Body Mount Upper Location Number 1 Cushion Replacement

Body Mount Upper Location Number 1 Cushion Replacement Single Use Fasteners and Components Fuel Tank Filler Pipe Housing Removal Procedure

Body Mount Upper Location Number 1 Cushion Replacement — figure 1

1. Front Bumper Fascia (1) » Remove — Front Bumper Fascia Removal and Installation
2. Remove the front tire and wheel assembly. Tire and Wheel Removal and Installation

Body Mount Upper Location Number 1 Cushion Replacement — figure 2

3. Front Wheelhouse Liner Bolt (1) » Remove [3x]

Body Mount Upper Location Number 1 Cushion Replacement — figure 3

4. Front Wheelhouse Liner Bolt (1) » Remove [3x]

Body Mount Upper Location Number 1 Cushion Replacement — figure 4

5. Front Wheelhouse Liner (1) » Remove

Body Mount Upper Location Number 1 Cushion Replacement — figure 5

Note

Left side shown, right side similar.

6. {with B3L} Extend the assist steps in the vehicle personal optimization chapter in the owners manual.

Note

Closing the doors will not re-tract the assist steps. 6.1. Scroll to Deploy Running Boards on the navigation screen. 6.2. Put the assist steps in the extended position. 6.3. Electrical Connector (1) @ Assist Step Motor (2) » Disconnect

Body Mount Upper Location Number 1 Cushion Replacement — figure 6

Note

Left side shown, right side similar. 6.4. Assist Step Bolt (1) » Remove [2x] 6.5. Support the assist step with a suitable jack.

Body Mount Upper Location Number 1 Cushion Replacement — figure 7

Note

Left side shown, right side similar. 6.6. Assist Step Bolt (1) » Remove [4x] 6.7. Assist Step (2) » Remove

Body Mount Upper Location Number 1 Cushion Replacement — figure 8

Note

Left side shown, right side similar. 6.8. {with BVE} Assist Step Bolt (1) @ Rocker Panel » Loosen [3x]

Body Mount Upper Location Number 1 Cushion Replacement — figure 9

Note

Left side shown, right side similar. 6.9. Assist Step Bolt (1) @ Rocker Panel » Remove [6x]

Body Mount Upper Location Number 1 Cushion Replacement — figure 10

Note

Left side shown, right side similar. 6.10. Slide the assist step (1), out from under the loosened bolts, and remove.

Caution

With wheels of the vehicle facing straight ahead, secure the steering wheel utilizing steering column anti-rotation pin, steering column lock, or a strap to prevent rotation. Locking of the steering column will prevent damage and a possible malfunction of the SIR system. The steering wheel must be secured in position before disconnecting the following components: The steering column The intermediate shaft(s) The steering gear After disconnecting these components, do not rotate the steering wheel or move the front tires and wheels. Failure to follow this procedure may cause the SIR coil assembly to become un-centered and cause possible damage to the SIR coil. If you think the SIR coil has became un-centered, refer to your specific SIR coil’s centering procedure to re-center SIR Coil.

7. Secure the steering wheel so it will not turn when the upper intermediate steering shaft and steering column are disconnected.

Body Mount Upper Location Number 1 Cushion Replacement — figure 11

8. Mid Intermediate Steering Shaft Bolt (1) » Remove

Body Mount Upper Location Number 1 Cushion Replacement — figure 12

9. Upper Intermediate Steering Shaft (1) @ Intermediate Steering Shaft » Separate

Body Mount Upper Location Number 1 Cushion Replacement — figure 13

10. Front Brake Hose Bracket Bolt (1) » Remove
11. Front Brake Hose Bracket (2) » Reposition away

Body Mount Upper Location Number 1 Cushion Replacement — figure 14

12. Engine Control Module Bracket Bolt » Remove [3x]
13. Engine Control Module Bracket (2) » Reposition away

Body Mount Upper Location Number 1 Cushion Replacement — figure 15

14. Position the fuel tank filler door (1) to the fill open position.
15. Using the appropriate tool, release the filler door retainers and remove the fuel tank filler door (1).
16. {with LM2} Remove the emission reduction fluid tank filler pipe cap.

Body Mount Upper Location Number 1 Cushion Replacement — figure 16

Note

The fuel tank filler pipe housing once removed cannot be reused and must be replaced with a NEW fuel tank filler pipe housing.

17. Using a flat-bladed tool that fits into the 4 depressions (1) , break through the 4 depressions with light pressure and then pry the clips free to release the fuel tank filler pipe housing from the body side outer panel.
18. Fuel Tank Filler Pipe Housing (2) » Remove and DISCARD

Body Mount Upper Location Number 1 Cushion Replacement — figure 17

19. Fuel Tank Filler Pipe Ground Bolt (1) » Remove [3x]
20. Install the tire and wheel assembly. Tire and Wheel Removal and Installation
21. Lower the vehicle.
22. Support the radiator with mechanics wire or something similar.

Body Mount Upper Location Number 1 Cushion Replacement — figure 18

23. Remove the 12 body mount bolts and washers (1).
24. Reposition the vehicle hoist onto the body pinch welds.

Body Mount Upper Location Number 1 Cushion Replacement — figure 19

25. Body Mount Nut (1) » Remove [2x]

Warning

When you remove the body cushions, do NOT separate the frame from the body more than is necessary. Possible personal injury and damage to multiple parts may result if you do not follow the guides outlined below: Intermediate steering shaft—Do not allow the shaft to extend more than 25 mm (1 in). Fuel tank filler hose—Do not stretch the hose excessively. Tail/Turn signal lamp wiring/rear lamps junction block—Leave slack in the wires. Park brake cable—Leave slack in the cable. Body ground straps—Leave slack in the wire.

26. Slowly raise the cab on the hoist approximately 76.2mm (3 inches) while observing the clearance needed to remove the body mount upper location number 1 cushion.

Body Mount Upper Location Number 1 Cushion Replacement — figure 20

27. Body Mount Upper Location Number 1 Cushion (1) » Remove Installation Procedure

28. Body Mount Upper Location Number 1 Cushion (1) » Install

29. Lower the vehicle.

30. Reposition the vehicle hoist onto the frame rail.

31. Raise and support the vehicle. Lifting and Jacking the Vehicle

32. Remove the front tire and wheel assembly. Tire and Wheel Removal and Installation

Caution

Refer to Fastener Caution.

6. Body Mount Nut (1) » Install and tighten [2x] — Fastener Specifications

7. Perform the following procedure before installing the body mount bolts (1) : 7.1. Remove any loose cured adhesive from the external threads of the components using a lint free cloth. 7.2. Thread the cleaned components into the internal mating threads and remove to loosen trapped cured adhesive. 7.3. Apply thread locking adhesive to the external threads of the components. Adhesives, Fluids, Lubricants, and Sealers 7.4. Ensure there are no gaps in the thread locking adhesive once applied to the component.

8. Install and hand tighten the 12 body mount washers and bolts (1).

9. Body Mount Bolt (1) » Tighten [12x] — Fastener Specifications

10. Fuel Tank Filler Pipe Ground Bolt (1) » Install and tighten [3x] — Fastener Specifications

11. Fuel Tank Filler Pipe Housing (2) » Install NEW

12. Press the fuel tank filler pipe housing  depressions (1) to the body side outer panel until fully seated.

13. Ensure the fuel tank filler pipe housing seal is full seated to the filler pipe.

14. Install the emission reduction fluid tank filler pipe cap.

Body Mount Upper Location Number 1 Cushion Replacement — figure 21

Note

When replacing the fuel tank filler pipe housing or door, always install NEW fuel labels to the component that was replaced.

15. Fuel Tank Filler Door (1) » Install

16. Engine Control Module Bracket (2) » Install

17. Engine Control Module Bracket Bolt » Install and tighten [3x] — Fastener Specifications

18. Front Brake Hose Bracket (2) » Install

19. Front Brake Hose Bracket Bolt (1) » Install and tighten — Fastener Specifications

20. Upper Intermediate Steering Shaft (1) @ Intermediate Steering Shaft » Install

21. If a NEW threaded component is being installed, loosen the adhesive using a metal pick or similar tool before proceeding. If threaded component is reused, prepare the threaded component using the following steps: 21.1. Remove any loose cured adhesive from the external threads of the component using a lint free cloth. 21.2. Thread the cleaned component into the internal mating threads and remove to loosen trapped cured adhesive. 21.3. Apply thread locking adhesive to the external threads of the component. Adhesives, Fluids, Lubricants, and Sealers 21.4. Ensure there are no gaps in the thread locking adhesive once applied to the component.

Caution

Refer to Fastener Caution.

22. Mid Intermediate Steering Shaft Bolt (1) » Install and tighten — Fastener Specifications

23. Front Wheelhouse Liner (1) » Install

24. Front Wheelhouse Liner Bolt (1) » Install and tighten [3x] — Fastener Specifications

25. Front Wheelhouse Liner Bolt (1) » Install and tighten [3x] — Fastener Specifications

26. {with BVE} Install the assist step (1) under the loosened bolts.

26.1. Assist Step Bolt (1) @ Rocker Panel » Install and tighten [6x] — Fastener Specifications

26.2. Assist Step Bolt (1) @ Rocker Panel » Tighten [3x] — Fastener Specifications

27. {with B3L} Assist Step (2) » Install 27.1. Assist Step Bolt (1) Install and tighten [4x] — Fastener Specifications

27.2. Assist Step Bolt (1) » Install and tighten [2x] — Fastener Specifications

27.3. Electrical Connector (1) @ Assist Step Motor (2) » Connect

28. Front Bumper Fascia (1) » Install — Front Bumper Fascia Removal and Installation
29. Install the front tire and wheel assembly. Tire and Wheel Removal and Installation