push the top of the access cover toward
the instrument panel and push each access cover spring clip (Item 7) into instrument panel spring clip
mounting holes (Item 8) to secure fuse panel access cover to instrument panel.
1. ACCESS COVER TAB 5. ACCESS COVER GUIDE

2. ACCESS COVER 6. SLOTTED HOLE
3. ACCESS COVER TAB 7. ACCESS COVER SPRING CLIP
MOUNTING HOLE 8. SPRING CLIP MOUNTING HOLE
4. INSTRUMENT PANEL
Figure 190 Fuse Panel Access Cover
15. Reconnect battery ground after servicing or installing instrument panel.
232
CAB DOORS INSTALL
5.9. CAB DOORS

Install Front Cab Door on Standard Cab, Extended Cab and Crew Cab for all Models
Doors are of all steel-welded construction. The front cab door is mounted on hinges located on the front
cab door hinge pillar and door adjustment is provided by enlarged holes in front cab door hinge. Door
check stop is located just below upper hinge on the front cab door hinge pillar. Front cab door latch striker
pin is also adjustable on front cab door lock pillar. Service on the door and its components are covered in
sections which follow.
support front cab door. Move front cab door (Item 6) from a padded work bench or other suitable support
covered with a material that protected painted surfaces of the door.
2. Once the front cab door (Item 6) is positioned at the cab. Carefully install the wiring harness and
connectors of front cab door through front cab door hinge pillar into the cab and pull them through as far as
they will go, as the cab door is placed on the hinges.
3. Once the wiring harness and connectors are installed into the cab. Slide four threaded studs (Item 5)
of front cab door (Item 6) into mounting holes of upper and lower front cab door hinges (Items 7 and
4. Install four hex nuts with washers (Item 4) onto threaded studs (Item 5) of front cab door (Item 6), driver
side shown. Tighten to 14 to 18 lbf-ft (19.6 to 24 N•m).
5. Position front cab door check link (Item 2) into front cab door check bracket (Item 3). Install front cab
door check stop pin (Item 1), driver side shown.
6. Once the front cab door is installed onto the cab. Reach up under the instrument panel to the left of the
steering wheel and connect CB radio cable connector (Item 1), electric window and electric door lock
wiring harness connector (Item 2) and lighted, heated or electric mirror wiring harness connector (Item
3), if so equipped, driver side shown.
7. Reach up under the instrument panel and push the cab door wiring harness (Item 1) and connectors (Item
2) up under the instrument panel, driver side shown.
8. Install door wiring harness rubber boot (Item 1) onto the cab hinge pillar (Item 2), driver side shown.
9. Repeat procedure to install passenger side front cab door.
Install Rear Cab Door on Crew Cab for all Models
Doors are of all steel-welded construction. The rear cab door is mounted on hinges located on the cab B - pillar
and door adjustment is provided by enlarged holes in rear cab door hinge. Rear cab door check stop is located
just below upper rear cab door hinge on the cab B - pillar. Rear cab door latch striker pin is also adjustable on
rear cab door lock pillar. Service on the door and its components are covered in sections which follow.
233
INSTALL CAB DOORS
support rear cab door. Move rear cab door (Item 6) from a padded work bench or other suitable support
covered with a material that protected painted surfaces of the door.
2. Once the rear cab door (Item 6) is positioned at the cab. Carefully install the wiring harness and connector
of rear cab door through rear cab door B - pillar into the cab and pull them through as far as they will go, as
the cab door is placed on the hinges.
3. Once the wiring harness and connector is installed into the cab. Slide four threaded studs (Item 5) of rear
cab door (Item 6) into mounting holes of upper and lower rear cab door hinges (Items 7 and 8), driver
side shown.
4. Install four hex nuts with washers (Item 4) onto threaded studs (Item 5) of rear cab door (Item 6), driver
side shown. Tighten to 14 to 18 lbf-ft (19.6 to 24 N•m).
5. Position rear cab door check link (Item 2) into rear cab door check bracket (Item 3). Install rear cab
door check stop pin (Item 1), driver side shown.
6. Once the rear cab door is installed onto the cab. Connect cab door light switch connector (Item 3) to cab
wiring harness light switch connector (Item 4), driver side shown.
7. Connect cab wiring harness electrical connector (Item 1) to cab door wiring harness electrical connector
8. Position B - pillar trim panel (Item 3) inside cab at the cab B - pillar. Lift seat belt retractor cover (Item 2,
Figure 40) (See Figure 40, page 43) and rear door seal plate (Item 4, Figure 40) (See Figure 40, page 43)
up enough to allow installation of B - pillar trim panel behind and underneath it.
9. Once the B - pillar trim panel (Item 3) is positioned properly against the cab B - pillar, install six push-in
fasteners (Item 2) through the B - pillar trim panel into cab B - pillar, driver side shown.
10. Install push-in fastener (Item 1) securing the seat belt retractor cover (Item 2) to the seat belt retractor
bracket, driver side shown.
11. Install torx head screw (Item 3) nearest the B - pillar securing the rear door seal plate (Item 4) to the
cab floor, driver side shown.
12. Install a new torx head bolt (Item 1) and secure shoulder belt D - ring (Item 2) to the B - pillar trim panel
(Item 3), driver side shown. Tighten to 25 to 35 lbf-ft (34 to 47.5 N•m).
13. Install door wiring harness rubber boot (Item 1) onto the cab hinge pillar (Item 2), driver side shown.
234
CAB DOOR HINGE INSTALL
14. Repeat procedure to install passenger side rear cab door.
5.10. CAB DOOR HINGE

Install Front Cab Door Hinge on Standard Cab, Extended Cab and Crew Cab for all Models
The front cab door is mounted on upper and lower cab door hinges (Items 1 and 2) located on the cab hinge
pillar (Item 3). Front cab door adjustment is provided by enlarged holes in front cab door hinge mounting holes.
If cab door hinges are removed from the cab, upper and lower hinges can be interchanged.
1. When installing upper and lower cab door hinges (Items 1 and 2) onto cab hinge pillar (Item 3), use
markings at upper and lower hinge position on cab hinge pillar to help position front cab door hinges
properly on the cab hinge pillar.
2. Position lower cab door hinge (Item 2), using markings on cab hinge pillar (Item 3). Install two hex bolts
with washers (Item 4) through lower cab door hinge and thread into the cab hinge pillar, driver side
shown. Tighten to 14 to 18 lbf-ft (19.6 to 24 N•m).
3. Position upper cab door hinge (Item 1), using markings on cab hinge pillar (Item 3). Install one hex bolt
with washer (Item 4) through mounting hole nearest cab door opening and one hex flanged locking bolt
(Item 5) through forward mounting hole of the upper cab door hinge and thread into the cab hinge pillar,
driver side shown. Tighten to 14 to 18 lbf-ft (19.6 to 24 N•m).
4. After installing upper and lower cab door hinges (Items 1 and 2) on cab hinge pillar (Item 3), install the
front cab door onto front cab door hinges. Refer to CAB DOORS (See CAB DOORS, page 233).
5. Repeat procedure to install upper and lower passenger side front cab door hinges.
Install Rear Cab Door Hinge on Crew Cab for all Models
The crew cab rear cab door is mounted on upper and lower crew cab rear door hinges (Items 1 and 2) located
on the crew cab B - pillar (Item 3). Rear cab door adjustment is provided by enlarged holes in rear cab
door hinge mounting holes. If hinges are removed from the crew cab B - pillar, upper and lower hinges can
be interchanged.
1. When installing upper and lower crew cab rear door hinges (Items 1 and 2) onto crew cab B - pillar (Item
3), use markings at upper and lower hinge position on crew cab B - pillar to help position crew cab rear
door hinges properly on the crew cab B - pillar.
2. Position lower crew cab rear door hinge (Item 2), using markings on crew cab B - pillar (Item 3). Install two
hex bolts with washers (Item 4) through lower crew cab rear door hinge and thread into the crew cab B -
pillar, driver side shown. Tighten to 14 to 18 lbf-ft (19.6 to 24 N•m).
3. Position upper crew cab rear door hinge (Item 1), using markings on crew cab B - pillar (Item 3). Install
one hex bolt with washer (Item 4) through mounting hole nearest cab door opening and one hex flanged
locking bolt (Item 5) through forward mounting hole of the upper crew cab rear door hinge and thread into
the crew cab B - pillar, driver side shown. Tighten to 14 to 18 lbf-ft (19.6 to 24 N•m).
4. After installing upper and lower crew cab rear door hinges (Items 1 and 2) on crew cab B - pillar (Item 3),
install the rear cab door onto rear cab door hinges. Refer to CAB DOORS (See CAB DOORS, page 233).
235
INSTALL CAB DOOR STRIKER PIN
5. Repeat procedure to install upper and lower passenger side crew cab rear door hinges.
5.11. CAB DOOR STRIKER PIN

Install Front Cab Door Striker Pin on Standard Cab, Extended Cab and Crew Cab for all Models
Front cab door striker pin (Item 1) mounted on cab lock pillar (Item 2) provides for positive engagement with
the door latch assembly (Item 7, Figure 72) (See Figure 72, page 80). Front cab door striker pin removal and
installation requires a torx head tool (Item 3). Enlarged mounting holes in cab lock pillar and floating tapped
striker pin mounting plate (Item 5) located inside cab lock pillar permits adjustment.
1. Position the front cab door striker pin (Item 1) at the cab lock pillar (Item 2) and install two torx head bolts
(Item 4) through front cab door striker pin, cab lock pillar into floating tapped striker pin mounting plate
(Item 5), located inside cab lock pillar, driver side shown. Use a torx head tool (Item 3) and tighten to 19
to 23.5 lbf-ft (26 to 32 N•m).
2. Repeat procedure to install passenger side front cab door striker pin.
Install Rear Cab Door Striker Pin on Crew Cab for all Models
Crew cab rear door striker pin (Item 1) mounted on cab lock pillar (Item 2) provides for positive engagement
with the door latch assembly (Item 7, Figure 74) (See Figure 74, page 83). Crew cab rear door striker pin
removal and installation requires a torx head tool (Item 3). Enlarged mounting holes in cab lock pillar and
floating tapped striker pin mounting plate (Item 5) located inside cab lock pillar permits adjustment.
1. Position the crew cab rear door striker pin (Item 1) at the cab lock pillar (Item 2) and install two torx
head bolts (Item 4) through crew cab rear door striker pin, cab lock pillar into floating tapped striker pin
mounting plate (Item 5), located inside cab lock pillar, driver side shown. Use a torx head tool (Item
3) and tighten to 19 to 23.5 lbf-ft (26 to 32 N•m).
2. Repeat procedure to install passenger side crew cab rear door striker pin.
5.12. CAB DOOR CHECK BRACKET

Install Front Cab Door Check Bracket on Standard Cab, Extended Cab and Crew Cab for all Models
1. Position the front cab door check Bracket (Item 3) at the cab hinge pillar (Item 4) and install two torx head
bolts (Item 2) through front cab door check bracket and thread into cab hinge pillar, driver side shown. Use
a torx head tool (Item 1) and tighten to 8 to 10 lbf-ft (11 to 13.6 N•m).
2. Repeat procedure to install passenger side front cab door check bracket.
Install Crew Cab Rear Door Check Bracket on Crew Cab for all Models
1. Position the crew cab rear door check bracket (Item 3) at the crew cab B - pillar (Item 4) and install two torx
head bolts (Item 2) through crew cab rear door check bracket and thread into crew cab B - pillar, driver
side shown. Use a torx head tool (Item 1) and tighten to 8 to 10 lbf-ft (11 to 13.6 N•m).
236
CAB DOOR CHECK LINK INSTALL
2. Repeat procedure to install passenger side crew cab rear door check bracket.
5.13. CAB DOOR CHECK LINK

Install Front Cab Door Check Link on Standard Cab, Extended Cab and Crew Cab for all Models
1. Position the front cab door check link (Item 2) inside the front cab door (Item 3) with threaded studs sticking
through mounting holes in front cab door. Install two hex nuts (Item 1) onto threaded studs of front cab
door check link, driver side shown. Tighten to 77 to 95 lbf-in (8.7 to 10.7 N•m).
2. Install front cab door inner door panel water shield, refer to CAB DOOR INNER DOOR PANEL WATER
SHIELD (See CAB DOOR INNER DOOR PANEL WATER SHIELD, page 240). For installing front cab door
inner door panel water shield, refer to Install Front Cab Door Inner Door Panel Water Shield on Standard
Cab, Extended Cab and Crew Cab for all Models.
3. Install front cab door trim panel, refer to CAB DOOR TRIM PANEL (See CAB DOOR TRIM PANEL, page
237). If front cab door is equipped with electric door window and locks, refer to Install Front Cab Door Trim
Panel with Electric Door Window and Locks. If front cab door is equipped with manual door window and
locks, refer to Install Front Cab Door Trim Panel with Manual Door Window and Locks.
4. Repeat procedure to install passenger side front cab door check link.
Install Crew Cab Rear Door Check Link on Crew Cab for all Models
1. Position the crew cab rear door check link (Item 2) inside the crew cab rear door (Item 3) with threaded
studs sticking through mounting holes in crew cab rear door. Install two hex nuts (Item 1) onto threaded
studs of crew cab rear door check link, driver side shown. Tighten to 77 to 95 lbf-in (8.7 to 10.7 N•m).
2. Install rear cab door inner door panel water shield, refer to CAB DOOR INNER DOOR PANEL WATER
SHIELD (See CAB DOOR INNER DOOR PANEL WATER SHIELD, page 240). For installing rear cab
door inner door panel water shield, refer to Install Rear Cab Door Inner Door Panel Water Shield on
3. Install rear cab door trim panel, refer to CAB DOOR TRIM PANEL (See CAB DOOR TRIM PANEL, page
237). If rear cab door is equipped with electric door window and locks, refer to Install Rear Cab Door Trim
locks, refer to Install Rear Cab Door Trim Panel with Manual Door Window and Locks.
4. Repeat procedure to install passenger side crew cab rear door check link.
5.14. CAB DOOR TRIM PANEL

Install Front Cab Door Trim Panel with Electric Door Window and Locks on Standard Cab, Extended
1. With the front cab door trim panel (Item 1) being held away from the front cab door (Item 2), connect
electrical connectors (Item 3) onto electric window and door lock switch (Item 4). If so equipped, connect
electrical connector (Item 5) onto electric mirror switch, driver side shown.
237
INSTALL CAB DOOR TRIM PANEL
2. Position front cab door trim panel (Item 1) in place at the front cab door (Item 2), driver side shown.
3. Once front cab door trim panel is positioned at the front cab door, install eight push-in fasteners (Item 7)
through front cab door trim panel (Item 3) into front cab door. Make sure all push-in fasteners have center
portion in the locked position securing front cab door trim panel to the front cab door Figure 52, view arrow
B (See Figure 52, page 56), driver side shown.
4. Install inner door pull cup (Item 2, view arrow A) into the front cab door trim panel (Item 3, view arrow
A). Install two torx head screws (Item 1, view arrow A), driver side shown. Tighten to 20 to 24.5 lbf-in
(2.3 to 2.8 N•m).
5. Install two torx head screws (Item 4) recessed in map pocket (Item 5) of front cab door trim panel (Item
3), driver side shown. Tighten to 20 to 24.5 lbf-in (2.3 to 2.8 N•m).
6. Repeat procedure to install passenger side front cab door trim panel with electric door window and locks.
Install Front Cab Door Trim Panel with Manual Door Window and Locks on Standard Cab, Extended
1. Position front cab door trim panel (Item 1) in place at the front cab door (Item 2), driver side shown.
2. Once front cab door trim panel is positioned at the front cab door, install eight push-in fasteners (Item 8)
through front cab door trim panel (Item 3) into front cab door. Make sure all push-in fasteners have center
portion in the locked position securing front cab door trim panel to the front cab door Figure 55, view arrow
3. Install inner door pull cup (Item 2, view arrow A) into the front cab door trim panel (Item 3, view arrow
A). Install two torx head screws (Item 1, view arrow A), driver side shown. Tighten to 20 to 24.5 lbf-in
(2.3 to 2.8 N•m).
4. Install two torx head screws (Item 4) recessed in map pocket (Item 5) of front cab door trim panel (Item
5. Install retaining clip onto window regulator handle (Item 6), then install window regulator handle onto
window regulator handle shaft until retaining clip locks into groove in the window regulator handle shaft,
driver side shown.
6. Repeat procedure to install passenger side front cab door trim panel with manual door window and locks.
Install Crew Cab Rear Cab Door Trim Panel with Electric Door Window and Locks on Crew Cab for
all Models
1. With the rear cab door trim panel (Item 1) being held away from the rear cab door (Item 2), connect
electrical connectors (Item 3) onto electric window and door lock switch (Item 4), driver side shown.
238
CAB DOOR TRIM PANEL INSTALL
2. Position rear cab door trim panel (Item 1) in place at the rear cab door (Item 2), driver side shown.
3. Once rear cab door trim panel is positioned at the rear cab door, install eight push-in fasteners (Item 7)
through rear cab door trim panel (Item 3) into rear cab door. Make sure all push-in fasteners have center
portion in the locked position securing rear cab door trim panel to the rear cab door Figure 56, view arrow
4. Install inner door pull cup (Item 2, view arrow A) into the rear cab door trim panel (Item 3, view arrow A).
Install two torx head screws (Item 1, view arrow A), driver side shown. Tighten to 20 to 24.5 lbf-in (2.3
to 2.8 N•m).
5. Install two torx head screws (Item 4) recessed in map pocket (Item 5) of rear cab door trim panel (Item
6. Repeat procedure to install passenger side rear cab door trim panel with electric door window and locks.
Install Crew Cab Rear Cab Door Trim Panel with Manual Door Window and Locks on Crew Cab for
all Models
1. Position rear cab door trim panel (Item 1) in place at the rear cab door (Item 2), driver side shown.
2. Once rear cab door trim panel is positioned at the rear cab door, install eight push-in fasteners (Item 8)
through rear door trim panel (Item 3) into rear cab door. Make sure all push-in fasteners have center
portion in the locked position securing rear cab door trim panel to the rear cab door Figure 59, view arrow
3. Install inner door pull cup (Item 2, view arrow A) into the rear cab door trim panel (Item 3, view arrow A).
Install two torx head screws (Item 1, view arrow A), driver side shown. Tighten to 20 to 24.5 lbf-in (2.3
to 2.8 N•m).
4. Install two torx head screws (Item 4) recessed in map pocket (Item 5) of rear cab door trim panel (Item
5. Install retaining clip (Item 13, Figure 61 (See Figure 61, page 66) onto window regulator handle (Item 6),
then install window regulator handle onto window regulator handle shaft until retaining clip locks into
groove in the window regulator handle shaft, driver side shown.
6. Repeat procedure to install passenger side rear cab door trim panel with manual door window and locks.
239
INSTALL CAB DOOR INNER DOOR PANEL WATER SHIELD
5.15. CAB DOOR INNER DOOR PANEL WATER SHIELD

Install Front Cab Door Inner Door Panel Water Shield on Standard Cab, Extended Cab and Crew
Cab for all Models
1. Before installing front cab door inner door panel water shield (Item 2), check to make sure it is not
damaged. Replace it if it is damaged. Carefully install the front cab door inner door panel water shield
back on the front cab door (Item 3). Make sure it is positioned properly before installing the front cab
door trim panel (Item 1).
3. Repeat procedure to install passenger side front cab door inner door panel water shield.
Install Rear Cab Door Inner Door Panel Water Shield on Crew Cab for all Models
1. Before installing rear cab door inner door panel water shield (Item 2), check to make sure it is not damaged.
Replace it if it is damaged. Carefully install the rear cab door inner door panel water shield back on the rear
cab door (Item 3). Make sure it is positioned properly before installing the rear cab door trim panel (Item 1).
3. Repeat procedure to install passenger side rear cab door inner door panel water shield.
5.16. CAB DOOR WINDOW SLIDE BLOCK

Install Front Cab Door Window Slide Block on Standard Cab, Extended Cab and Crew Cab for all Models
NOTE – It is not necessary to replace the plastic retaining tab broken off to remove the front cab door
window slide block from the front cab door window slide rail.
1. Check cab door window slide block (Item 3) for ware or damage, if worn or damaged, replace it. Working
through the cab door access opening, slide the cab door window slide block (Item 3) into the cab door
window slide rail (Item 4), driver side shown.
2. Working through the cab door access opening (Item 8), carefully push window regulator arm (Item 10) into
the cab door window slide block (Item 11) in the cab door window slide rail (Item 12), driver side shown.
240
CAB DOOR WINDOW SLIDE BLOCK INSTALL
5. Repeat procedure to install passenger side front cab door window slide block.
241
INSTALL CAB DOOR WINDOW SLIDE BLOCK
Install Rear Cab Door Window Slide Block on Crew Cab for all Models
NOTE – It is not necessary to replace the plastic retaining tab broken off to remove the rear cab door
window slide block from the rear cab door window slide rail.
1. Working through the cab door access opening, slide the cab door window slide block (Item 3) into the cab
5. Repeat procedure to install passenger side rear cab door window slide block.
242
CAB DOOR GLASS INSTALL
5.17. CAB DOOR GLASS

Install Front Cab Door Glass on Standard Cab, Extended Cab and Crew Cab for all Models
1. From outside front cab door (Item 1), position front cab door glass (Item 2) in front cab door glass opening
2. Lower front cab door glass (Item 2) in front cab door glass opening (Item 3) between inner and outer front
cab door (Item 1). Make sure front cab door glass slides into both front and rear cab door glass run
channels of the modular door hardware assembly, driver side shown.

2. FRONT CAB DOOR GLASS OPENING
Figure 191 Front Cab Door Glass
243
INSTALL CAB DOOR GLASS
3. Lower front cab door glass (Item 4) down to bottom of front cab door (Item 2), driver side shown. Modular
door hardware assembly removed for clarity.
4. Check front cab door glass seal and inner belt (Item 1) for damage, if damaged replace it. Position front
cab door glass seal and inner belt over inner lower flange of front cab door (Item 2) and push it down on
the inner front cab door flange, driver side shown.
5. Check front cab door glass seal and outer belt (Item 3) for damage, if damaged replace it. Position front
cab door glass seal and outer belt over outer lower flange of front cab door (Item 2) and push it down on
the outer front cab door flange, driver side shown.
1. FRONT CAB DOOR GLASS SEAL 3. FRONT CAB DOOR GLASS SEAL
Figure 192 Front Cab Door Glass Seal and Inner and Outer Belt
244
6. Check front cab door glass seal and run channel (Item 1) for damage, if damaged replace it. Position
right side of front cab door glass seal and run channel (Item 1) in the proper position at the front cab door
(Item 2) and push it into place, driver side shown.
1. RIGHT SIDE OF FRONT CAB 2. FRONT CAB DOOR

CHANNEL
245
7. Position the top of front cab door glass seal and run channel (Item 1) in the proper position at the front cab
door (Item 2) and push it into place. Then position left side of front cab door glass seal and run channel
(Item 3) in the proper position at the front cab door and push it into place, driver side shown.
1. TOP OF FRONT CAB DOOR 3. LEFT SIDE OF FRONT CAB

GLASS SEAL AND RUN DOOR GLASS SEAL AND RUN
CHANNEL CHANNEL
2. FRONT CAB DOOR
9. If vehicle is equipped with manual door window, temporarily place the window regulator handle (Item 6) on
the window regulator handle shaft (Item 7) and raise and lower cab door glass (Item 4) in the front cab
door (Item 3). Make sure cab door glass goes up and down smoothly without binding before continuing.
Once it is determined the cab door glass goes up and down properly, remove window regulator handle and
continue to next step, driver side shown.
10. If vehicle is equipped with electric door window, temporarily hold front cab door trim panel (Item 1) up to
the front cab door (Item 3) and connect electric connectors (Item 3, Figure 54) (See Figure 54, page 58)
and use electric window switch panel (Item 5) to raise and lower cab door glass (Item 4) in the front cab
door. Make sure cab door glass goes up and down smoothly without binding before continuing. Once it is
determined the cab door glass goes up and down properly, disconnect electric connector to front cab door
trim panel and continue to next step, driver side shown.
246
13. Repeat procedure to install passenger side front cab door glass.
Install Rear Cab Door Glass on Crew Cab for all Models
1. From outside rear cab door (Item 1), position rear cab door glass (Item 2) in rear cab door glass opening
2. Lower rear cab door glass (Item 2) in rear cab door glass opening (Item 3) between inner and outer rear
cab door (Item 1). Make sure rear cab door glass slides into both front and rear cab door glass run
channels of the modular door hardware assembly, driver side shown.

2. REAR CAB DOOR GLASS OPENING
Figure 195 Rear Cab Door Glass
247
3. Lower rear cab door glass (Item 4) down to bottom of rear cab door (Item 2), driver side shown. Modular
door hardware assembly removed for clarity.
4. Check rear cab door glass seal and inner belt (Item 1) for damage, if damaged replace it. Position rear
cab door glass seal and inner belt over inner lower flange of rear cab door (Item 2) and push it down on
the inner rear cab door flange, driver side shown.
5. Check rear cab door glass seal and outer belt (Item 3) for damage, if damaged replace it. Position rear
cab door glass seal and outer belt over outer lower flange of rear cab door (Item 2) and push it down on
the outer rear cab door flange, driver side shown.
1. REAR CAB DOOR GLASS SEAL 3. REAR CAB DOOR GLASS SEAL
Figure 196 Rear Cab Door Glass Seal and Inner and Outer Belt
248
6. Check rear cab door glass seal and run channel (Item 1) for damage, if damaged replace it. Position right
side of rear cab door glass seal and run channel (Item 1) in the proper position at the rear cab door
(Item 2) and push it into place, driver side shown.
1. RIGHT SIDE OF REAR CAB 2. REAR CAB DOOR

CHANNEL
249
7. Position the top of rear cab door glass seal and run channel (Item 1) in the proper position at the rear cab
door (Item 2) and push it into place. Then position left side of rear cab door glass seal and run channel
(Item 3) in the proper position at the rear cab door and push it into place, driver side shown.
1. TOP OF REAR CAB DOOR 3. LEFT SIDE OF REAR CAB

GLASS SEAL AND RUN DOOR GLASS SEAL AND RUN
CHANNEL CHANNEL
2. REAR CAB DOOR
the window regulator handle shaft (Item 7) and raise and lower cab door glass (Item 4) in the rear cab
Once it is determined the cab door glass goes up and down properly, remove window regulator handle and
continue to next step, driver side shown.
10. If vehicle is equipped with electric door window, temporarily hold rear cab door trim panel (Item 1) up to
the rear cab door (Item 3) and connect electric connectors (Item 3, Figure 58) (See Figure 58, page 62)
and use electric window switch panel (Item 5) to raise and lower cab door glass (Item 4) in the rear cab
door. Make sure cab door glass goes up and down smoothly without binding before continuing. Once it is
determined the cab door glass goes up and down properly, disconnect electric connector to rear cab door
trim panel and continue to next step, driver side shown.
250
MODULAR DOOR HARDWARE ASSEMBLY INSTALL
13. Repeat procedure to install passenger side rear cab door glass.
5.18. MODULAR DOOR HARDWARE ASSEMBLY

Install Front Cab Door Modular Door Hardware Assembly on Standard Cab, Extended Cab and Crew
Cab for all Models
The front cab door modular door hardware assembly (Item 1) consists of the window regulator assembly (Item
2), front window run channel (Item 3), rear window run channel (Item 4), inner cab door handle (Item 5), outer
cab door handle (Item 6) and door latch assembly (Item 7). This assembly is installed and removed as
1. Position front cab door modular door hardware assembly (Item 3) at the front cab door (Item 4). While
holding front cab door modular door hardware assembly away from front cab door, connect wiring harness
connector (Item 6) into connector of door latch assembly (Item 7), driver side shown. Inner cab door
handle (Item 5, Figure 72) (See Figure 72, page 80) removed for clarity.
2. Slide the top of the front and rear window run channels (Items 3 and 4) of the front cab door modular door
hardware assembly (Item 1) up inside front cab door (Item 9), driver side shown.
3. While holding front cab door modular door hardware assembly (Item 1) with the top of the front and rear
window run channels (Items 3 and 4) inside front cab door (Item 9), position door latch assembly (Item
7) and outer cab door handle (Item 6) of the front cab door modular door hardware assembly inside
front cab door and slide it to the left.
4. Install mounting guide pin (Item 14) on the right end of the front cab door modular door hardware assembly
(Item 1) into mounting guide pin hole (Item 15) in the front cab door (Item 9), driver side shown.
5. Align mounting holes on left end of front cab door modular door hardware assembly (Item 1) with mounting
holes on front cab door and install two torx head bolt (Item 13) finger tight, driver side shown.
6. Install two torx head bolts (Item 13) through mounting holes on right end of front cab door modular door
hardware assembly (Item 1) into the weld nuts in the front cab door (Item 9), driver side shown. Tighten
the four torx head bolts (Item 13) to 8 to 10 lbf-ft (11 to 13.6 N•m).
251
INSTALL MODULAR DOOR HARDWARE ASSEMBLY
7. Once the front cab door modular door hardware assembly (Item 3) is secured to the front cab door (Item
4), install wiring harness push-in fasteners four places (Item 5) into mounting holes of front cab door
modular door hardware assembly. Connect wiring harness connector (Item 1) into the connector of the
electric window motor (Item 2), driver side shown. Inner door handle (Item 5, Figure 72) (See Figure 72,
page 80) removed for clarity.
8. Reach through cab door access opening and position door latch assembly (Item 7) on front cab door (Item
9) and install three torx head bolts (Item 8), driver side shown. Tighten to 8 to 10 lbf-ft (11 to 13.6 N•m).
9. Reach through cab door access opening and position outer cab door handle (Item 6) on front cab door (Item
9) and install four torx pan head screws (Item 12), driver side shown. Tighten to 35 to 44 lbf-in (4 to 5 N•m).
NOTE – A new outer cab door handle trim bezel (Item 11) will need to be installed if the plastic tabs
securing it to the cab door, broke off during removal.
10. Position four plastic tabs of the outer cab door handle trim bezel (Item 11) into mounting holes in the outer
cab door handle (Item 6) and carefully push it in place to secure it , driver side shown.
11. Once the front cab door modular door hardware assembly (Item 1) has been secured in the front cab door
(Item 9). Make sure the door lock, inner cab door handle (Item 5), outer cab door handle (Item 6) and
door latch assembly (Item 7) are working properly before proceeding.
12. Install front cab door glass, refer to CAB DOOR GLASS (See CAB DOOR GLASS, page 243).
15. Repeat procedure to install passenger side front cab door modular door hardware assembly.
Install Rear Cab Door Modular Door Hardware Assembly on Crew Cab for all Models
The rear cab door modular door hardware assembly (Item 1) consists of the window regulator assembly (Item
2), front window run channel (Item 3), rear window run channel (Item 4), inner cab door handle (Item 5), outer
cab door handle (Item 6) and door latch assembly (Item 7). This assembly is installed and removed as
1. Position rear cab door modular door hardware assembly (Item 3) at the rear cab door (Item 4). While
holding rear cab door modular door hardware assembly away from rear cab door, connect wiring harness
connector (Item 6) into connector of door latch assembly (Item 7), driver side shown.
252
MODULAR DOOR HARDWARE ASSEMBLY INSTALL
2. Slide the top of the front and rear window run channels (Items 3 and 4) of the rear cab door modular door
hardware assembly (Item 1) up inside rear cab door (Item 9), driver side shown.
3. While holding rear cab door modular door hardware assembly (Item 1) with the top of the front and rear
window run channels (Items 3 and 4) inside rear cab door (Item 9), position door latch assembly (Item
7) and outer cab door handle (Item 6) of the rear cab door modular door hardware assembly inside rear
cab door and slide it to the left.
4. Install mounting guide pin (Item 14) on the right end of the rear cab door modular door hardware assembly
(Item 1) into mounting guide pin hole (Item 15) in the rear cab door (Item 9), driver side shown.
5. Align mounting holes on left end of rear cab door modular door hardware assembly (Item 1) with mounting
holes on rear cab door and install two torx head bolt (Item 13) finger tight, driver side shown.
6. Install two torx head bolts (Item 13) through mounting holes on right end of rear cab door modular door
hardware assembly (Item 1) into the weld nuts in the rear cab door (Item 9), driver side shown. Tighten
the four torx head bolts (Item 13) to 8 to 10 lbf-ft (11 to 13.6 N•m).
7. Once the rear cab door modular door hardware assembly (Item 3) is secured to the rear cab door (Item
4), install wiring harness push-in fasteners four places (Item 5) into mounting holes of rear cab door
modular door hardware assembly. Connect wiring harness connector (Item 1) into the connector of the
electric window motor (Item 2), driver side shown.
8. Reach through cab door access opening and position door latch assembly (Item 7) on rear cab door (Item
9) and install three torx head bolts (Item 8), driver side shown. Tighten to 8 to 10 lbf-ft (11 to 13.6 N•m).
9. Reach through cab door access opening and position outer cab door handle (Item 6) on rear cab door (Item
9) and install four torx pan head screws (Item 12), driver side shown. Tighten to 35 to 44 lbf-in (4 to 5 N•m).
11. Once the rear cab door modular door hardware assembly (Item 1) has been secured in the rear cab door
(Item 9). Make sure the door lock, inner cab door handle (Item 5), outer cab door handle (Item 6) and
door latch assembly (Item 7) are working properly before proceeding.
12. Install rear cab door glass, refer to CAB DOOR GLASS (See CAB DOOR GLASS, page 243).
253
INSTALL CAB DOOR VENT WINDOW
15. Repeat procedure to install passenger side rear cab door modular door hardware assembly.
5.19. CAB DOOR VENT WINDOW

Install Front Cab Door Vent Window on Standard Cab, Extended Cab and Crew Cab for all Models
1. Position lower cab door vent window mounting pin (Item 7, View Circle B) in the lower cab door vent
window hinge (Item 8, View Circle B). With front cab door vent window (Item 1) still open, swing it out
away from front cab door vent window opening so the upper cab door vent window hinge (Item 5, View
Circle A) is accessible and carefully push the upper cab door vent window mounting pin (Item 6, View
Circle A) into upper cab door vent window hinge, driver side shown.
2. Close front cab door vent window (Item 1). Position vent window latch pivot (Item 3) on cab door vent
window frame (Item 4) and install two torx head screws (Item 2), driver side shown. Tighten to 53 to
70.5 lbf-in (6 to 8 N•m).
3. Repeat procedure to install passenger side front cab door vent window.
5.20. CAB DOOR VENT WINDOW HINGE

Install Front Cab Door Vent Window Hinge on Standard Cab, Extended Cab and Crew Cab for all Models
1. Position cab door vent window hinge (Item 2) on the cab door vent window frame (Item 3) by installing
both cab door vent window hinge locating pins (Item 7) on the cab door vent window hinge into holes in
cab door vent window frame. Install two torx head screws (Item 1), driver side shown. Tighten to 53 to
70.5 lbf-in (6 to 8 N•m).
2. Install front cab door vent window, refer to CAB DOOR VENT WINDOW (See CAB DOOR VENT
WINDOW, page 254).
3. Repeat procedure to install passenger side front cab door vent window hinge.
5.21. CAB DOOR VENT WINDOW SEAL

Install Front Cab Door Vent Window Seal on Standard Cab, Extended Cab and Crew Cab for all Models
1. Position cab door vent window seal (Item 4) in cab door vent window opening (Item 5) of front cab door
(Item 6) and push into place on cab door vent window frame (Item 3), driver side shown.
2. Install front cab door vent window, refer to CAB DOOR VENT WINDOW (See CAB DOOR VENT
WINDOW, page 254).
3. Repeat procedure to install passenger side front cab door vent window seal.
254
CAB DOOR LOCK CYLINDER INSTALL
5.22. CAB DOOR LOCK CYLINDER

Install Cab Door Lock Cylinder on Front Cab Door on Standard Cab, Extended Cab and Crew Cab
Models and Rear Cab Doors on Crew Cab Models
The cab door lock cylinder (Item 7) on the front doors on standard cab, extended cab and crew cab models
and rear cab doors on crew cab models are key coded the same as the ignition switch on instrument panel, so
that one key operates both the ignition switch and door locks.
1. Position cab door lock cylinder (Item 7) back in the cavity of the outer cab door handle (Item 6), make
sure cab door lock cylinder is positioned properly. Install retaining clip (Item 5) securing it in outer cab
door handle , driver side shown.
2. Once the cab door lock cylinder (Item 7) has been secured in the outer cab door handle (Item 6). Make
sure the cab door lock cylinder is working properly before proceeding.
4. Repeat procedure to install passenger side cab door lock cylinder into front or rear cab doors.
5.23. CAB DOOR WINDOW ELECTRIC MOTOR

Install Front Cab Door Window Electric Motor on Standard Cab, Extended Cab and Crew Cab for
all Models
1. Position cab door window electric motor (Item 2) in place on the mounting studs (Item 5) of the modular
door hardware assembly (Item 4). Carefully align the shaft and gear of the electric motor with the gear
(Item 6) and shaft bushing (Item 7) of the window regulator assembly and push electric motor all the way
against the modular door hardware assembly. Install three hex nuts (Item 3), driver side shown. Tighten to
62 to 115 lbf-in (7 to 13 N•m).
2. Connect wiring harness connector (Item 1) into connector on cab door window electric motor (Item 2),
driver side shown.
5. Repeat procedure to install passenger side front cab door window electric motor.
255
INSTALL CAB DOOR WINDOW REGULATOR ARM ASSEMBLY
Install Rear Cab Door Window Electric Motor on Crew Cab for all Models
1. Position cab door window electric motor (Item 2) in place on the mounting studs (Item 5) of the modular
door hardware assembly (Item 4). Carefully align the shaft and gear of the electric motor with the gear
(Item 6) and shaft bushing (Item 7) of the window regulator assembly and push electric motor all the way
against the modular door hardware assembly. Install three hex nuts (Item 3), driver side shown. Tighten to
62 to 115 lbf-in (7 to 13 N•m).
2. Connect wiring harness connector (Item 1) into connector on cab door window electric motor (Item 2),
driver side shown.
5. Repeat procedure to install passenger side rear cab door window electric motor.
5.24. CAB DOOR WINDOW REGULATOR ARM ASSEMBLY

Install Front Cab Door Window Regulator Arm Assembly on Standard Cab, Extended Cab and Crew
Cab for all Models
1. Position window regulator arm (Item 1) in behind the modular door hardware assembly (Item 2), line up the
hole in the window regulator arm with the hole in the modular door hardware assembly. Install window
regulator arm assembly shaft (Item 3) through the modular door hardware assembly into the window
regulator arm. Using a flat blade screw driver (Item 4) in the slot of the window regulator arm assembly
shaft, rotate it clockwise to lock it in the window regulator arm, driver side shown.
256
CAB DOOR WINDOW REGULATOR ARM ASSEMBLY INSTALL
1. WINDOW REGULATOR ARM 3. WINDOW REGULATOR ARM

2. MODULAR DOOR HARDWARE ASSEMBLY SHAFT
ASSEMBLY 4. FLAT BLADE SCREW DRIVER
Figure 199 Window Regulator Arm and Window Regulator Arm Assembly Shaft
2. Install window regulator assembly coil spring (Item 2) into slot of window regulator arm assembly shaft
WARNING
Be sure to use an appropriate tool and use care when installing the window regulator
assembly coil spring behind the retaining tab on the modular door hardware assembly
per step 3, to prevent bodily injury since the window regulator assembly coil spring will
be loaded during installation.
3. Once the window regulator assembly coil spring (Item 2) is installed properly on the window regulator
arm assembly shaft (Item 5). Using an appropriate tool, rotate window regulator assembly coil spring
clockwise around to the retaining tab (Item 3) on the modular door hardware assembly (Item 4) and
position behind retaining tab, driver side shown.
257
INSTALL CAB DOOR WINDOW REGULATOR ARM ASSEMBLY
4. Rotate inner cab door handle (Item 1) back down over the window regulator assembly coil spring (Item
5. Position both retaining tabs (Item 3) on the inner cab door handle (Item 2) into the slots in the modular
door hardware assembly (Item 4) and slide inner cab door handle to the left to secure retaining tabs
in place, driver side shown.
6. Once the inner cab door handle (Item 2) is positioned properly. Install hex bolt (Item 1) securing inner
cab door handle to the modular door hardware assembly (Item 4), driver side shown. Tighten to 71
to 88.5 lbf-in (8 to 10 N•m).
7. Lower cab door glass (Item 4) to the bottom of front cab door (Item 3).
the window regulator handle shaft (Item 7) and raise and lower cab door glass (Item 4) in the front cab
Once it is determined the cab door glass goes up and down properly, remove window regulator handle
and continue to step 11 below, driver side shown.
10. If vehicle is equipped with electric door window, temporarily hold front cab door trim panel (Item 1) up to
the front cab door (Item 3) and connect electric connectors (Item 3, Figure 54) (See Figure 54, page 58)
and use electric window switch panel (Item 5) to raise and lower cab door glass (Item 4) in the front cab
door. Make sure cab door glass goes up and down smoothly without binding before continuing. Once it
is determined the cab door glass goes up and down properly, disconnect electric connector to front cab
door trim panel and continue to step 11 below, driver side shown.
11. Install front cab door window electric motor, refer to CAB DOOR WINDOW ELECTRIC MOTOR (See CAB
DOOR WINDOW ELECTRIC MOTOR, page 255).
14. Repeat procedure to install passenger side front cab door window regulator arm and window regulator arm
assembly shaft.
Install Rear Cab Door Window Regulator Arm Assembly on Crew Cab for all Models
258
CAB DOOR WINDOW REGULATOR ARM ASSEMBLY INSTALL
1. Position window regulator arm (Item 1) in behind the modular door hardware assembly (Item 2), line up the
hole in the window regulator arm with the hole in the modular door hardware assembly. Install window
regulator arm assembly shaft (Item 3) through the modular door hardware assembly into the window
regulator arm. Using a flat blade screw driver (Item 4) in the slot of the window regulator arm assembly
shaft, rotate it clockwise to lock it in the window regulator arm, driver side shown.
2. Install window regulator assembly coil spring (Item 2) into slot of window regulator arm assembly shaft
WARNING
Be sure to use an appropriate tool and use care when installing the window regulator
assembly coil spring behind the retaining tab on the modular door hardware assembly
per step 3, to prevent bodily injury since the window regulator assembly coil spring will
be loaded during installation.
3. Once the window regulator assembly coil spring (Item 2) is installed properly on the window regulator
arm assembly shaft (Item 5). Using an appropriate tool, rotate window regulator assembly coil spring
clockwise around to the retaining tab (Item 3) on the modular door hardware assembly (Item 4) and
position behind retaining tab, driver side shown.
4. Rotate inner cab door handle (Item 1) back down over the window regulator assembly coil spring (Item
to 88.5 lbf-in (8 to 10 N•m).
7. Lower cab door glass (Item 4) to the bottom of rear cab door (Item 3).
the window regulator handle shaft (Item 7) and raise and lower cab door glass (Item 4) in the rear cab
Once it is determined the cab door glass goes up and down properly, remove window regulator handle
and continue to step 11 below, driver side shown.
10. If vehicle is equipped with electric door window, temporarily hold rear cab door trim panel (Item 1) up to
the rear cab door (Item 3) and connect electric connectors (Item 3, Figure 58) (See Figure 58, page 62)
and use electric window switch panel (Item 5) to raise and lower cab door glass (Item 4) in the rear cab
259
INSTALL OUTER CAB DOOR HANDLE
door. Make sure cab door glass goes up and down smoothly without binding before continuing. Once it
is determined the cab door glass goes up and down properly, disconnect electric connector to rear cab
door trim panel and continue to step 11 below, driver side shown.
11. Install rear cab door window electric motor, refer to CAB DOOR WINDOW ELECTRIC MOTOR (See CAB
DOOR WINDOW ELECTRIC MOTOR, page 255).
14. Repeat procedure to install passenger side rear cab door window regulator arm and window regulator arm
assembly shaft.
5.25. OUTER CAB DOOR HANDLE

Install Front Cab Door Outer Cab Door Handle on Standard Cab, Extended Cab and Crew Cab for
all Models
1. Install door lock cylinder lever (Item 2) on outer cab door handle (Item 3), driver side shown.
2. Install door lock control rod (Item 1) into door lock cylinder lever (Item 2) on outer cab door handle (Item
3. Install front cab door lock cylinder, refer to CAB DOOR LOCK CYLINDER (See CAB DOOR LOCK
CYLINDER, page 255). For installing front cab door lock cylinder, refer to Install Cab Door Lock Cylinder
on Front Cab Door on Standard Cab, Extended Cab and Crew Cab Models and Rear Cab Doors on
Crew Cab Models.
4. If the hanger support bracket (Item 2) was removed from outer cab door handle (Item 1), position the slot
(Item 3) in the hanger support bracket over the T shaped locking tab (item 4) on the outer cab door handle
and rotate hanger support bracket clockwise to lock it in place, driver side shown.
5. Slide control rod (Item 5) coming from the cab door latch (Item 4) into mounting hole at the top of outer
cab door handle (Item 2). Rotate outer cab door handle to position it on the control rod properly, driver
side shown.
6. Slide the control rod (Item 1) coming from the outer cab door handle (Item 2) into the lock lever (Item 3)
260
OUTER CAB DOOR HANDLE INSTALL
placed on a suitable work surface. Position the hanger support bracket (Item 4) of the outer cab door
handle (Item 1) in place at window run channel (Item 2) and slide the hanger support bracket into window
run channel until the locking tab (Item 3) locks it in place, driver side shown.
8. Install front cab door modular door hardware assembly, refer to MODULAR DOOR HARDWARE
ASSEMBLY (See MODULAR DOOR HARDWARE ASSEMBLY, page 251). For installing front cab door
modular door hardware assembly, refer to Install Front Cab Door Modular Door Hardware Assembly on
11. Repeat procedure to install passenger side outer cab door handle on front cab door of standard cab,
extended cab and crew cab for all models.
Install Rear Cab Door Outer Cab Door Handle on Crew Cab for all Models
1. Install door lock cylinder lever (Item 2) on outer cab door handle (Item 3), driver side shown.
2. Install door lock control rod (Item 1) into door lock cylinder lever (Item 2) on outer cab door handle (Item
3. Install rear cab door lock cylinder, refer to CAB DOOR LOCK CYLINDER (See CAB DOOR LOCK
CYLINDER, page 255). For installing front cab door lock cylinder, refer to Install Cab Door Lock Cylinder
on Front Cab Door of Standard Cab or Extended Cab Models and Front and Rear Cab Doors of Crew
Cab Models.
4. If the hanger support bracket (Item 2) was removed from outer cab door handle (Item 1), position the slot
(Item 3) in the hanger support bracket over the T shaped locking tab (item 4) on the outer cab door handle
and rotate hanger support bracket clockwise to lock it in place, driver side shown.
5. Slide control rod (Item 5) coming from the cab door latch (Item 4) into mounting hole at the top of outer
cab door handle (Item 2). Rotate outer cab door handle to position it on the control rod properly, driver
side shown.
6. Slide the control rod (Item 1) coming from the outer cab door handle (Item 2) into the lock lever (Item 3)
261
INSTALL OUTER CAB DOOR HANDLE
handle (Item 1) in place at window run channel (Item 2) and slide the hanger support bracket into window
run channel until the locking tab (Item 3) locks it in place, driver side shown.
8. Install rear cab door modular door hardware assembly, refer to MODULAR DOOR HARDWARE
ASSEMBLY (See MODULAR DOOR HARDWARE ASSEMBLY, page 251). For installing rear cab door
modular door hardware assembly, refer to Install Rear Cab Door Modular Door Hardware Assembly
11. Repeat procedure to install passenger side outer cab door handle on rear cab door of crew cab for
all models.
262
CAB DOOR LATCH INSTALL
5.26. CAB DOOR LATCH

Install Front Cab Door Latch on Standard Cab, Extended Cab and Crew Cab for all Models
1. Position cab door latch (Item 1) onto inner cab door handle control rods (Items 2 and 3) and rotate the cab
door latch up around inner cab door handle control rods, driver side shown.
1. CAB DOOR LATCH 3. INNER CAB DOOR HANDLE

CONTROL ROD
Figure 200 Cab Door Latch and Inner Cab Door Handle Control Rods
placed on a suitable work surface. Position the hanger support bracket (Item 4) of the cab door latch (Item
1) in place at window run channel (Item 2) and slide the hanger support bracket into window run channel
until the locking tab (Item 3) locks it in place, driver side shown.
263
INSTALL INNER CAB DOOR HANDLE
6. Repeat procedure to install passenger side front cab door latch.
Install Rear Cab Door Latch on Crew Cab for all Models
1. Position cab door latch (Item 1) onto inner cab door handle control rods (Items 2 and 3) and rotate the cab
door latch up around inner cab door handle control rods, driver side shown.
6. Repeat procedure to install passenger side rear cab door latch.
5.27. INNER CAB DOOR HANDLE

Install Front Cab Door Inner Cab Door Handle on Standard Cab, Extended Cab and Crew Cab for
all Models
1. If removed, install inner cab door control rod (Item 3) with the spring (Item 4) into slotted hole of inner
cab door handle (Item 1), then install inner cab door control rod (Item 2) onto inner cab door handle,
driver side shown.
264
INNER CAB DOOR HANDLE INSTALL
2. Install inner cab door handle control rods (Items 2 and 5, Figure 90) (See Figure 90, page 106) through the
opening from the front side of the modular door hardware assembly (Item 1, Figure 90) (See Figure 90,
page 106) and slide inner cab door handle (Item 2) to the left until the inner cab door handle is positioned
over the window regulator assembly , driver side shown.
to 88.5 lbf-in (8 to 10 N•m).
5. With the modular door hardware assembly (Item 1) laying on it's front, install inner cab door control
rod (Item 2) with the spring (Item 3) into retaining clip (Item 4). Make sure the spring is to the right of
the retaining clip, driver side shown.
placed on a suitable work surface. Install outer cab door handle and cab door latch as follows.
7. Install front cab door latch, refer to CAB DOOR LATCH (See CAB DOOR LATCH, page 263). For
installing front cab door latch, refer to Install Front Cab Door Latch on Standard Cab, Extended Cab
and Crew Cab for all Models.
8. Install front cab door outer cab door handle, refer to OUTER CAB DOOR HANDLE (See OUTER CAB
DOOR HANDLE, page 260). For installing front cab door outer cab door handle, refer to Install Front Cab
Door Outer Cab Door Handle on Standard Cab, Extended Cab and Crew Cab for all Models.
12. Repeat procedure to install passenger side front cab door inner cab door handle.
Install Rear Cab Door Inner Cab Door Handle on Crew Cab for all Models
1. If removed, install inner cab door control rod (Item 3) with the spring (Item 4) into slotted hole of inner
cab door handle (Item 1), then install inner cab door control rod (Item 2) onto inner cab door handle,
driver side shown.
265
INSTALL INNER CAB DOOR HANDLE
2. Install inner cab door handle control rods (Items 2 and 5, Figure 90) (See Figure 90, page 106) through the
opening from the front side of the modular door hardware assembly (Item 1, Figure 90) (See Figure 90,
page 106) and slide inner cab door handle (Item 2) to the left until the inner cab door handle is positioned
over the window regulator assembly , driver side shown.
to 88.5 lbf-in (8 to 10 N•m).
5. With the modular door hardware assembly (Item 1) laying on it's front, install inner cab door control
rod (Item 2) with the spring (Item 3) into retaining clip (Item 4). Make sure the spring is to the right of
the retaining clip, driver side shown.
placed on a suitable work surface. Install outer cab door handle and cab door latch as follows.
7. Install rear cab door latch, refer to CAB DOOR LATCH (See CAB DOOR LATCH, page 263). For installing
rear cab door latch, refer to Install Rear Cab Door Latch on Crew Cab for all Models.
8. Install rear cab door outer cab door handle, refer to OUTER CAB DOOR HANDLE (See OUTER CAB
DOOR HANDLE, page 260). For installing rear cab door outer cab door handle, refer to Install Rear Cab
Door Outer Cab Door Handle on Crew Cab for all Models.
12. Repeat procedure to install passenger side rear cab door inner cab door handle.
266
CAB DOOR WINDOW RUN CHANNELS INSTALL
5.28. CAB DOOR WINDOW RUN CHANNELS

Install Front Cab Door Window Run Channels on Standard Cab, Extended Cab and Crew Cab for
all Models
1. With the modular door hardware assembly (Item 1) laying on it's back, position window run channel (Item
4) with locking tab (Item 3) at the top of the window run channel in place at the modular door hardware
assembly and slide window run channel to the right into the modular door hardware assembly until it locks
2. Position window run channel (Item 4) with locking tab (Item 5) at the bottom of the window run channel in
place at the modular door hardware assembly (Item 1) and slide window run channel to the right into the
modular door hardware assembly until it locks in place, driver side shown.
3. Position window run channel (Item 6) with locking tab (Item 7) at the top of the window run channel in
place at the modular door hardware assembly (Item 1) and slide window run channel to the left into the
handle (Item 1) in place at window run channel (Item 2) and slide the hanger support bracket into rear
window run channel until the locking tab (Item 3) locks it in place, driver side shown.
9. Install front cab door cab door trim panel, refer to CAB DOOR TRIM PANEL (See CAB DOOR TRIM
PANEL, page 237). If front cab door is equipped with electric door window and locks, refer to Install Front
Cab Door Trim Panel with Electric Door Window and Locks. If front cab door is equipped with manual door
window and locks, refer to Install Front Cab Door Trim Panel with Manual Door Window and Locks.
10. Repeat procedure to install passenger side front cab door window run channels.
267
INSTALL CAB DOOR WINDOW RUN CHANNELS
Install Rear Cab Door Window Run Channels on Crew Cab for all Models
1. With the modular door hardware assembly (Item 1) laying on it's back, position window run channel (Item
4) with locking tab (Item 3) at the top of the window run channel in place at the modular door hardware
assembly and slide window run channel to the right into the modular door hardware assembly until it locks
place at the modular door hardware assembly (Item 1) and slide window run channel to the right into the
3. Position window run channel (Item 6) with locking tab (Item 7) at the top of the window run channel in
handle (Item 1) in place at window run channel (Item 2) and slide the hanger support bracket into rear
window run channel until the locking tab (Item 3) locks it in place, driver side shown.
10. Repeat procedure to install passenger side rear cab door window run channels.
268
CAB DOOR ELECTRIC WINDOW AND DOOR LOCK SWITCH INSTALL
5.29. CAB DOOR ELECTRIC WINDOW AND DOOR LOCK SWITCH

Install Front Cab Door Electric Window and Door Lock Switch on Standard Cab, Extended Cab and
1. Connect both wiring harness connectors (Item 6) to the front cab door electric window and door lock switch
2. Once both wiring harness connectors (Item 6) are connected to the front cab door electric window and door
lock switch (Item 1), push wiring harness into opening in cab door trim panel (Item 5), driver side shown.
3. With the wiring harness properly positioned inside cab door trim panel (Item 5), position front cab door
electric window and door lock switch (Item 1) into the opening of cab door trim panel and push it down until
the spring retaining clips (Item 4) secure it in place, driver side shown.
4. Repeat procedure to install passenger side front cab door electric window and door lock switch.
Install Rear Cab Door Electric Window and Door Lock Switch on Crew Cab for all Models
1. Connect both wiring harness connectors (Item 6) to the rear cab door electric window and door lock switch
2. Once both wiring harness connectors (Item 6) are connected to the rear cab door electric window and door
lock switch (Item 1), push wiring harness into opening in cab door trim panel (Item 5), driver side shown.
3. With the wiring harness properly positioned inside cab door trim panel (Item 5), position rear cab door
electric window and door lock switch (Item 1) into the opening of cab door trim panel and push it down until
the spring retaining clips (Item 4) secure it in place, driver side shown.
4. Repeat procedure to install passenger side rear cab door electric window and door lock switch.
5.30. CAB DOOR ELECTRIC MIRROR SWITCH

Install Front Cab Door Electric Mirror Switch on Standard Cab, Extended Cab and Crew Cab for all
Models
1. Connect wiring harness connector (Item 3) to the front cab door electric mirror switch (Item 1), driver
side shown.
2. Once the wiring harness connector (Item 3) is connected to the front cab door electric mirror switch (Item
1), push wiring harness into opening in front cab door trim panel (Item 2), driver side shown.
3. With the wiring harness properly positioned inside front cab door trim panel (Item 2), position front cab
door electric mirror switch (Item 1) into the opening of front cab door trim panel and push it down until the
retaining tabs secure it in place, driver side shown.
269
INSTALL SEATS
5.31. SEATS
Install Passenger Bucket Seat on Standard Cab, Extended Cab and Crew Cab for all Models
IMPORTANT – It is recommended that when installing seats back into a vehicle, that all new mounting
1. Place passenger side bucket seat (Item 2) inside cab.
2. Position passenger side bucket seat (Item 2) in place over threaded mounting studs in cab floor and install
four hex nuts and washers (Item 1). Tighten to 15 to 20 lbf-ft (20.5 to 27 N•m). If so equipped, connect air
line (Item 3) to passenger bucket seat at the quick disconnect connector (Item 4).
3. Position outer seat belt (Item 6, view arrow B) onto seat belt mounting bracket (Item 7, view arrow B) and
install hex flanged bolt (Item 5, view arrow B). Tighten to 25 to 35 lbf-ft (34 to 47.5 N•m).
4. Position inner seat belt (Item 9, view arrow A) onto seat belt mounting bracket (Item 10, view arrow A) and
install hex flanged bolt (Item 8, view arrow A). Tighten to 25 to 35 lbf-ft (34 to 47.5 N•m).
5. Repeat procedure to install driver side bucket seat.
Install Fixed Passenger Seat on Standard Cab, Extended Cab and Crew Cab for all Models
1. Place fixed passenger seat (Item 3) inside cab.
2. Position fixed passenger seat (Item 3) in place over threaded mounting studs (Item 2) in floor mat (Item 6)
and install four hex nuts and washers (Item 1). Tighten to 15 to 20 lbf-ft (20.5 to 27 N•m).
3. Repeat procedure to install fixed driver seat.
Install Two Man Fixed Bench Seat without Tool Box on Standard Cab, Extended Cab and Crew Cab for
all Models
1. Place two man fixed bench seat without tool box (Item 4) inside cab.
2. Position two man fixed bench seat without tool box (Item 4) in place over threaded mounting studs (Item
2) in floor mat (Item 6) and install four hex nuts and washers (Item 1). Tighten to 15 to 20 lbf-ft (20.5
to 27 N•m).
3. Push seat belts through from back side of seat between upper and lower seat of two man fixed bench seat
without tool box (Item 4) and pull them all the way through from the front side of the seat.
270
CAB DOOR OPENING SCUFF PLATE AND SEAT BELT RETRACTOR COVER INSTALL
Install Two Man Fixed Bench Seat with Tool Box on Standard Cab, Extended Cab and Crew Cab for
all Models
1. Place two man fixed bench seat with tool box (Item 5) inside cab.
2. Position two man fixed bench seat with tool box (Item 5) in place over threaded mounting studs (Item 2) in
floor mat (Item 6) and install four hex nuts and washers (Item 1). Tighten to 15 to 20 lbf-ft (20.5 to 27 N•m).
3. Push seat belts through from back side of seat between upper and lower seat of two man fixed bench seat
without tool box (Item 5) and pull them all the way through from the front side of the seat.
Install Full Width Rear Bench Seat on Extended Cab and Crew Cab for all Models
1. Place full width rear bench seat (Item 3) inside cab.
2. Position full width rear bench seat (Item 3) in place over threaded mounting studs (Item 2) in rear floor mat
(Item 6) and install four hex nuts with washers (Item 1). Tighten to 14.5 to 18 lbf-ft (19.6 to 24 N•m).
3. Push seat belts (Item 4) through from back side of seat between upper and lower seat of full width rear
bench seat (Item 3) and pull them all the way through from the front side of the seat.
5.32. CAB DOOR OPENING SCUFF PLATE AND SEAT BELT RETRACTOR COVER
Install Cab Door Opening Scuff Plate and Seat Belt Retractor Cover on Standard Cab, Extended Cab
NOTE – This procedure applies to all front door openings for all cabs and models and rear door openings
for crew cab models.
1. Position cab door opening scuff plate (Item 2) on cab floor and install four torx head screws (Item 1),
passenger side shown. Tighten to 20 to 24.5 lbf-in (2.3 to 2.8 N•m).
2. Install push-in fastener (Item 3) securing seat belt retractor cover (Item 4) to seat belt retractor assembly
(Item 5), passenger side shown.
3. Repeat procedure to install driver side cab door opening scuff plate and seat belt retractor cover.
271
INSTALL EXTENDED CAB BUNK/STORAGE UNIT
5.33. EXTENDED CAB BUNK/STORAGE UNIT

Install Bunk/Storage Unit on Extended Cab for all Models
1. Slide driver side seat all the way forward to allow installation of bunk/storage unit (Item 4) into the cab.
2. Turn bunk/storage unit on it's side and install into cab through passenger side door opening. Position
bunk/storage unit (Item 4) over the four threaded studs in cab floor.
3. Position seat belts (Item 7) over mounting holes in rear floor mat (Item 8) and cab floor and install torx
head bolts (Item 6). Tighten to 25 to 35 lbf-ft (34 to 47.5 N•m).
NOTE – Seat belt attachment will allow seat belt to swivel after mounting bolt is fully torqued.
4. With the bunk/storage unit (Item 4) positioned over the mounting studs in the cab floor. Install four hex
flanged nuts (Item 5), two each end. Tighten to 14.5 to 17.8 lbf-ft (19.6 to 24 N•m).
5. Position bunk mattress (Item 3) onto bunk/storage unit (Item 4).
6. If so equipped, install protective plate (Item 1) over both rear seat mounting studs (Item 2) in cab floor.
7. Install passenger bucket seat, fixed passenger seat and/or fixed passenger bench seat, refer to SEATS
5.34. SIDE AND CORNER INTERIOR TRIM PANEL

Install Side and Corner Interior Trim Panel on Standard Cab for all Models
1. Place passenger side side and corner interior trim panel (Item 5) inside the cab.
2. Position passenger side and corner interior trim panel (Item 5) over mounting holes in cab side panel and
rear interior trim panel and install seven push-in fasteners (Item 4), passenger side shown.
3. Position shoulder belt (Item 2) in place on side and corner interior trim panel (Item 5) inside cab and install
torx head bolt (Item 1), passenger side shown. Tighten to 20 to 25 lbf-ft (27 to 34 N•m).
4. Install passenger bucket seat and/or fixed passenger seat and/or two man fixed bench seat without tool
box and/or two man fixed bench seat with tool box and driver seat, refer to SEATS (See SEATS, page 270).
5. Install passenger side cab door opening scuff plate and seat belt retractor cover, refer to CAB DOOR
6. Repeat procedure to install driver side side and corner interior trim panel on standard cab.
272
SIDE AND CORNER INTERIOR TRIM PANEL INSTALL
Install Side and Corner Interior Trim Panel on Extended Cab for all Models
2. Position passenger side side and corner interior trim panel (Item 5) over mounting holes in cab side panel
and rear interior trim panel and install nine push-in fasteners (Item 4), passenger side shown.
3. Position shoulder belt (Item 2) in place on side and corner interior trim panel (Item 5) and install torx head
bolt (Item 1), passenger side shown. Tighten to 20 to 25 lbf-ft (27 to 34 N•m).
4. Install passenger bucket seat and/or fixed passenger seat and/or two man fixed bench seat without tool
box and/or two man fixed bench seat with tool box and driver seat, refer to SEATS (See SEATS, page 270).
5. If so equipped, install bunk/storage unit from behind front seats, refer to EXTENDED CAB
7. Repeat procedure to install driver side side and corner interior trim panel on extended cab.
Install Side and Corner Interior Trim Panel on Crew Cab for all Models
2. Position passenger side side and corner interior trim panel (Item 5) over mounting holes in cab side panel
and rear interior trim panel and install seven push-in fasteners (Item 4), passenger side shown.
3. Position shoulder belt (Item 2) in place on side and corner interior trim panel (Item 5) and install torx head
bolt (Item 1), passenger side shown. Tighten to 20 to 25 lbf-ft (27 to 34 N•m).
4. Install full width rear bench seat, refer to SEATS (See SEATS, page 270). To install full width rear bench
seat, refer to Install Full Width Rear Bench Seat on Extended cab and Crew Cab for all Models.
6. Repeat procedure to install driver side side and corner interior trim panel on crew cab.
273
INSTALL EXTENDED CAB REAR SIDE WINDOW
5.35. EXTENDED CAB REAR SIDE WINDOW

Install Rear Side Window Latch onto Rear Side Window on Extended Cab for all Models
1. If removed, install rear side window latch (Item 2) onto rear side window (Item 1) as follows.
2. With the rear side window (Item 1) laying on a padded work surface latch side up.
3. Position latch bar (Item 4) of rear side window latch (Item 2) into latch mounting pedestal slot (Item 5) of
latch mounting pedestal (Item 3) on the rear side window. Rotate rear side window latch counter clockwise
until the latch bar is locked in place.
4. This procedure is the same to install driver or passenger side rear side window latch on extended cab for
all models.
Install Rear Side Window on Extended Cab for all Models
1. From outside the cab, install two threaded studs (Item 7) of rear side window (Item 5) into mounting
holes in rear side window fence (Item 3).
2. From inside the cab, install two hex flanged nuts (Item 6) onto threaded studs (Item 7) at the front of
window opening for rear side window (Item 5). Tighten to 6.4 to 8 lbf-ft (8.7 to 10.7 N•m).
3. Position rear side window latch (Item 1) at the mounting holes for the rear side window latch at the rear of
the rear side window (Item 5) and install two hex flanged bolts (Item 4). Tighten to 6.4 to 8 lbf-ft (8.7 to
10.7 N•m).
4. Install passenger side side and corner interior trim panel, refer to SIDE AND CORNER INTERIOR TRIM
PANEL (See SIDE AND CORNER INTERIOR TRIM PANEL, page 272). Install Side and Corner Interior
Trim Panel on Extended Cab for all Models.
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EXTENDED CAB REAR SIDE WINDOW INSTALL
5. Open rear side window latch (Item 1) and install rear side window seal (Item 2) with rear side window seal
seam (Item 3) centered at the rear side window latch. Starting at the center of rear side window latch push
enter groove (Item 4) of rear side window seal over flange of rear side window fence (Item 5) and outer
groove (Item 6) of rear side window seal over the side and corner interior trim panel.
1. REAR SIDE WINDOW LATCH 5. REAR SIDE WINDOW FENCE

2. REAR SIDE WINDOW SEAL 6. OUTER GROOVE OF REAR SIDE
3. REAR SIDE WINDOW SEAL WINDOW SEAL
SEAM
4. ENTER GROOVE OF REAR SIDE
WINDOW SEAL
Figure 201 Rear Side Window Seal
275
INSTALL REAR INTERIOR TRIM PANEL
7. Install passenger bucket seat, fixed passenger seat or fixed passenger bench seat, and if so equipped,
full width rear bench seat. Refer to SEATS (See SEATS, page 270).
8. If so equipped, install bunk/storage unit behind front seats, refer to EXTENDED CAB BUNK/STORAGE
UNIT (See EXTENDED CAB BUNK/STORAGE UNIT, page 272).
9. Repeat procedure to install driver side rear side window on extended cab for all models.
5.36. REAR INTERIOR TRIM PANEL

Install Rear Interior Trim Panel on Standard Cab, Extended Cab and Crew Cab for all Models
NOTE – The step below shows installing both driver and passenger side side and corner interior trim
panels after installing rear interior trim panel. If one or the other of the side and corner interior trim
panels was not removed during the removal step, you will need only to re-install the side and corner
interior trim panel that was removed.
1. Place rear interior trim panel (Item 3) inside the cab.
2. Position rear interior trim panel (Item 3) over mounting holes in cab back panel and install five push-in
fasteners (Item 2) across the top of the rear interior trim panel. Make sure floor mat is properly fitted
around rear interior trim panel at the bottom.
3. Install passenger and driver side side and corner interior corner trim panel, refer to SIDE AND CORNER
INTERIOR TRIM PANEL (See SIDE AND CORNER INTERIOR TRIM PANEL, page 272).
5.37. HEADER CONSOLE PANEL

Install Header Console Panel on Standard Cab, Extended Cab and Crew Cab for all Models
1. Place header console panel (Item 2) inside the cab across the top of the dash panel.
2. Install six retaining clips with ty-wraps (Item 8) with the wiring harness (Item 9) back onto the tabs of the
header console panel (Item 10).
3. Connect wiring harness connector (Item 4) to driver side speaker (Item 5).
4. Connect wiring harness connector (Item 6) to passenger side speaker (Item 7).
5. Connect wiring harness connector (Item 1) to pig tail connector (Item 3) of electronic control panel (Item
2), if so equipped.
6. Lift header console panel (Item 2) off the dash panel. Position the front of the header console panel at cab
header just above windshield. Line up the three mounting hooks (Item 8) of the header console panel
with the slots in the cab header. Slide the header console panel forward securing the three mounting
hooks into the slots in the cab header. Raise the back of header console panel up to the headliner trim
276
HEADLINER TRIM PANEL INSTALL
panel and line up plastic alignment tab (Item 9) with the slot in the headliner trim panel and cab header.
Carefully push the two retaining clips of header console panel through slots in the headliner trim panel and
into cab header until they snap in place.
7. Install two torx head screws (Item 5) near driver side speaker through header console panel (Item 2) and
headliner trim panel into cab header. Tighten to 20 to 24.5 lbf-in (2.3 to 2.8 N•m).
8. Install two torx head screws (Item 6) near passenger side speaker through header console panel (Item 2)
and headliner trim panel into cab header. Tighten to 20 to 24.5 lbf-in (2.3 to 2.8 N•m).
9. Install two torx head screws (Item 4) inside cavity for courtesy light (Item 1) through header console panel
(Item 2) and headliner trim panel into cab header. Tighten to 20 to 24.5 lbf-in (2.3 to 2.8 N•m).
10. Connect wiring harness connector (Item 3) to courtesy light (Item 1).
11. Position courtesy light (Item 1) into header console panel (Item 2), push it in until it snaps into place.
12. Install sun visor and clip, refer to SUN VISOR AND CLIP (See SUN VISOR AND CLIP, page 229).
13. Line up retaining clips of passenger side A pillar trim panel (Item 5) with slots in the cab A pillar (Item 8).
Carefully push retaining clips of passenger side A pillar trim panel into slots in the cab A pillar until it
snaps in place.
14. Position passenger side grab handle (Item 6) in place on passenger side A pillar trim panel (Item 5). Install
two hex bolts (Item 4) through passenger side A pillar trim panel into cab A pillar (Item 8). Tighten to 77
to 95 lbf-in (8.7 to 10.7 N•m).
15. Line up retaining clips (Item 9) of driver side A pillar trim panel (Item 1) with slots in the cab A pillar (Item
3). Carefully push retaining clips of driver side A pillar trim panel into slots in the cab A pillar until it
snaps in place.
5.38. HEADLINER TRIM PANEL

Install Headliner Trim Panel on Standard Cab for all Models
1. Place headliner trim panel (Item 7) inside cab. Position headliner trim panel in behind passenger and
driver side side and corner interior trim panels (Items 3 and 5).
2. Hold the front of the headliner trim panel (Item 7) up at the center of the headliner trim panel above
windshield and install push-in fastener (Item 13) through headliner trim panel into the cab header.
3. Position headliner trim panel (Item 7) above driver side door opening and install push-in fastener (Item 12)
through headliner trim panel into the cab header.
4. Position headliner trim panel (Item 7) above passenger side door opening and install push-in fastener
(Item 11) through headliner trim panel into the cab header.
5. Install two push-in fasteners (Item 4) at the top of driver side corner interior trim panel (Item 5) through
driver side side and corner interior trim panel and headliner trim panel into the cab header.
277
INSTALL HEADLINER TRIM PANEL
6. Install two push-in fasteners (Item 2) at the top of passenger side side and corner interior trim panel (Item
3) through passenger side corner interior trim panel and headliner trim panel into the cab header.
7. Install two push-in fasteners (Item 6) into back of headliner trim panel (Item 7) through headliner trim
panel into the cab header.
8. Install coat hook (Item 8) into back of headliner trim panel (Item 7) until it snaps into place and close
cover (Item 9).
9. Install header console panel, refer to HEADER CONSOLE PANEL (See HEADER CONSOLE PANEL,
page 276).
Install Front Headliner Trim Panel on Extended Cab for all Models
1. Place front headliner trim panel (Item 3) inside cab. Position the front of front headliner trim panel at the
windshield. Slide the rear edge of front headliner trim panel in between cab roof and rear headliner trim
panel (Item 11).
2. Hold the front of the front headliner trim panel (Item 3) up at the center of the front headliner trim panel
above windshield and install push-in fastener (Item 10) through front headliner trim panel into the cab
header.
3. Align mounting holes of rear headliner trim panel (Item 11) with front headliner trim panel (Item 3) and
install five push-in fastener (Item 9) through rear headliner trim panel and front headliner trim panel into
the cab header.
4. Install push-in fastener (Item 7) through the front mounting hole of driver side side and corner interior trim
panel (Item 8) and front headliner trim panel (Item 3) into the cab header.
5. Install push-in fastener (Item 6) above driver side door opening through front headliner trim panel (Item
3) into the cab header.
6. Install push-in fastener (Item 4) through the front mounting hole of passenger side side and corner interior
trim panel (Item 5) and front headliner trim panel (Item 3) into the cab header.
7. Install push-in fastener (Item 2) above passenger side door opening through front headliner trim panel
(Item 3) into the cab header.
page 276).
Install Rear Headliner Trim Panel on Extended Cab for all Models
1. Place rear headliner trim panel (Item 11) inside cab. Hold rear headliner trim panel up to cab roof and
connect electrical connector into courtesy light (Item 18).
2. While holding rear headliner trim panel (Item 11) up to the cab roof. Slide rear headliner trim panel
rearward and carefully slide it between both passenger and driver side side and corner interior trim panels
(Items 5 and 8) and cab roof.
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HEADLINER TRIM PANEL INSTALL
the cab header.
4. Install coat hook (Item 15) into the opening at the back of rear headliner trim panel (Item 11) until it snaps
into place and close cover (Item 16).
5. Install two push-in fasteners (Item 14) through the back of rear headliner trim panel (Item 11) into the
cab header.
6. Install four push-in fasteners (Item 7 and 13) through the mounting holes of driver side side and corner
interior trim panel (Item 8) and rear headliner trim panel (Item 11) into the cab header.
7. Install four push-in fasteners (Item 4 and 12) through the mounting holes of passenger side side and corner
interior trim panel (Item 5) and rear headliner trim panel (Item 11) into the cab header.
Install Front Headliner Trim Panel on Crew Cab for all Models
1. Place front headliner trim panel (Item 3) inside cab. Position the front of front headliner trim panel at the
windshield. Position right and left side of front headliner trim panel between cab roof and passenger and
drive side B - pillar trim panels (Items 5 and 8). Slide the rear edge of front headliner trim panel in between
cab roof and rear headliner trim panel (Item 11).
2. Hold the front of the front headliner trim panel (Item 3) up at the center of the front headliner trim panel
above windshield and install push-in fastener (Item 10) through front headliner trim panel into the cab
header.
the cab header.
4. Install push-in fastener (Item 7) through the front mounting hole of driver side B - pillar trim panel (Item 8)
and front headliner trim panel (Item 3) into the cab header.
5. Install push-in fastener (Item 6) above driver side door opening through front headliner trim panel (Item
3) into the cab header.
6. Install push-in fastener (Item 4) through the front mounting hole of passenger side B - pillar trim panel
(Item 5) and front headliner trim panel (Item 3) into the cab header.
7. Install push-in fastener (Item 2) above passenger side door opening through front headliner trim panel
(Item 3) into the cab header.
page 276).
Install Rear Headliner Trim Panel on Crew Cab for all Models
1. Place rear headliner trim panel (Item 11) inside cab. Hold rear headliner trim panel up to cab roof and
connect electrical connector into courtesy light (Item 23).
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INSTALL CREW CAB B - PILLAR TRIM PANEL
2. While holding rear headliner trim panel (Item 11) up to the cab roof. Position right and left side of front
headliner trim panel between cab roof and passenger and drive side B - pillar trim panels (Items 5 and 8).
Slide rear headliner trim panel rearward and carefully slide it between both passenger and driver side
side and corner interior trim panels (Items 14 and 17) and cab roof.
3. Install two push-in fasteners (Item 22) through rear headliner trim panel (Item 11) into the cab header just
to the rear of courtesy light (Item 23).
the cab header.
5. Install two push-in fasteners (Item 21) through the back of rear headliner trim panel (Item 11) into the
cab header.
6. Install coat hook (Item 18) into the opening at the back of rear headliner trim panel (Item 11) until it snaps
into place and close cover (Item 19).
7. Install two push-in fasteners (Item 16) through the mounting holes of driver side side and corner interior
trim panel (Item 17) and rear headliner trim panel (Item 11) into the cab header in the back corner.
8. Install push-in fastener (Item 15) through the rear mounting hole of driver side B - pillar trim panel (Item 8)
and rear headliner trim panel (Item 11) into the cab header.
9. Install two push-in fasteners (Item 13) through the mounting holes of passenger side side and corner
interior trim panel (Item 14) and rear headliner trim panel (Item 11) into the cab header in the back corner.
10. Install push-in fastener (Item 12) through the rear mounting hole of passenger side B - pillar trim panel
(Item 5) and rear headliner trim panel (Item 11) into the cab header.
5.39. CREW CAB B - PILLAR TRIM PANEL

Install B - Pillar Trim Panel on Crew Cab for all Models
1. To install the B - pillar trim panel on crew cab models, refer to CAB DOORS (See CAB DOORS, page
233). Refer to Install Rear Cab Door on Crew Cab for all Models.
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CAB DOOR OPENING WEATHER SEALS INSTALL
5.40. CAB DOOR OPENING WEATHER SEALS

Install Front Cab Door Opening Weather Seals on Standard Cab, Extended Cab and Crew Cab for
all Models
1. Position secondary rubber weather seal (Item 3) at the cab door opening weather seal flange (Item 4) of
the top and front of cab door opening. Carefully push secondary rubber weather seal onto the cab door
opening weather seal flange until it is completely seated, driver side shown.
2. Position primary rubber weather seal (Item 1) at the cab door opening weather seal flange (Item 2) all the
way around cab door opening. Carefully push primary rubber weather seal onto the cab door opening
weather seal flange all the way around cab door opening until it is completely seated, driver side shown.
3. Install cab door opening scuff plate and seat belt retractor cover. Refer to CAB DOOR OPENING SCUFF
PLATE AND SEAT BELT RETRACTOR COVER (See CAB DOOR OPENING SCUFF PLATE AND SEAT
BELT RETRACTOR COVER, page 271).
4. Repeat procedure to install passenger side primary rubber weather seal and secondary rubber weather
seal on front cab door opening.
Install Rear Cab Door Opening Weather Seals on Crew Cab for all Models
1. Position secondary rubber weather seal (Item 3) at the cab door opening weather seal flange (Item 4) of
the top and front of cab door opening. Carefully push secondary rubber weather seal onto the cab door
opening weather seal flange until it is completely seated, driver side shown.
2. Position primary rubber weather seal (Item 1) at the cab door opening weather seal flange (Item 2) all the
way around cab door opening. Carefully push primary rubber weather seal onto the cab door opening
weather seal flange all the way around cab door opening until it is completely seated, driver side shown.
3. Install cab door opening scuff plate and seat belt retractor cover. Refer to CAB DOOR OPENING SCUFF
PLATE AND SEAT BELT RETRACTOR COVER (See CAB DOOR OPENING SCUFF PLATE AND SEAT
BELT RETRACTOR COVER, page 271).
4. Repeat procedure to install passenger side primary rubber weather seal and secondary rubber weather
seal on rear cab door opening of crew cab models.
281
INSTALL WINDSHIELD WIPER ARM AND BLADE ASSEMBLY

Install Windshield Wiper Arm and Blade Assembly on Standard Cab, Extended Cab and Crew Cab for
all Models
1. Using whatever reference point made before removing driver side windshield wiper arm and blade
assembly (Item 1) from wiper pivot post (Item 4), position windshield wiper arm and blade assembly
over wiper pivot post and push it firmly down onto wiper pivot post until it locks in place. Install washer
hose (Item 2) onto “T” fitting (Item 3).
2. Using whatever reference point made before removing passenger side windshield wiper arm and blade
assembly (Item 6) from wiper pivot post (Item 9), position windshield wiper arm and blade assembly over
wiper pivot post and push it firmly down onto wiper pivot post until it locks in place. Install washer hose
(Item 7) onto fitting (Item 8).
3. Lower tilt hood to closed position and latch hood on both sides.
4. Turn wipers on to high speed and activate windshield washer to check for proper operation. Adjust position
of windshield wiper arm and blade assembly if required to obtain proper wiper operation.
5.42. CAB COWL TRAY

Install Cab Cowl Tray on Standard Cab, Extended Cab and Crew Cab for all Models before September
2000
1. Position the hole in the passenger side of the cowl tray (Item 2) over the antenna (Item 4), lower cowl
tray into position at cab cowl.
2. Slide the holes in the cowl tray (Item 2) over both driver and passenger side wiper pivot posts (Item 16).
3. Slide mounting holes of cowl tray (Item 2) at the bottom of both driver and passenger side over the
mounting studs (Item 13) on the cab cowl. Make sure that the plastic bracket on the passenger side of the
cowl tray slides in behind the mounting bracket (Item 6, view arrow D) and that the plastic bracket (Item 8,
view arrow C) at the lower front of the cowl tray is in place at the evaporator box (Item 14) of AC unit.
4. Install hex flanged nut (Item 11, view arrow B) under cowl tray (Item 2, view arrow B) on driver side.
Tighten to 16 lbf-ft (22 N•m), DO NOT exceed 18 lbf-ft (24 N•m).
5. Install hex flanged nut (Item 12, view arrow D) under cowl tray (Item 2, view arrow D) on passenger side.
6. Install hex flanged bolt (Item 9, section A-A) into center mounting bracket (Item 10, section A-A) at the
center of cowl tray (Item 2, section A-A). DO NOT over tighten.
7. Install torx pan head screw (Item 7, view arrow C) through plastic bracket (Item 8, view arrow C) at the lower
front of the cowl tray (Item 2, view arrow C) into evaporator box (Item 14) of AC unit. DO NOT over tighten.
8. Install hex flanged bolt (Item 5, view arrow D) through mounting bracket (Item 6, view arrow D) into
u-shaped speed nut (Item 15) on plastic bracket under cowl tray (Item 2) on passenger side. DO NOT
over tighten.
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CAB COWL TRAY INSTALL
9. Slide rubber seal (Item 3, view arrow E) down over antenna (Item 4, view arrow E) on passenger side.
10. Install washer hose (Item 1, view arrow A) onto fitting under cowl tray (Item 2, view arrow A) on driver side.
11. After installing cowl tray, install driver and passenger side windshield wiper arm and blade assembly.
Refer to WINDSHIELD WIPER ARM AND BLADE ASSEMBLY (See WINDSHIELD WIPER ARM AND
BLADE ASSEMBLY, page 282).
Install Cab Cowl Tray on Standard Cab, Extended Cab and Crew Cab for all Models after September
2000
mounting studs (Item 13) on the cab cowl. Make sure that the plastic bracket on the passenger side of the
cowl tray slides in behind the mounting bracket (Item 6, view arrow D) and that the plastic bracket (Item 8,
view arrow C) at the lower front of the cowl tray is in place at the evaporator box (Item 14) of AC unit.
4. Install hex flanged nut (Item 11, view arrow B) under cowl tray (Item 2, view arrow B) on driver side.
8. Install hex flanged bolt (Item 5, view arrow D) through mounting bracket (Item 6, view arrow D) into
u-shaped speed nut (Item 15) on plastic bracket under cowl tray (Item 2) on passenger side. DO NOT
over tighten.
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INSTALL WINDSHIELD WIPER ASSEMBLY
Install Cab Cowl Tray on Standard Cab, Extended Cab and Crew Cab for all Models after February 2002
mounting studs (Item 11) on the cab cowl. Make sure that the cowl tray center mounting bracket (Item
6) of the cowl tray slides over the plastic bracket (Item 15) at the upper right front of the evaporator
box (Item 16) of AC unit.
4. Install washer bottle vent hose (Item 12, view arrow B) into driver side of cowl tray (Item 2, view arrow B)
by installing vent hose push-in fastener (Item 13, view arrow B) into hole in cowl tray.
5. Install hex flanged nut (Item 9, view arrow B) under cowl tray (Item 2, view arrow B) on driver side. Tighten
to 16 lbf-ft (22 N•m), DO NOT exceed 18 lbf-ft (24 N•m).
5.43. WINDSHIELD WIPER ASSEMBLY

Install Windshield Wiper Assembly on Standard Cab, Extended Cab and Crew Cab for all Models
1. Install windshield wiper assembly (Item 8) onto the four mounting studs (Items 5, 9 and 11) on the cab cowl.
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ELECTRIC WINDSHIELD WIPER MOTOR INSTALL
2. Install hex flanged nut (Item 7, view arrow B) securing windshield wiper assembly (Item 8, view arrow B)
to mounting stud (Item 9) on driver side of the cab cowl. Tighten to 16 lbf-ft (22 N•m), DO NOT exceed
18 lbf-ft (24 N•m).
3. Install hex flanged nut (Item 10, view arrow C) securing windshield wiper assembly (Item 8, view arrow
C) to mounting stud (Item 11) on passenger side of the cab cowl. Tighten to 16 lbf-ft (22 N•m), DO NOT
exceed 18 lbf-ft (24 N•m).
4. Install two hex flanged nuts (Item 3, view arrow A) securing windshield wiper motor mounting bracket (Item
4, view arrow A) to mounting studs (Item 5) just below the windshield wiper motor at the center of the cab
cowl. Tighten to 16 lbf-ft (22 N•m), DO NOT exceed 18 lbf-ft (24 N•m).
5. Connect wiring harness connector (Item 1) to windshield wiper motor connector (Item 2).
6. If required, position wiring harness (Item 13, view arrow A) at windshield wiper motor (Item 6) and/or
windshield wiper motor mounting bracket (Item 4) and secure with ty-wrap (Item 12, view arrow A).
7. Install the cab cowl tray. Refer to CAB COWL TRAY (See CAB COWL TRAY, page 282).
8. Install driver and passenger side windshield wiper arm and blade assembly. Refer to WINDSHIELD WIPER
ARM AND BLADE ASSEMBLY (See WINDSHIELD WIPER ARM AND BLADE ASSEMBLY, page 282).

Install Electric Windshield Wiper Motor on Standard Cab, Extended Cab and Crew Cab for all Models
The windshield wiper system consists of a single unitized 12 volt electric motor that operates the wiper arms
through linkage (Figure 119) (See Figure 119, page 153).
Since the wiper motor is of unitized construction, there is no need for motor rebuild or adjustments. There are
no serviceable parts; the complete assembly is replaced.
CAUTION
NOTE – Windshield wipers and cowl tray have been removed in part of Figure 119 (See Figure 119, page
153) to show the windshield wiper assembly located under the cowl tray.
1. Position electric wiper motor (Item 3, view arrow A) in place on the wiper motor mounting bracket (Item 6,
view arrow A). Install three hex flanged bolts (Item 7, view arrow A) securing electric wiper motor to the
wiper motor mounting bracket. Tighten to 44.3 to 62 lbf-in (5 to 7 N•m).
2. Position wiper drive arm (Item 2, view arrow A) and lock washer (Item 4, view arrow A) onto electric wiper
motor shaft. Install hex retaining nut (Item 1, view arrow A and view arrow B) securing wiper drive arm
285
INSTALL WINDSHIELD WASHER BOTTLE AND/OR PUMP MOTOR
(Item 2, view arrow A) to electric wiper motor (Item 3, view arrow A). Tighten to 104 to 140 lbf-in (11.8 to
15.8 N•m).
3. If required, position wiring harness (Item 13, view arrow A) at windshield wiper motor (Item 6) and/or
windshield wiper motor mounting bracket (Item 4) and secure with ty-wrap (Item 12, view arrow A).
4. Connect wiring harness connector (Item 1) to windshield wiper motor connector (Item 2).
5. With ignition key in ON position, cycle wiper arm to the end of the sweep cycle (wiper blade by left side of
windshield). Turn key to OFF position.
5.45. WINDSHIELD WASHER BOTTLE AND/OR PUMP MOTOR

Install Windshield Washer Bottle and/or Pump Motor on Standard Cab, Extended Cab and Crew Cab for
all Models
Refer to Figure 120 (See Figure 120, page 155) for all models before July 2001 or Figure 121 (See Figure 121,
page 156) for all models after July 2001 or Figure 122 (See Figure 122, page 157) for all models after June
2002 for Items in parentheses.
1. If pump motor (Item 3) was removed or being replaced, position pump motor into washer bottle (Item 2)
and push it into place until it snaps securely into washer bottle.
2. Position washer bottle (Item 2) face down at the washer bottle bracket (Item 4).
3. Install washer hose (Item 6) onto pump motor outlet fitting (Item 7).
4. Connect wiring harness connector (Item 5) to pump motor (Item 3).
5. Connect wiring harness connector (Item 8) to washer bottle wiring harness connector (Item 9) coming
from low fluid sensor (Item 10) in washer bottle.
6. Position washer bottle (Item 2) with pump motor (Item 3) onto washer bottle bracket (Item 4). Install two
hex flanged bolts (Item 1) through washer bottle into washer bottle bracket. Do not over tighten.
7. Fill washer bottle (Item 2) with windshield washer solvent and check for leaks and washer operation.
8. Tilt hood to fully closed position and latch hood on both sides.
5.46. ENGINE COVER AND CUP HOLDER

Install Engine Cover on Standard Cab, Extended Cab and Crew Cab for all Models
286
ENGINE COVER AND CUP HOLDER INSTALL
1. Position engine cover (Item 4) inside cab. Slide engine cover under dash panel, lift bottom front edge of
engine cover over transmission shift lever shaft (Item 4, Figure 125) (See Figure 125, page 160), if so
equipped, and slide it completely under dash panel.
2. Pull floor mat (Item 5) from under bottom edge of the engine cover (Item 4) to allow engine cover mounting
hole flanges to rest on the cab floor.
3. Pull floor mat (Item 5, view circle B) back away from bottom edge across the front of the engine cover
(Item 4, view circle B). Install hex flanged bolt (Item 7, view circle B) through engine cover into cab
floor. Do not tighten.
4. Pull floor mat (Item 5, view circle C) back away from bottom edge across the front of the engine cover
(Item 4, view circle C). Install hex flanged bolt (Item 8, view circle C) through engine cover into cab
floor. Do not tighten.
5. Pull floor mat (Item 5, view circle A) back away from bottom edge on driver side of the engine cover (Item
4, view circle A). Install two hex flanged bolts (Item 6, view circle A) on driver side of the engine cover
through engine cover into cab floor. Do not tighten.
6. Pull floor mat (Item 5, view circle D and E) back away from bottom edge on passenger side of the engine
cover (Item 4, view circle D and E). Install two hex flanged bolts (Item 9, view circle D and E) on passenger
side of the engine cover through engine cover into cab floor. Do not tighten.
7. Install two hex flanged bolts (Item 3) at the top of the engine cover (Item 4) through engine cover into
dash panel. Do not tighten.
8. Once all hex flanged bolts (Items 3, 6, 7, 8 and 9) have been installed, tighten them to 77 to 95 lbf-in
(8.7 to 10.7 N•m).
9. On a vehicle with standard transmission and air brakes, install gear shift lever (Item 2) with rubber boot
(Item 1). If the rubber boot is not on the gear shift lever, slide the rubber boot over the gear shift lever
before installing gear shift lever.
10. Hold rubber boot (Item 1) up on the gear shift lever (Item 2) and install gear shift lever onto transmission
shift lever shaft (Item 4). Install allen screw (Item 3) securing gear shift lever to transmission shift lever
shaft and tighten.
11. Install rubber boot (Item 1) into cab floor around the gear shift lever (Item 2).
12. On a vehicle with automatic transmission and hydraulic brakes, position hydraulic hand brake lever (Item
2) in place on the cab floor and install four hex flanged bolts (Item 1) through the hydraulic hand brake
lever mounting flange into the cab floor. Tighten to 77 to 95 lbf-in (8.7 to 10.7 N•m).
Install Cup Holder on Standard Cab, Extended Cab and Crew Cab for all Models
1. If so equipped, install cup holder and ashtray (Item 4) as follows.
287
INSTALL CAB
2. Position cup holder and ashtray (Item 4) underneath center dash panel (Item 1), slide cup holder and
ashtray forward to hook the back of the cup holder and ashtray to the underside of the center dash panel.
Install two torx head screws (Item 3) through the front center dash panel into the cup holder and ashtray.
Tighten them to 20 to 25 lbf-in (2.3 to 3.0 N•m).
3. Position the center dash panel trim bezel (Item 2) in place over the center dash panel (Item 1). Carefully
push it into center dash panel until it snaps into place.
4. Install passenger bucket seat, fixed passenger seat and/or fixed passenger bench seat, refer to SEATS
5.47. CAB
The installation of the cab onto the chassis can be performed provided an overhead crane and cab lifting
fixture are available. Installation procedures may vary for various models depending on type of equipment
and accessories.
Cab Squaring
Cab squaring is the centering and perpendicular positioning of the cab structure to the frame. The cab must be
squared whenever the cab has been removed from the chassis for repair, or if a new cab is being mounted.
The cab must be properly squared to the frame as this will affect the relationship between the cab and hood.
Improper squaring may result in unacceptable appearance and interference between the cab and hood. Be
sure the chassis is on a level surface before squaring.
Center cab on frame rail by measuring from inside of cab cowl to outside of frame rail on both sides,
measurement should be equal on both sides, front and rear.
Install Cab with Low Mount Front Cab Mounting and Low Mount Rear Cab Mounting for 4100, 4200,
4300 and 4400 Standard Cab and Extended Cab Models
1. To install cabs with Low Mount Front Cab Mounting and Low Mount Rear Cab Mounting for 4100, 4200,
4300 and 4400 Standard Cab and Extended Cab Models. Carefully lower cab down to the front and rear
mounting locations, make sure that mounting studs, bolts and mounting holes are positioned properly as
the cab is lowered onto the cab mounting brackets. Refer to (Figure 126) (See Figure 126, page 163) for
Cab with Low Mount Front Cab Mounting for 4100, 4200, 4300 and 4400 Standard Cab and Extended Cab
Models and (Figure 127) (See Figure 127, page 165) for Cab with Low Mount Rear Cab Mounting for
4100, 4200, 4300 and 4400 Standard Cab and Extended Cab Models.
Install Low Mount Front Cab Mounting Isolators for 4100, 4200, 4300 and 4400 Standard Cab and
Extended Cab Models Before January 2003
1. If the front cab mounting isolator (Item 6) was removed, or being replaced. Install the front cab mounting
isolator onto the cab chassis mounting bracket (Item 3) before the cab is installed on the chassis, driver
side shown.
2. Position front cab mounting isolator (Item 6) in place on top of the cab chassis mounting bracket (Item
3). Install two hex flanged bolts (Item 8) through front cab mounting isolator and cab chassis mounting
bracket and install two hex flanged nuts (Item 7), driver side shown. Tighten them to 88 to 106 lbf-ft
(119 to 144 N•m).
3. Repeat procedure to install passenger side front cab mounting isolator.
288
CAB INSTALL
Install Low Mount Rear Cab Carriage Bolts and Compression Isolators for 4100, 4200, 4300 and 4400
Standard Cab and Extended Cab Models Before January 2003
1. If the carriage bolts were removed or being replaced, from inside the cab, lift the rear of the floor mat at the
rear cab panel below the rear window and install the two carriage bolts (Item 4) through the cab floor and
cab underbody sill (Item 5) which is part of the cab floor.
2. While holding carriage bolts (Item 4) so that the square shank under the head of the carriage bolts are
secured in the cab floor, thread retaining clips (Item 6) onto both carriage bolts until they are against the
bottom of the cab underbody sill (Item 5).
Cab with Low Mount Front Cab Mounting and Low Mount Rear Cab Mounting for 4100, 4200, 4300 and
4400 Standard Cab and Extended Cab Models
1. Using an overhead crane and cab lifting fixture lift cab, carefully lift cab over chassis.
2. Lower cab over chassis, as the cab is lowered onto the chassis, position front and rear cab mounting
properly per step a and step b below.
a. Position the rear cab compression isolators (Item 7, Figure 127) (See Figure 127, page 165) on
the rear cab chassis crossmember (Item 3, Figure 127) (See Figure 127, page 165). Align both
carriage bolts (Item 4, Figure 127) (See Figure 127, page 165) with rear cab compression isolators
and mounting holes in rear cab chassis crossmember as the cab is lowered onto the chassis.
b. Position properly the front cab mounting bracket (Item 5, Figure 126) (See Figure 126, page 163) over
the front cab mounting isolator (Item 6, Figure 126) (See Figure 126, page 163) and front cab chassis
mounting bracket (Item 3, Figure 126) (See Figure 126, page 163).
CAUTION
Do not put all cab weight on chassis until all mounting bolts are tightened.
CAUTION
Inspect all cab to frame attaching points to be sure they are aligned properly or damage
can result.
3. Install hex flanged bolt (Item 4) through front cab mounting bracket (Item 5), front cab mounting isolator
(Item 6) and front cab chassis mounting bracket (Item 3), driver side shown.
4. Position cab mount safety retainer (Item 2) under cab chassis mounting bracket (Item 3) and slide over
hex flanged bolt (Item 4). Install hex flanged nut (Item 1), driver side shown. Tighten to 254 to 310
lbf-ft (344 to 420 N•m).
5. Repeat procedure to install passenger side front cab mounting hardware.
6. Install rear cab rebound isolator (Item 2) over the two carriage bolts (Item 4) under rear cab chassis
crossmember (Item 3). Install two hex flanged nut (Item 1). Tighten them to 88 to 106 lbf-ft (119 to 144
N•m).
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INSTALL CAB
7. Remove cab lifting fixture.
Install Cab with Low Mount Front Cab Mounting for all Crew Cabs and 4100, 4200, 4300 and 4400
1. To install cabs with Low Mount Front Cab Mounting for all Crew Cabs and 4100, 4200, 4300 and 4400
Mounting for all Crew Cabs. Carefully lower cab down to the front and rear mounting locations, make sure
that mounting studs, bolts and mounting holes are positioned properly as the cab is lowered onto the cab
mounting brackets. Refer to (Figure 128) (See Figure 128, page 167) for Cab with Low Mount Front Cab
Mounting for all Crew Cabs and 4100, 4200, 4300 and 4400 Standard Cab and Extended Cab Models
after January 2003 and (Figure 129) (See Figure 129, page 168) for Cab with Low Mount Rear Cab Air
Suspension Mounting for all Crew Cab Models.
Install Low Mount Rear Cab Air Suspension Mounting Carriage Bolts for all Crew Cab Models
1. If removed or being replaced, from inside the cab, lift the rear of the floor mat at the rear cab panel below
the rear window and install the two carriage bolts (Item 2) through the cab floor and cab underbody sill
(Item 4) which is part of the cab floor.
Install Low Mount Rear Cab Air Suspension for all Crew Cab Models
1. If removed or being replaced, position the rear cab air suspension assembly (Item 3) in place on the frame
rail crossmember (Item 8) and install per steps below.
2. Connect the air line connection to the rear cab air suspension assembly (Item 3).
3. Line up the four mounting holes in the bottom plate of the rear cab air suspension assembly (Item 3) with
the four mounting holes in the frame rail crossmember (Item 8). Install the four hex flanged bolts (Item 7)
through the mounting holes in the rear cab air suspension assembly and the frame rail crossmember.
Install four hex flanged nuts (Item 6) onto the four hex flanged bolts. Tighten them to 88 to 106 lbf-ft
(119 to 144 N•m).
Cab with Low Mount Front Cab Mounting for all Crew Cab Models and 4100, 4200, 4300 and 4400
a. Position the two carriage bolts (Item 2, Figure 129) (See Figure 129, page 168) properly through the
rear air suspension assembly (Item 3, Figure 129) (See Figure 129, page 168).
290
CAB INSTALL
b. Position properly the threaded stud (Item 2, Figure 128) (See Figure 128, page 167) of the cab chassis
mounting bracket (Item 3, Figure 128) (See Figure 128, page 167) through the front cab mounting
bracket (Item 4, Figure 128) (See Figure 128, page 167).
CAUTION
CAUTION
can result.
3. Install hex flanged nut (Item 1) onto the threaded stud (Item 2) of the cab chassis mounting bracket (Item
3), driver side shown. Tighten to 142 to 175 lbf-ft (193 to 237 N•m)
5. Install two hex flanged nuts (Item 1) onto the two carriage bolts (Item 2). Tighten them to 88 to 106
lbf-ft (119 to 144 N•m).
Install Cab with Mid High Front Cab Mounting and Mid High Rear Cab Air Suspension Mounting for
4400 Model for City Tractor Applications
1. To install cabs with Mid High Mount Front Cab Mounting and Mid High Mount Rear Cab Air Suspension
Mounting for 4400 Model for City Tractor Applications. Carefully lower cab down to the front and rear
mounting locations, make sure that mounting studs, bolts and mounting holes are positioned properly as
the cab is lowered onto the cab mounting brackets. Refer to (Figure 130) (See Figure 130, page 170) for
Cab with Mid High Mount Front Cab Mounting for 4400 Model for City Tractor Applications and (Figure
131) (See Figure 131, page 171) for Cab with Mid High Mount Rear Cab Air Suspension Mounting for
4400 Model for City Tractor Applications.
Install Mid High Mount Rear Cab Air Suspension Mounting Carriage Bolts for 4400 Model for City
Tractor Applications
1. If removed or being replaced, from inside the cab, lift the rear of the floor mat at the rear cab panel below
the rear window and install the two carriage bolts (Item 2) through the cab floor and cab underbody sill
(Item 4) which is part of the cab floor.
Install Mid High Mount Rear Cab Air Suspension for 4400 Model for City Tractor Applications
291
INSTALL CAB
1. If removed or being replaced, position the rear cab air suspension assembly (Item 3) in place on the frame
rail crossmember (Item 8) and install per steps below.
2. Connect the air line connection to the rear cab air suspension assembly (Item 3).
3. Line up the four mounting holes in the bottom plate of the rear cab air suspension assembly (Item 3) with
the four mounting holes in the frame rail crossmember (Item 8). Install the four hex flanged bolts (Item 7)
through the mounting holes in the rear cab air suspension assembly and the frame rail crossmember.
Install four hex flanged nuts (Item 6) onto the four hex flanged bolts. Tighten them to 88 to 106 lbf-ft
(119 to 144 N•m).
Cab with Mid High Front Cab Mounting and Mid High Rear Cab Air Suspension Mounting for 4400
Model for City Tractor Applications
a. Position the two carriage bolts (Item 2, Figure 131) (See Figure 131, page 171) properly through the
rear air suspension assembly (Item 3, Figure 131) (See Figure 131, page 171).
b. Position properly the threaded stud (Item 2, Figure 130) (See Figure 130, page 170) of the cab chassis
mounting bracket (Item 3, Figure 130) (See Figure 130, page 170) through the front cab mounting
bracket (Item 4, Figure 130) (See Figure 130, page 170).
CAUTION
CAUTION
can result.
3. Install hex flanged nut (Item 1) onto the threaded stud (Item 2) of the cab chassis mounting bracket (Item
3), driver side shown. Tighten to 142 to 175 lbf-ft (193 to 237 N•m)
5. Install two hex flanged nuts (Item 1) onto the two carriage bolts (Item 2). Tighten them to 88 to 106
lbf-ft (119 to 144 N•m).
General Procedures for Cab Installation
NOTE – The remaining steps can be performed with the aid of the appropriate service sections. Refer
to the Master Service Manual for the component being installed.
292
CAB INSTALL
1. Attach exhaust system if it is the vertical type.
2. Attach shift lever to transmission.
3. Connect the following items:
— air conditioning lines (if so equipped). Refer to GROUP 16 - AIR CONDITIONING BASIC THEORY,
DIAGNOSIS AND SERVICE in the Master Service Manual for the proper procedures to charge air
conditioning system.
— brake system (air or hydraulic). Refer to GROUP 04 - BRAKES in the Master Service Manual for
bleeding instructions.
— clutch linkage.
— electric connections and ground wire.
— accelerator linkage.
— steering shaft at gear.
— heater hose.
4. Fill cooling system. Refer to GROUP 12- COOLING in the Master Service Manual for the proper coolant
requirements and procedures.
5. Connect battery ground cable.
6. Reattach any other connections between cab and frame, if required.
7. Replace or lower hood, unblock wheels, and release parking brake.
8. Road test vehicle. Be sure all vehicle components are operating properly before putting vehicle back
into service.
293
TROUBLESHOOTING ELECTRIC WINDSHIELD WIPER MOTOR
6. TROUBLESHOOTING
Table 2 Electric Windshield Wiper Motor
CONDITION PROBABLE CAUSE REMEDY

Stripped Gear Teeth 1. None 1. Replace complete unit.
Wiper Will Not Operate 1. Binding condition in wiper arm 1. Eliminate binding condition.
shaft assemblies, connecting
links, gear and shaft assembly
or armature.
2. Short, open, or ground in 2. Refer to Electrical
cable harness. Troubleshooting Manual.
3. Faulty manual switch. 3. Replace switch.

4. Shorted, open, or grounded 4. Replace motor.
armature.
5. Broken wire to motor. 5. Correct or replace wire.
Wiper Will Not Shut Off 1. Faulty parking switch 1. Replace complete unit.
assembly.
2. Faulty manual switch. 2. Replace manual switch.
Wiper Continually Shutting Off 1. Binding condition in wiper arm 1. Eliminate binding condition.
shaft assemblies, connecting
Wiper Operates At One Speed link, or gear and shaft assembly.
Only
2. Electrical overload due to 2. Replace motor.
faulty motor.
3. Faulty wire connections. 3. Correct wire connections.
Wiper Operates At One Speed 1. Short, open, or ground in 1. Refer to Electrical
Only cable harness. Troubleshooting Manual.
2. Faulty manual switch. 2. Replace switch.
294
WASHER PUMP MOTOR TROUBLESHOOTING
6.2. WASHER PUMP MOTOR

Table 3 Washer Pump Motor
CONDITION PROBABLE CAUSE REMEDY

Pump will not operate 1. No voltage to pump motor. 1. Check for open circuit or blown fuse.
2. Defective switch. 2. Replace switch.
3. Defective pump motor. 3. Replace pump/motor assembly.
Pump operates but 1. Hoses loose, kinked or damaged. 1. Reinstall or replace hose.
pressure is weak
2. Nozzles plugged or dirt in reservoir. 2. Clean nozzles and service reservoir
as required.
3. Defective motor or pump. 3. Replace pump/motor assembly.
Pump operates but 1. No solution in reservoir. 1. Fill reservoir.
no washer solution
2. Hoses loose, kinked or damaged. 2. Reinstall or replace hoses.
delivered.
3. Nozzles plugged or dirt in reservoir. 3. Clean nozzles or reservoir as
required.
4. Solution frozen. 4. Thaw out system and replace washer
solvent.
5. Defective pump. 5. Replace pump/motor assembly.
295
LUBRICATION 4000 MILES (6000 KM) OR MONTHLY
7. LUBRICATION
Cab hardware and other mechanisms require a periodic application of lubricant to increase service life and
prevent objectionable squeaking. New cabs are lubricated at the factory and before they are delivered to
customer. After the cab is placed in service, regular lubricating intervals based on type of service should be
established. Thorough lubrication at definite intervals adds greatly to cab service life and reduces overall
expense.
Wipe off all lubricant points before applying new lube to prevent lube contamination. Apply lube sparingly
and wipe away excess.
7.1. 4000 MILES (6000 KM) OR MONTHLY

1. Lubricate door stop, hinges, latches and strikers with DEXRON II™ .
2. Lubricate the hood tilt linkage with Fleetrite EP Moly grease or equivalent to NLGl No. 2 Multi-Purpose
Lithium grease.
7.2. AS REQUIRED
Lubricate seat adjuster slides with Fleetrite EP Moly grease or equivalent to NLGl No. 2 Multi-Purpose Lithium
grease.
Lubricate window regulator gear teeth, window regulator lever roller and window guide with Lubriplate 105
grease or equivalent.
296
CAB DOOR ADJUSTMENTS
8. ADJUSTMENTS
8.1. CAB DOOR
Getting a good cab door to door opening fit requires a knowledge of where the various adjustments are located
and what effect each adjustment has on door fit. These adjustments apply whether door has been removed or
door adjustment is simply being changed or improved.
When the door is properly adjusted, it should fit the opening with 1/4 to 5/16 inch (6 to 8 mm) space all
around the door frame. A newspaper sheet should not be able to pass between the weather seal and door
frame (paper should tear).
1. Door weather seal should contact the door frame with slight pressure but without damage to the seal.
2. Door should latch, lock and release without undue effort.
3. Door should not rattle when vehicle is moving.
8.2. HINGE AT CAB HINGE PILLAR

Adjust door up and down or forward and back at enlarged holes in upper door hinge (Item 1) and lower door
hinge (Item 2) at cab hinge pillar location (Item 3).
1. Slightly loosen two hex flanged bolts (Items 4) at upper door hinge (Item 1), driver side shown.
2. Move door up, down, forward or back as required at upper door hinge (Item 1) to obtain proper door
position.
3. Once door adjustment is made, hold door in place and tighten both hex flanged bolts (Item 4) at the cab
hinge pillar location (Item 3). Tighten to 13 to 15 lbf-ft (17.6 to 20 N•m).
4. Once the upper door hinge (Item 1) is adjusted, adjust the lower door hinge (Item 2).
5. Slightly loosen two hex flanged bolts (Item 5), at lower door hinge (Item 2), driver side shown.
6. Move door up, down, forward or back as required at lower door hinge (Item 2) to obtain proper door position.
7. Once door adjustment is made, hold door in place and tighten both hex flanged bolts (Item 5) at the cab
hinge pillar location (Item 3). Tighten to 13 to 15 lbf-ft (17.6 to 20 N•m).
8. After both upper and lower door hinges (Items 1 and 2) have been adjusted, close door and check for
proper fit. If further adjustment is required, repeat this procedure.
9. Repeat procedure to adjust passenger side door at upper and lower door hinges.
297
ADJUSTMENTS STRIKER PIN AT LOCK PILLAR
1. UPPER DOOR HINGE 4. HEX FLANGED BOLTS

2. LOWER DOOR HINGE 5. HEX FLANGED BOLTS
3. CAB HINGE PILLAR
Figure 202 Hinge at Cab Hinge Pillar
8.3. STRIKER PIN AT LOCK PILLAR

1. Use a torx head tool (Item 1) and slightly loosen two torx head bolts (Item 2), driver side shown.
2. This will allow the cab door striker pin (Item 3) and floating tapped striker pin mounting plate (Item 4) to
move up or down and in or out at the cab door lock pillar (Item 5) as required, driver side shown.
3. Move cab door striker pin (Item 3) up, down, in or out as required at cab door lock pillar (Item 5) to obtain
proper door fit and latching position.
4. Once cab door striker pin (Item 3) adjustment is made, hold it in place and tighten both torx head bolts
(Item 2) at the cab door lock pillar (Item 5). Tighten to 19 to 23.5 lbf-ft (26 to 32 N•m).
5. After the cab door striker pin (Item 3) has been adjusted, close door and check for proper fit. If further
adjustment is required, repeat this procedure.
6. Repeat procedure to adjust passenger side door at the cab door striker pin.
298
STRIKER PIN AT LOCK PILLAR ADJUSTMENTS
1. TORX HEAD TOOL 4. FLOATING TAPPED STRIKER

2. TORX HEAD BOLT PIN MOUNTING PLATE
3. CAB DOOR STRIKER PIN 5. CAB DOOR LOCK PILLAR
Figure 203 Striker Pin at Lock Pillar
299
ADJUSTMENTS WINDSHIELD WIPER ARM AND BLADE ASSEMBLY

To check wiper pattern on the windshield turn wipers on to high speed, make sure wipers do not run off the
glass or go below horizontal position to bottom edge of glass. To adjust wiper arm and blade assembly
use the following procedure.
NOTE – Water sprayed on windshield may help to determine wiper pattern.
1. If driver or passenger side windshield wiper arm and blade assemblies (Items 1 and 6) need adjustment to
get the proper wiper pattern, lift wiper arm and blade assembly (Item 1) or (Item 6) off the wiper pivot post
(Item 4) or (Item 9) by lifting windshield wiper arm lock lever (Item 5) or (Item 10) and lift wiper arm and
blade assembly off wiper pivot post.
2. Position wiper arm and blade assembly (Item 1) or (Item 6) at the wiper pivot post (Item 4) or (Item 9) with
wiper blade horizontal to bottom edge of windshield and lift windshield wiper arm lock lever (Item 5) or
(Item 10) and push wiper arm and blade assembly down onto wiper pivot post, windshield wiper arm lock
lever will lock wiper arm and blade assembly into place once it is pushed all the way down.
3. Turn wipers on to high speed and check for proper operation.
300
CAB AIR SUSPENSION ADJUSTMENTS
8.5. CAB AIR SUSPENSION

To adjust cab ride height, measure cab ride height between jounce bumper strike plate (Item 1) and jounce
bumper rate cup (Item 2), measurement must be made between measuring points (Item 5). If dimension does
not meet specified height of 1.5 inches (38 mm) for all 4000 Models except crew cab models and 1.6 inches
(41 mm) for all crew cab Models, adjust as necessary using the following procedure.
1. JOUNCE BUMPER STRIKE 4. HEIGHT CONTROL VALVE

PLATE LINKAGE
2. JOUNCE BUMPER RATE CUP 5. RIDE HEIGHT MEASUREMENT
3. HEIGHT CONTROL VALVE
Figure 204 CAB AIR SUSPENSION
301
ADJUSTMENTS CAB AIR SUSPENSION
WARNING
To prevent property damage or personal injury, park the vehicle on a level surface, set
the parking brake, chock the wheels, and turn the engine off.
1. Apply parking brake and chock wheels.
2. Charge the air system to operating pressure of 90 to 110 psi.
3. Measure cab ride height between jounce bumper strike plate (Item 1, Figure 203) (See Figure 204, page
301) and jounce bumper rate cup (Item 2, Figure 203) (See Figure 204, page 301), measurement must
be made between measuring points (Item 5, Figure 203) (See Figure 204, page 301) and must meet
specified height of 1.5 inches (38 mm) for all 4000 Models except crew cab models and 1.6 inches (41
mm) for all crew cab Models.
4. To adjust height control valve (Item 1), loosen the jam nut (Item 2) on the height control valve linkage (Item
3) and back off the nut several turns.
5. Unlatch the linkage socket clip (Item 4) and pry the linkage socket (Item 5) from the pivot ball.
6. Turn the linkage socket (Item 5) clockwise to shorten height control valve linkage or turn linkage socket
counter-clockwise to lengthen height control valve linkage.
CAUTION
To avoid product damage, there must be a minimum of five (5) full threads between
the threaded rod and the linkage socket. To maintain the required minimum thread
requirement, it may be necessary to loosen the jam nut at the other end of the height
control valve linkage and turn linkage socket at that end to obtain the required
adjustment.
7. Attach the linkage socket (Item 5) back onto the pivot ball, re-mearsure the cab ride height, and adjust
as required.
8. When proper adjustment is achieved (1.5 inches (38 mm) for all 4000 Models except crew cab models and
1.6 inches (41 mm) for all crew cab Models), latch linkage socket clip (Item 4) and tighten jam nut (Item 2).
9. Remove wheel chocks from wheels.
302
CAB AIR SUSPENSION ADJUSTMENTS
1. HEIGHT CONTROL VALVE 4. LINKAGE SOCKET CLIP

2. JAM NUT 5. LINKAGE SOCKET
3. HEIGHT CONTROL VALVE 6. HEIGHT CONTROL VALVE ARM
LINKAGE
Figure 205 Cab Air Suspension Height Control Valve Adjustment
303
FORMS BONDED WINDSHIELD REPLACEMENT REPORT
9. FORMS
9.1. BONDED WINDSHIELD REPLACEMENT REPORT
This self-carboning form Figure 205 below, MUST be filled out and gone over with the customer before
starting windshield replacement.
304
BONDED WINDSHIELD REPLACEMENT REPORT FORMS
305
TORQUE TORQUE CHART
10. TORQUE
10.1. TORQUE CHART
Table 4 Torque Chart
Item No.* Location lbf-in/lbf-ft N·m

4 Passenger Side Grab Handle, Hex Flanged Bolts 77 to 95 lbf-in 8.7 to 10.7
(Figure 9) (See Figure 9, page 11)
1 Sunshade Clearance Lights, Self-Tapping Screws 20 to 24.7 lbf-in 2.3 to 2.8
6 Sunshade, Hex Flanged Head Mounting Screws 34 to 38 lbf-ft 46 to 52
1 Sun Visor, Torx Head Screws (Figure 27) (See 20 to 24.7 lbf-in 2.3 to 2.8
Figure 27, page 28)
6 Sun Visor Clip, Torx Head Screw (Figure 27) (See 20 to 24.7 lbf-in 2.3 to 2.8
Figure 27, page 28)
1 Instrument Panel Mounting under right and left side, 15.5 to 19 lbf-ft 21 to 26
Hex Bolt Assemblies (Figure 34) (See Figure 34,
page 35)
5 Automatic Transmission Shifter Unit Mounting, Hex 14.5 to 17.7 lbf-ft 19.6 to 24
Flanged Bolts (Figure 34) (See Figure 34, page 35)
13 Instrument Panel Mounting across the top, Hex Bolt 84 to 106 lbf-in 9.5 to 12
Assemblies (Figure 34) (See Figure 34, page 35)
4 Front Cab Door Hinge on Front Cab Door Mounting 14 to 18 lbf-ft 19.6 to 24
Studs, Hex Nuts (Figure 38) (See Figure 38, page
41)
1 Shoulder Belt D - ring Mounting, Torx Head 25 to 35 lbf-ft 34 to 47.5
Bolt(Figure 39) (See Figure 39, page 42)
4 Rear Cab Door Hinge on Rear Cab Door Mounting 14 to 18 lbf-ft 19.6 to 24
Studs, Hex Nuts (Figure 43) (See Figure 43, page
46)
4 Lower Front Cab Door Hinge on Front Cab Door 14 to 18 lbf-ft 19.6 to 24
Hinge Pillar, Hex Bolts with Washers (Figure 44)
(See Figure 44, page 48)
4 and 5 Upper Front Cab Door Hinge on Front Cab Door 14 to 18 lbf-ft 19.6 to 24
Hinge Pillar, Hex Bolt with Washer and Hex Flanged
Locking Bolt (Figure 44) (See Figure 44, page 48)
4 Lower Rear Cab Door Hinge on Rear Cab Door 14 to 18 lbf-ft 19.6 to 24
Hinge Pillar, Hex Bolts with Washers (Figure 45)
4 Upper Rear Cab Door Hinge on Rear Cab Door 14 to 18 lbf-ft 19.6 to 24
Hinge Pillar, Hex Bolt with Washer (Figure 45) (See
Figure 45, page 49)
4 Front Cab Door Striker Pin on Cab Lock Pillar, Torx 19 to 23.5 lbf-ft 26 to 32
Head Bolts (Figure 46) (See Figure 46, page 50)
306
TORQUE CHART TORQUE
Table 4 Torque Chart (cont.)

4 Rear Cab Door Striker Pin on Cab Lock Pillar, Torx 19 to 23.5 lbf-ft 26 to 32
Head Bolts (Figure 47) (See Figure 47, page 51)
2 Front Cab Door Check Bracket on Cab Hinge Pillar, 8 to 10 lbf-ft 11 to 13.6
Torx Head Bolts (Figure 48) (See Figure 48, page
52)
2 Rear Cab Door Check Bracket on Cab Hinge Pillar, 8 to 10 lbf-ft 11 to 13.6
Torx Head Bolts (Figure 49) (See Figure 49, page
53)
1 Front Cab Door Check Link Threaded Studs, Hex 77 to 95 lbf-in 8.7 to 10.7
Nuts (Figure 50) (See Figure 50, page 54)
1 Crew Cab Rear Door Check Link Threaded Studs, 77 to 95 lbf-in 8.7 to 10.7
Hex Nuts (Figure 51) (See Figure 51, page 55)
1 Front Cab Door Inner Door Pull Cup, Torx Head 20 to 24.5 lbf-in 2.3 to 2.8
Screws (Figure 52, view arrow A) (See Figure 52,
page 56)
4 Front Cab Door Map Pocket Mounting, Torx Head 20 to 24.5 lbf-in 2.3 to 2.8
Screws (Figure 52) (See Figure 52, page 56)
1 Front Cab Door Inner Door Pull Cup, Torx Head 20 to 24.5 lbf-in 2.3 to 2.8
page 59)
4 Front Cab Door Map Pocket Mounting, Torx Head 20 to 24.5 lbf-in 2.3 to 2.8
1 Rear Cab Door Inner Door Pull Cup, Torx Head 20 to 24.5 lbf-in 2.3 to 2.8
page 60)
4 Rear Cab Door Map Pocket Mounting, Torx Head 20 to 24.5 lbf-in 2.3 to 2.8
1 Rear Cab Door Inner Door Pull Cup, Torx Head 20 to 24.5 lbf-in 2.3 to 2.8
page 63)
4 Rear Cab Door Map Pocket Mounting, Torx Head 20 to 24.5 lbf-in 2.3 to 2.8
8 Door Latch on Front Cab Door, Torx Head Bolts 8 to 10 lbf-ft 11 to 13.6
(Figure 72, view arrow A) (See Figure 72, page 80)
12 Outer Cab Door Handle on Front Cab Door, Torx 35 to 44 lbf-in 4 to 5
Head Screws (Figure 72, view arrow B) (See Figure
72, page 80)
13 Front Cab Door Modular Door Hardware Assembly, 8 to 10 lbf-ft 11 to 13.6
Torx Pan Head Bolts (Figure 72) (See Figure 72,
page 80)
8 Door Latch on Rear Cab Door, Torx Head Bolts 8 to 10 lbf-ft 11 to 13.6
(Figure 74, view arrow A) (See Figure 74, page 83)
307
TORQUE TORQUE CHART

12 Outer Cab Door Handle on Rear Cab Door, Torx 35 to 44 lbf-in 4 to 5
Head Screws (Figure 74, view arrow B) (See Figure
74, page 83)
13 Rear Cab Door Modular Door Hardware Assembly, 8 to 10 lbf-ft 11 to 13.6
Torx Pan Head Bolts (Figure 74) (See Figure 74,
page 83)
2 Vent Window Latch Pivot Mounting, Torx Head 53 to 70.5 lbf-in 6 to 8
1 Cab Door Vent Window Hinge Mounting, Torx Head 53 to 70.5 lbf-in 6 to 8
3 Front Cab Door Window Electric Motor Mounting, 62 to 115 lbf-in 7 to 13
3 Rear Cab Door Window Electric Motor Mounting, 62 to 115 lbf-in 7 to 13
1 Front or Rear Cab Door Inner Cab Door Handle 71 to 88.5 lbf-in 8 to 10
Mounting, Hex Bolt (Figure 81) (See Figure 81,
page 93)
1 Passenger Bucket Seat Mounting, Hex Nuts with 15 to 20 lbf-ft 20.5 to 27
Washers (Figure 96) (See Figure 96, page 116)
5 Passenger Seat Belt to Seat Belt Bracket, Hex 25 to 35 lbf-ft 34 to 47.5
Flanged Bolt (Figure 96, view arrow B) (See Figure
96, page 116)
8 Passenger Seat Belt to Seat Belt Bracket, Hex 25 to 35 lbf-ft 34 to 47.5
Flanged Bolt (Figure 96, view arrow A) (See Figure
96, page 116)
1 Fixed Passenger Seat Mounting, Hex Nuts with 15 to 20 lbf-ft 20.5 to 27
Washers (Figure 97) (See Figure 97, page 118)
1 Two Man Fixed Bench Seat without Tool Box 15 to 20 lbf-ft 20.5 to 27
Mounting, Hex Nuts with Washers (Figure 97) (See
1 Two Man Fixed Bench Seat with Tool Box Mounting, 15 to 20 lbf-ft 20.5 to 27
Hex Nuts with Washers (Figure 97) (See Figure 97,
page 118)
1 Full Width Rear Bench Seat Mounting, Hex Nuts 14.5 to 18 lbf-ft 19.6 to 24
with Washers (Figure 98) (See Figure 98, page 120)
1 Front or Rear Cab Door Opening Scuff Plate 20 to 24.5 lbf-in 2.3 to 2.8
Mounting, Torx Head Screws (Figure 99) (See
5 Bunk/Storage Unit Mounting on Studs in Cab Floor, 14.5 to 17.8 lbf-ft 19.6 to 24
Hex Flanged Nuts (Figure 100, view arrow A) (See
6 Rear Seat Belt to Cab Floor, Torx Head Bolts (Figure 25 to 35 lbf-ft 34 to 47.5
100, view arrow A) (See Figure 100, page 122)
308
TORQUE CHART TORQUE

1 Standard Cab Shoulder Belt Mounting, Torx Head 20 to 25 lbf-ft 27 to 34
Bolt (Figure 101) (See Figure 101, page 123)
1 Extended Cab Shoulder Belt Mounting, Torx Head 20 to 25 lbf-ft 27 to 34
Bolt (Figure 102) (See Figure 102, page 125)
1 Crew Cab Shoulder Belt Mounting, Torx Head Bolt 20 to 25 lbf-ft 27 to 34
4 Extended Cab Rear Side Window Latch Mounting, 6.4 to 8 lbf-ft 8.7 to 10.7
Hex Flanged Bolts (Figure 104) (See Figure 104,
page 128)
6 Extended Cab Rear Side Window Mounting, Hex 6.4 to 8 lbf-ft 8.7 to 10.7
Flanged Nuts (Figure 104) (See Figure 104, page
128)
4 Header Console Panel Mounting inside Courtesy 20 to 24.5 lbf-in 2.3 to 2.8
Light Cavity, Torx Head Screws (Figure 107) (See
5 Header Console Panel Mounting near Driver Side 20 to 24.5 lbf-in 2.3 to 2.8
Speaker, Torx Head Screw (Figure 107) (See Figure
107, page 131)
6 Header Console Panel Mounting near Passenger 20 to 24.5 lbf-in 2.3 to 2.8
Side Speaker, Torx Head Screw (Figure 107) (See
4 Antenna Hex Mounting(Figure 115) (See Figure 77 to 95 lbf-in 8.7 to 10.7
115, page 145)
5 Passenger Side Cowl Tray Plastic Mounting at Do NOT over Do NOT over
Mounting Bracket, Hex Flanged Bolt (Figure 115, tighten tighten
view arrow D) (See Figure 115, page 145)
7 Cowl Tray Mounting into Evaporator Box, Torx Pan Do NOT over Do NOT over
Head Screw (Figure 115, view arrow C) (See Figure tighten tighten
115, page 145)
9 Center Cowl Tray Mounting to Center Cab Cowl Do NOT over Do NOT over
Bracket, Hex Flanged Bolt (Figure 115, section A-A) tighten tighten
11 Driver Side Cowl Tray Mounting on Cab Cowl Stud, 16 lbf-ft, Do NOT 22, Do NOT
Hex Flanged Nut (Figure 115, view arrow B) (See exceed 18 lbf-ft exceed 24
12 Passenger Side Cowl Tray Mounting on Cab Cowl 16 lbf-ft, Do NOT 22, Do NOT
Stud, Hex Flanged Nut (Figure 115, view arrow D) exceed 18 lbf-ft exceed 24
116, page 147)
5 Passenger Side Cowl Tray Plastic Mounting at Do NOT over Do NOT over
Mounting Bracket, Hex Flanged Bolt (Figure 116, tighten tighten
view arrow D) (See Figure 116, page 147)
309
TORQUE TORQUE CHART

116, page 147)
117, page 149)
117, page 149)
3 Windshield Wiper Motor Mounting Bracket on Cab 16 lbf-ft, Do NOT 22, Do NOT
Cowl Studs, Hex Flanged Nuts (Figure 118, view exceed 18 lbf-ft exceed 24
arrow A) (See Figure 118, page 151)
7 Driver Side Windshield Wiper Assembly Mounting 16 lbf-ft, Do NOT 22, Do NOT
on Cab Cowl Stud, Hex Flanged Nut (Figure 118, exceed 18 lbf-ft exceed 24
view arrow B) (See Figure 118, page 151)
10 Passenger Side Windshield Wiper Assembly 16 lbf-ft, Do NOT 22, Do NOT
Mounting on Cab Cowl Stud, Hex Flanged Nut exceed 18 lbf-ft exceed 24
(Figure 118, view arrow C) (See Figure 118, page
151)
1 Wiper Drive Arm Mounting to Electric Wiper Motor 104 to 140 lbf-in 11.8 to 15.8
Shaft, Hex Retaining Nut (Figure 119, view arrow A
and view arrow B) (See Figure 119, page 153)
7 Windshield Wiper Motor Mounting to Windshield 44.3 to 62 lbf-in 5 to 7
Wiper Motor Bracket, Hex Flanged Bolts (Figure
119, view arrow A) (See Figure 119, page 153)
1 Washer Bottle Mounting, Hex Flanged Bolts (Figure Do NOT over Do NOT over
120) (See Figure 120, page 155) tighten tighten
310
TORQUE CHART TORQUE

3 Cup Holder and Ash Tray Mounting, Torx Head 20 to 25 lbf-in 2.3 to 3.0
1 Hydraulic Hand Brake Lever Mounting, Hex Flanged 77 to 95 lbf-in 8.7 to 10.7
Bolts (Figure 124) (See Figure 124, page 159)
3 Engine Cover Mounting, Hex Flanged Bolts (Figure 77 to 95 lbf-in 8.7 to 10.7
124) (See Figure 124, page 159)
124, view circle A) (See Figure 124, page 159)
124, view circle B) (See Figure 124, page 159)
124, view circle C) (See Figure 124, page 159)
124, view circle D and E) (See Figure 124, page
159)
1&4 Low Mount Front Cab Mount to Front Cab Chassis 254 to 310 lbf-ft 344 to 420
Mounting Bracket, Hex Flanged Bolt and Hex
Flanged Nut (Figure 126) (See Figure 126, page
163)
7&8 Front Cab Mounting Isolator onto Cab Chassis 88 to 106 lbf-ft 119 to 144
Mounting Bracket, Hex Flanged Bolts and Hex
163)
1&4 Low Mount Rear Cab Mounting, Carriage Bolts and 88 to 106 lbf-ft 119 to 144
Hex Flanged Nuts (Figure 127) (See Figure 127,
page 165)
1 Low Mount Front Cab Mount to Front Cab Chassis 142 to 175 lbf-ft 193 to 237
Mounting Bracket, Hex Flanged Nut (Figure 128)
1&2 Low Mount Rear Cab Air Suspension Mounting to 88 to 106 lbf-ft 119 to 144
Cab Floor, Carriage Bolts and Hex Flanged Nuts
6&7 Low Mount Rear Cab Air Suspension Mounting to 88 to 106 lbf-ft 119 to 144
Crossmember, Carriage Bolts and Hex Flanged
Nuts (Figure 129) (See Figure 129, page 168)
1 Mid High Mount Front Cab Mount to Front Cab 142 to 175 lbf-ft 193 to 237
Chassis Mounting Bracket, Hex Flanged Nut (Figure
130) (See Figure 130, page 170)
311
TORQUE TORQUE CHART

1&2 Mid High Mount Rear Cab Air Suspension Mounting 88 to 106 lbf-ft 119 to 144
to Cab Floor, Carriage Bolts and Hex Flanged Nuts
6&7 Mid High Mount Rear Cab Air Suspension Mounting 88 to 106 lbf-ft 119 to 144
to Crossmember, Hex Flanged Bolts and Hex
171)
4 Upper Cab Door Hinge Mounting, Hex Flanged 13 to 15 lbf-ft 17.6 to 20
5 Lower Cab Door Hinge Mounting, Hex Flanged 13 to 15 lbf-ft 17.6 to 20
2 Striker Pin Mounting at Lock Pillar, Torx Head Bolts 19 to 23.5 lbf-ft 26 to 32
* Refer to Figures specified in the Location column.
312

Navistar, Inc.: 2701 Navistar Drive, Lisle, IL 60532 USA

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EPA 10 - US, Canada, Mexico

CAB - DuraStar®, TerraStar®

DuraStar® - 4100, 4200, 4300, 4400

2701 Navistar Drive, Lisle, IL 60532 USA

Section / Location Changes

TABLE OF CONTENTS (CONT.)

TABLE OF CONTENTS (CONT.)

TABLE OF CONTENTS (CONT.)

TABLE OF CONTENTS (CONT.)

TABLE OF CONTENTS (CONT.)

TABLE OF CONTENTS (CONT.)

TABLE OF CONTENTS (CONT.)

TABLE OF CONTENTS (CONT.)

10. TORQUE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 306

1.2. VEHICLE IDENTIFICATION NUMBER (VIN) TAG LOCATION

1. CAB “ VIN ” TAG 3. CAB DOOR LATCH PILLAR

1.3. ELECTRIC WINDSHIELD WIPERS

1. ELECTRIC WIPER MOTOR 3. WIPER LINKAGE

1.4. WINDSHIELD WASHER

1. PUMP MOTOR 2. WASHER BOTTLE

1. PUMP MOTOR 2. WASHER BOTTLE

2.2. WINDSHIELD WASHER

Figure 7 One Piece Encapsulated Windshield

2. Place protective coverings over areas near windshield.

Refer to Figure 8 for Items in parentheses.

1. SUNSHADE 3. SUNSHADE MOUNTING

1. DRIVER SIDE A PILLAR TRIM 6. GRAB HANDLE

5. Remove one piece encapsulated windshield as follows.

Refer to Figure 9 for Items in parentheses.

Refer to Figure 10 for Items in parentheses.

1. POWER KNIFE 4. OUTSIDE CUTTING BLADE

Refer to Figure 12 for Items in parentheses.

4.2. REAR WINDOW GLASS ON VEHICLES WITHOUT VAN BODY

1. REAR WINDOW GLASS 3. SPRING CLIP

1. Chock the vehicle wheels.

4. Remove bonded rear window glass as follows.

Refer to Figure 15 for Items in parentheses.

1. POWER KNIFE 3. REAR WINDOW GLASS FENCE

1. REAR WINDOW GLASS

4.3. REAR WINDOW GLASS ON VEHICLES WITH VAN BODY

1. Chock the vehicle wheels.

4. Remove bonded rear window glass as follows.

Refer to Figure 17 for Items in parentheses.

1. SUCTION CUP 5. FLAT HEAD SCREW

1. DRIVER'S SIDE SUCTION CUP 3. PASSENGER'S SIDE SUCTION

1. SUCTION CUP 3. BLOCK ON SUCTION CUP

1. SLIDE RAIL 3. SUCTION CUP

1. SUCTION CUP 3. BLOCK ON SUCTION CUP

1. REAR WINDOW GLASS 2. SUCTION CUP

1. REAR WINDOW GLASS 2. SUCTION CUP

Refer to Figure 24 for Items in parentheses.

1. REAR WINDOW GLASS

4.4. HOOD SEAL

Refer to Figure 25 for Items in parentheses.

1. HOOD SEAL 3. WINDSHIELD

1. MOUNTING BRACKET 5. MOUNTING BOLTS

2. Pull clearance lights partially out of sunshade to expose mounting bolts.

4. Disconnect electrical connector, and remove sunshade.

4.6. SUN VISOR AND CLIP

Refer to Figure 27 for Items in parentheses.

1. TORX HEAD SCREW 5. RETAINING WASHER

4.7. IGNITION SWITCH AND IGNITION SWITCH CYLINDER

Refer to Figure 28 for Items in parentheses.