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

EPA 10 - US, Canada, Mexico
CAB - TranStar®, WorkStar®

SERVICE MANUAL
SERVICE MANUAL
CAB
TranStar®
WorkStar®
0000002324
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 AND EXTENDED CAB. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2. CAB INTERIOR TRIM PANELS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.3. VEHICLE IDENTIFICATION NUMBER (VIN) AND COMPLIANCE TAG LOCATIONS. . . . . . . . . . . . . 2
1.4. WINDSHIELD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.5. ELECTRIC WINDSHIELD WIPERS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.6. WINDSHIELD WASHER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.7. IGNITION SWITCH CYLINDER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.8. REAR CAB AIR SUSPENSION SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2. REMOVAL AND INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

2.1. WINDSHIELD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Windshield - Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Windshield - Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.2. REAR WINDOW GLASS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Rear Window Glass (Unobstructed Access) – Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Rear Window Glass (Unobstructed Access) – Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Rear Window Glass (Obstructed Access) – Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Rear Window Glass (Obstructed Access) – Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
2.3. REAR SIDE WINDOW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Rear Side Window – Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Latch – Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Latch – Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Rear Side Window – Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
2.4. HOOD SEAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Hood Seal – Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Hood Seal – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
2.5. CAB COWL TRAY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Cab Cowl Tray – Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Cab Cowl Tray – Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
2.6. WINDSHIELD WIPER ARM AND BLADE ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Windshield Wiper Arm and Blade Assembly – Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Windshield Wiper Arm and Blade Assembly – Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
2.7. WINDSHIELD WIPER ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Windshield Wiper Assembly – Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Windshield Wiper Assembly – Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
2.8. WINDSHIELD WASHER BOTTLE WITH PUMP MOTOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
WorkStar® Windshield Washer Bottle With Pump Motor – Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
WorkStar® Windshield Washer Bottle With Pump Motor – Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
TranStar® Windshield Washer Bottle With Pump Motor – Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
TranStar® Windshield Washer Bottle With Pump Motor – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
2.9. WINDSHIELD WASHER PUMP MOTOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Windshield Washer Pump Motor – Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Windshield Washer Pump Motor – Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
2.10. ELECTRIC WINDSHIELD WIPER MOTOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Electric Windshield Wiper Motor – Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Electric Windshield Wiper Motor – Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
2.11. CAB DOORS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Cab Doors – Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Cab Doors – Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
2.12. DOOR HINGE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
i
TABLE OF CONTENTS
TABLE OF CONTENTS (CONT.)

Door Hinge – Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Door Hinge – Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
2.13. DOOR STRIKER PIN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Door Striker Pin – Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Door Striker Pin – Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
2.14. DOOR CHECK BRACKET. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Door Check Bracket – Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Door Check Bracket – Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
2.15. DOOR CHECK LINK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Door Check Link – Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Door Check Link – Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
2.16. DOOR TRIM PANEL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Door Trim Panel – Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Door Trim Panel – Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
2.17. DOOR VAPOR BARRIER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Door Vapor Barrier – Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Door Vapor Barrier – Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
2.18. WINDOW SLIDE BLOCK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Window Slide Block – Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Window Slide Block – Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
2.19. DOOR GLASS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Door Glass – Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Door Glass – Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
2.20. MODULAR DOOR HARDWARE ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Modular Door Hardware Assembly – Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Modular Door Hardware Assembly – Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
2.21. VENT WINDOW, LATCH, AND SEAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Vent Window, Latch, And Seal – Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Vent Window, Latch, And Seal – Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
2.22. DOOR LOCK CYLINDER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Door Lock Cylinder – Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Door Lock Cylinder – Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
2.23. WINDOW ELECTRIC MOTOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Window Electric Motor – Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Window Electric Motor – Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
2.24. REGULATOR ARM ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Regulator Arm Assembly – Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Regulator Arm Assembly – Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
2.25. OUTER DOOR HANDLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Outer Door Handle – Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Outer Door Handle – Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
2.26. DOOR LATCH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Door Latch – Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Door Latch – Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
2.27. INNER DOOR HANDLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Inner Door Handle – Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Inner Door Handle – Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
2.28. WINDOW RUN CHANNELS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Window Run Channels – Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Window Run Channels – Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
2.29. ELECTRIC WINDOW AND DOOR LOCK SWITCH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
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Electric Window And Door Lock Switch – Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Electric Window And Door Lock Switch – Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
2.30. ELECTRIC MIRROR SWITCH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Electric Mirror Switch – Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Electric Mirror Switch – Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
2.31. WEATHER SEALS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Weather Seals – Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Weather Seals – Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
2.32. SCUFF PLATE AND SEAT BELT RETRACTOR COVER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Scuff Plate and Seat Belt Retractor Cover – Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Scuff Plate and Seat Belt Retractor Cover – Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
2.33. SUNSHADE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Sunshade – Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Sunshade – Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
2.34. SUN VISOR AND CLIP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Sun Visor and Clip – Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Sun Visor and Clip – Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
2.35. IGNITION SWITCH AND IGNITION SWITCH CYLINDER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Ignition Switch – Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Ignition Switch – Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Ignition Switch Cylinder – Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Ignition Switch Cylinder – Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
2.36. INSTRUMENT PANEL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Gauge Cluster – Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Gauge Cluster – Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Instrument Panel – Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Instrument Panel – Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
2.37. FRONT SEATS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
Front Seats – Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
Front Seats – Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
2.38. REAR BENCH SEAT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Rear Bench Seat – Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Rear Bench Seat – Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
2.39. CORNER AND SIDE INTERIOR TRIM PANEL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
Corner and Side Interior Trim Panel – Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
Corner and Side Interior Trim Panel – Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
2.40. REAR INTERIOR TRIM PANEL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
Rear Interior Trim Panel – Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
Rear Interior Trim Panel – Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
2.41. HEADER CONSOLE PANEL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
Header Console Panel – Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
Header Console Panel – Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
2.42. HEADLINER TRIM PANEL (STANDARD CAB). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
Headliner Trim Panel (Standard Cab) – Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
Headliner Trim Panel (Standard Cab) – Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
2.43. HEADLINER TRIM PANEL (EXTENDED CAB). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
Headliner Trim Panel (Extended Cab) Front – Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
Headliner Trim Panel (Extended Cab) Front – Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
Headliner Trim Panel (Extended Cab) Rear – Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
Headliner Trim Panel (Extended Cab) Rear – Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
2.44. ENGINE COVER AND CUP HOLDER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
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Cup Holder and Ashtray – Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143

Cup Holder and Ashtray – Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
Engine Cover – Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
Engine Cover – Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
2.45. CAB. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
Initial Procedures Before Cab Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
Cab – Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
Cab – Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
Final Procedures After Cab Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
2.46. REAR CAB AIR SUSPENSION ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
Rear Cab Air Suspension Assembly – Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
Rear Cab Air Suspension Assembly – Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
2.47. FRONT CAB MOUNTING BUSHINGS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
Front Cab Mounting Bushings – Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
Front Cab Mounting Bushings – Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
2.48. REAR CAB AIR SUSPENSION SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
Height Control Valve – Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
Height Control Valve – Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
Shock Absorber – Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
Shock Absorber – Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
Suspension Air Spring (Bag) – Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
Suspension Air Spring (Bag) – Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
Lateral Control Rod – Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
Lateral Control Rod – Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
Jounce Bumper – Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
Jounce Bumper – Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
3. TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
3.1. ELECTRIC WINDSHIELD WIPER MOTOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
3.2. WASHER PUMP MOTOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
3.3. REAR CAB AIR SUSPENSION SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
4. LUBRICATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
4.1. 4,000 MILES (6,000 KM) OR MONTHLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
4.2. AS REQUIRED. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
5. ADJUSTMENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
5.1. CAB SQUARING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
5.2. CAB DOOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
5.3. DOOR HINGE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
5.4. STRIKER PIN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
5.5. WINDSHIELD WIPER ARM AND BLADE ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
5.6. REAR CAB AIR SUSPENSION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
Ride Height. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
TORQUE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
iv
STANDARD CAB AND EXTENDED CAB DESCRIPTION
1. DESCRIPTION
1.1. STANDARD CAB AND EXTENDED CAB
1. STANDARD CAB 2. EXTENDED CAB

Figure 1 Cab Configuration
The standard and extended cabs for the WorkStar® and TranStar® models are made of double-sided
galvanized steel, which provides a strong cab with less weight and excellent corrosion protection.
1.2. CAB INTERIOR TRIM PANELS
Figure 2 ZTSE4839 Interior Trim Tool
The cab interior trim panels are installed with push-in fasteners, and care must be taken when removing any of
the cab interior trim panels. All push-in fasteners may not be shown in the illustrations of this manual.
1
DESCRIPTION VEHICLE IDENTIFICATION NUMBER (VIN) AND COMPLIANCE TAG LOCATIONS
A sufficient interior trim removal tool, such as the ZTSE4839 interior trim tool, is required to remove all cab
interior trim panels.
1.3. VEHICLE IDENTIFICATION NUMBER (VIN) AND COMPLIANCE TAG LOCATIONS
1. COMPLIANCE TAG 4. VIN TAG

2. ECE 29 CAB STRENGTH TAG
3. ECE 93 FUPD CERTIFICATION
TAG
Figure 3 VIN and Compliance Tag Locations
The vehicle identification number (VIN) is 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 VIN and compliance
tags are located on the face of the latch pillar of the cab door opening on the driver side.
2
WINDSHIELD DESCRIPTION
1.4. WINDSHIELD
Figure 4 Windshield
The windshield features a curved, swept-back glass that provides excellent cab sealing to reduce exterior
noise and water leakage. The large, curved design also provides excellent visibility and aerodynamics, which
supports improved fuel economy. Additionally, the curved swept-back design eliminates snow packing at the
A-pillar and reduces the risk of damage from glancing road debris.
Two types of adhesives can be used to install windshields on the vehicles covered. Refer to the removal and
installation procedures in this Service Manual for adhesive and tool information.
3
DESCRIPTION ELECTRIC WINDSHIELD WIPERS
1.5. ELECTRIC WINDSHIELD WIPERS
1. WIPER ARM 3. WIPER LINKAGE

2. ELECTRIC WIPER MOTOR
Figure 5 Electric Windshield Wipers
The windshield wiper system consists of a single, unitized, 12v electric wiper motor that operates the wiper
arms through wiper linkage. 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.
1.6. WINDSHIELD WASHER
1. PUMP MOTOR 2. WASHER BOTTLE

Figure 6 WorkStar® Washer Bottle Location
The windshield washer consists of a washer bottle and a motor-driven, displacement-type pump that delivers
washer solution to the windshield through hoses and nozzles in the wiper arms. The pump motor is detachable
4
IGNITION SWITCH CYLINDER DESCRIPTION
from the washer bottle and is replaceable. The washer bottle and pump motor are located under the passenger
side door for the WorkStar® models.
1. PUMP MOTOR 2. WASHER BOTTLE

Figure 7 TranStar® Washer Bottle Location
The washer bottle and pump motor are located under the driver's side door for the TranStar® model.
1.7. IGNITION SWITCH CYLINDER

The ignition switch and door locks are coded the same, so that one key operates the 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 the ignition switch body or door lock assembly.
5
DESCRIPTION REAR CAB AIR SUSPENSION SYSTEM
1.8. REAR CAB AIR SUSPENSION SYSTEM
1. AIR SPRING (BAG) 3. SHOCK ABSORBER

2. HEIGHT CONTROL VALVE
Figure 8 Rear Cab Air Suspension
Rear cab air suspension enhances ride and cab component durability, resulting in less driver fatigue and
greater productivity. The cab and cab components experience greater durability due to less shock. The rear
cab air suspension is standard on WorkStar® and TranStar® model cabs.
NOTE – The height control valve, air springs (bags), and shock absorbers are serviceable and can be
replaced individually.
The rear cab air suspension system contains one or two air springs (bags) and two shock absorbers and is
controlled by the height control valve. The rear cab air suspension assembly needs no lubrication and very
little maintenance.
The following components - air lines (to air springs), tee fitting, elbow fitting, air springs (bags), height control
valve, shock absorbers, and lateral control rod - should be checked at the time the truck is being serviced.
Immediate corrective action should be taken if a malfunction occurs.
Periodically check the tightness of all fasteners and air line fitting connections. Refer to the TORQUE CHART
(See TORQUE, page 171) for proper tightening of all fasteners and air line fitting connections.
6
REAR CAB AIR SUSPENSION SYSTEM REMOVAL AND INSTALLATION
2. REMOVAL AND INSTALLATION

WARNING
To prevent personal injury or death, park the vehicle on a flat, level surface. Make sure
the engine ignition is in the off position and the transmission is in neutral or in the park
position if the vehicle is equipped with an automatic transmission. Set the parking brake,
chock the wheels, and disconnect the batteries at the negative terminal before doing any
service procedures on the engine or vehicle.
WARNING
To prevent personal injury or death, whenever any component is serviced or removed

from the air system, be sure to set the parking brake and/or block the vehicle wheels to
prevent it from moving while service is being performed.
WARNING
To prevent personal injury or death, rear cab air suspension must be supplied from a
pressure-protected air supply.
NOTE – Before performing any work on the cab components, be sure to perform these basic procedures:
1. Park the vehicle on a flat, level surface.

2. Place the transmission in neutral (or park, if automatic transmission).
3. Set the parking brake.
4. Turn off ignition.
5. Install wheel chocks.
6. Disconnect the battery.
7
REMOVAL AND INSTALLATION WINDSHIELD
2.1. WINDSHIELD
Windshield - Removal
NOTE – For proper windshield removal you will need a pneumatic or electric power knife with:
• Short Inside Cutting Blade

• Long Inside Cutting Blade
• Outside Cutting Blade
1. Unlatch and open the hood.
2. Place protective coverings over areas near windshield.
3. Remove the windshield wiper arms and blades (See Windshield Wiper Arm and Blade Assembly, page 61).
1. Sunshade 3. MOUNTING BRACKET

2. TAPE
Figure 9 Taping the Mounting Brackets
4. If the unit is equipped with an exterior sunshade, place a piece of tape on the bottom side of the three
mounting brackets to protect the paint. To remove the sunshade (See Sunshade, page 115).
8
WINDSHIELD REMOVAL AND INSTALLATION
1. DRIVER SIDE A-PILLAR TRIM 2. GRAB HANDLE

PANEL 3. BOLT
Figure 10 Driver Side A-Pillar Trim Panel and Grab Handle
5. Remove two bolts from grab handle and remove handle.
6. Remove driver side A-pillar trim panel by beginning at the top and pulling free from the cab A-pillar.
9
1. HEADLINER TRIM PANEL 4. INSTRUMENT PANEL

2. CAB A-PILLAR
3. PASSENGER SIDE A-PILLAR
TRIM PANEL
Figure 11 Passenger Side A-Pillar Trim Panel
7. Remove passenger side A-pillar trim panel by beginning at the top and pulling free from the cab A-pillar.
10
WARNING
To prevent personal injury or death, wear protective eyewear and work gloves when
removing windshield.
1. UTILITY KNIFE 2. RUBBER TRIM FLANGE

Figure 12 Cutting Off Rubber Trim Flange
8. Lift outer flange of encapsulation rubber trim and, with a utility knife, cut rubber trim flange entirely off
windshield.
NOTE – When using a power knife to cut around the windshield, use a spray bottle filled with water to
lubricate the cutting area. This will prevent burning of the urethane and rebonding of the windshield.
11
1. POWER KNIFE 4. OUTSIDE CUTTING BLADE

2. SHORT INSIDE CUTTING BLADE 5. LONG-HANDLE UTILITY KNIFE
3. LONG INSIDE CUTTING BLADE
Figure 13 Cutting Windshield Out
9. Using a power knife with a short inside cutting blade (or long inside cutting blade and/or outside cutting
blade), cut all the way around windshield until it is free from the cab windshield fence. If windshield will
not lift off, use a long-handle utility knife to cut through the adhesive.
10. With the aid of an assistant, lift windshield off of the cab and place it out of the way.
Windshield - Installation
NOTE – For windshield installation, use the Windshield Replacement Kit 2592784C91. A pneumatic or
electric caulking gun is required for application of the adhesive.
12
1. 43532 BODY PRIMER 4. BETASEAL EXPRESS ONE-PART

2. 43518 CLEAR GLASS PRIMER URETHANE ADHESIVE
3. 43520A BLACK-OUT GLASS 5. CARTRIDGE TIP
PRIMER
Figure 14 Windshield Replacement Kit
The windshield replacement kit includes the following components:
• 43532 Body Primer

• 43518 Clear Glass Primer
• 43520A Black-Out Glass Primer
• Betaseal Express One-Part Urethane Adhesive
• Cartridge Tips
NOTE – These materials must be used on or before the expiration date marked on the container. Please
refer to the individual containers for expiration dates.
Additional materials needed include the following:
• Essex® GC800 Glass Cleaner

• White or Brown Paper Towels
• Pneumatic or Electric Caulking Gun
13
WARNING
To prevent personal injury or death, 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 –
• Windshield must be made of laminated safety glass only (AS-1 per ANSI Z26.1 - latest revision and
Navistar TMS - 9522 SAE J1203).
• Before installing new windshield, wipe off any water remaining around windshield fence and
surrounding cab area with a lint-free cloth.
1. Dry-fit the new windshield to ensure it fits properly. While the windshield is in place, attach a piece of tape
(as a reference mark) across the center, top portion of windshield and cab. Use a utility knife and cut the
tape between the cab and windshield.
2. Remove windshield and place on a suitable padded work stand.
1. OLD ADHESIVE 3. GASKET CHISEL

2. WINDSHIELD FENCE 4. OLD ADHESIVE
Figure 15 Removing Urethane Adhesive
3. Using a gasket chisel, remove old adhesive from windshield fence. Leaving a thin layer 2- to 3-mm (5/64 -
to 1/8-in.) thick of old adhesive is acceptable. While removing old adhesive, try to maintain a consistent
thickness on the windshield fence.
4. Remove any dirt or water remaining from windshield removal with a brush or clean, lint-free cloth.
14
1. 43532 BODY PRIMER 3. WINDSHIELD FENCE

2. APPLICATOR
Figure 16 Applying Body Primer
5. Shake 43532 body primer container for at least 1 minute.
6. Apply 43532 body primer with a clean, dry applicator to cover scratches and bare metal on the windshield
fence. DO NOT apply 43532 body primer over old urethane adhesive left on windshield fence. Allow
primer to dry for 6 to 10 minutes minimum after application.
1. BONDING SURFACE 2. RAZOR BLADE

Figure 17 Removing Flash
7. Using a razor blade, if necessary, and plastic scrubbing pad, remove any flash from bonding surface of
new windshield. Clean new windshield thoroughly with Essex® glass cleaner GC800 and dry thoroughly
with paper towels. Ensure windshield is completely clean and dry before proceeding.
15
NOTE – Read next step thoroughly and completely to ensure the correct application and removal of the
43518 clear glass primer.
1. 43518 CLEAR GLASS PRIMER 4. WHITE OR BROWN PAPER

2. APPLICATOR TOWEL
3. WINDSHIELD 5. BONDING SURFACE
Figure 18 Applying Clear Glass Primer
8. Shake 43518 clear glass primer container for at least 1 minute.
9. Apply 43518 clear glass primer with a clean, dry applicator to the windshield bonding surface only.
NOTE – If clear glass primer is applied to clear glass surface, glass will haze.
10. Immediately wipe clear glass primer off bonding surface by following 20 to 25 cm (8 to 10 in.) behind the
applicator with a white or brown paper towel. DO NOT use a cloth shop towel. After completing first
application of clear glass primer, repeat application and removal process.
16
1. 43520A BLACK-OUT GLASS 3. WINDSHIELD

PRIMER 4. BONDING SURFACE
2. APPLICATOR
Figure 19 Applying Black-Out Glass Primer
11. Shake 43520A black-out glass primer container for at least one minute.
12. Apply 43520A black-out glass primer with a clean, dry applicator to the windshield bonding surface. Allow
primer to dry to a tack-free condition for 6 to 10 minutes minimum after application.
17
CAUTION
To prevent damage to windshield and cab after priming the windshield, ensure there
is no contact with the bonding surface, as oil from the skin will affect bonding
performance. If the windshield is not bonded properly, the cab strength and safety
would be compromised. If contact with the bonding surface has occurred, repeat the
cleaning process and reapply 43520A black-out glass primer and allow it to dry for 6 to
10 minutes before applying Betaseal Express one-part urethane adhesive.
1. TRIM DIMENSIONS 3. ADHESIVE TUBE

2. CARTRIDGE TIP
Figure 20 Adhesive Tube and Cartridge Tip
13. Measure, mark, and trim the cartridge tip to trim dimensions shown for proper adhesive application.
14. Attach cartridge tip to adhesive tube.
18
1. PNEUMATIC OR ELECTRIC 3. WINDSHIELD FENCE

CAULKING GUN
2. BETASEAL ONE-PART
URETHANE ADHESIVE
Figure 21 Applying Adhesive to Weld Seams
15. Load adhesive tube into a pneumatic or electric caulking gun.
16. Apply a small bead of adhesive to the weld seams at the top and bottom of the windshield fence on
both sides.
NOTE – Application of adhesive bead on new windshield shall be 0 to 2 mm (0 to 5/64 in.) from
encapsulation edge and be at least 16 to 19 mm (5/8 to 3/4 in.) high and 10 to 13 mm (3/8 to 1/2 in.)
wide maximum.
19
1. PNEUMATIC OR ELECTRIC 4. PLASTIC OR WOOD TONGUE

CAULKING GUN DEPRESSOR
2. CARTRIDGE TIP 5. LOCATING TAB
3. ADHESIVE
Figure 22 Applying Adhesive to Windshield
17. Holding pneumatic or electric caulking gun as close to a 90-degree angle as possible, start applying
adhesive at the outer edge of locating tab at the bottom of the windshield. Apply a uniform bead all the way
around the windshield. Overlap adhesive at the seam slightly and use a plastic or wood tongue depressor
to smooth or even out adhesive as required before installing windshield.
20
1. WINDSHIELD 3. WINDSHIELD LOCATOR TAB

2. TAPE MARK 4. TAB LOCATOR POST
Figure 23 Positioning Windshield
18. With the aid of an assistant, align windshield with tape marks on windshield and cab. Align windshield
locator tabs with cab locator post at the bottom of the windshield opening. Be careful not to touch
windshield on cab when installing.
21
1. TAPE ON WINDSHIELD 4. WINDSHIELD FENCE

2. TAPE ON CAB 5. WINDSHIELD ENCAPSULATION
3. WINDSHIELD RUBBER TRIM
Figure 24 Pushing Windshield into Place
19. While holding windshield locator tabs in place on cab locator posts, push windshield back against
windshield fence. Check windshield encapsulation rubber trim to make sure it is positioned properly
around windshield opening.
20. With the aid of an assistant, gently push on the windshield all around the outer edges to seat it properly
against the windshield fence. Tabs built into the windshield prevent it from being pushed in too far.
21. Remove tape from windshield, cab, and sunshade mounting brackets (if applicable).
22. If the vehicle is equipped with an exterior sunshade, install sunshade (See Sunshade, page 115).
23. Install passenger side A-pillar trim panel by aligning trim panel retaining clips with the mounting holes and
push in to secure (Figure 11, Item 3).
24. Install driver side A-pillar trim panel by aligning trim panel retaining clips with the mounting holes and
25. Install driver side grab handle and secure with two bolts (Figure 10, Items 2 and 3). Tighten bolts to 9
to 11 N•m (77 to 95 Lbf-in).
26. Install windshield wiper arms and blades (See Windshield Wiper Arm and Blade Assembly, page 61).
27. Test operation of windshield wipers and washer.
22
REAR WINDOW GLASS REMOVAL AND INSTALLATION
28. Clean windshield and surrounding areas.
29. Close and latch the hood.
NOTE – The Betaseal Express one-part urethane adhesive should be allowed to cure for 60 minutes
before driving the vehicle.
2.2. REAR WINDOW GLASS
1. WINDOW GLASS 3. SPRING CLIP

2. LOCATOR TAB
Figure 25 Rear Window Glass
Rear Window Glass (Unobstructed Access) – Removal
NOTE – For proper rear window glass removal you will need a pneumatic or electric power knife with a
short inside cutting blade.
1. Place protective coverings over areas near the rear window glass inside the cab.
2. Before removing rear window glass, it may be necessary to remove the seats. For removing rear bench
seat (See Rear Bench Seat, page 129).
3. For removing the front seats (See Front Seats, page 127).
23
REMOVAL AND INSTALLATION REAR WINDOW GLASS
WARNING
To prevent personal injury or death, wear protective eye wear and work gloves when
removing rear window glass.
NOTE – When using a power knife to cut around the rear window glass, use a spray bottle filled with
water and lubricate the cutting area. This will prevent burning of the urethane and rebonding of the rear
window glass.
1. POWER KNIFE 3. REAR WINDOW GLASS FENCE

2. SHORT INSIDE CUTTING BLADE
Figure 26 Cutting Rear Window Out
4. From inside the cab, use a power knife with a short inside cutting blade and cut all the way around the
rear window glass until it is free from the rear window glass fence.
5. With the aid of an assistant, remove rear window glass and place it out of the way.
24
Rear Window Glass (Unobstructed Access) – Installation
NOTE – For rear window glass installation, use the Windshield Replacement Kit 2592784C91. A
pneumatic or electric caulking gun is required for application of the adhesive.

PRIMER

• Cartridge Tips
25

WARNING
To prevent personal injury or death, wear protective work gloves when handling the rear
window glass. Also wear appropriate protective gloves when using any of the Betaseal
NOTE –
• Use only heat-treated glass (AS-2 per ANSI Z26.1 - latest revision).
• Before installing new rear window glass, wipe off any water remaining around rear window fence
and surrounding cab area with a lint-free cloth.
1. Dry-fit the rear window glass in the rear window fence to ensure it fits properly. Align window locator tabs
between window locators on the cab and ensure window spring clip is inside the top of the rear window
fence.
2. While the rear window glass is in place, attach 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.
3. Remove rear window glass and place it on a suitable padded work stand.
1. OLD ADHESIVE 3. GASKET CHISEL

2. REAR WINDOW FENCE 4. OLD ADHESIVE
Figure 28 Removing Old Adhesive
4. Using a gasket chisel, remove old adhesive from rear window fence. Leaving a thin layer 2 to 3 mm (5/64
to 1/8 in.) thick of old adhesive is acceptable. While removing old adhesive, try to maintain a consistent
thickness on the windshield fence.
5. Remove any dirt or water remaining from rear window removal with a brush or clean, lint-free cloth.
26

2. APPLICATOR
6. Shake 43532 body primer container for at least one minute.
7. Apply 43532 body primer with a clean, dry applicator to cover scratches and bare metal on the rear
window fence. DO NOT apply 43532 body primer over old urethane adhesive left on rear window fence.
Allow primer to dry for 6 to 10 minutes minimum after application.
27

8. Using a razor blade, if necessary, and plastic scrubbing pad, remove any flash from bonding surface
of new rear window. Clean new, rear window thoroughly with Essex® glass cleaner GC800 and dry
thoroughly with paper towels. Ensure rear window is completely clean and dry before proceeding.
28

2. APPLICATOR TOWEL
3. REAR WINDOW GLASS 5. BONDING SURFACE
9. Shake 43518 clear glass primer container for at least one minute.
10. Apply 43518 clear glass primer with a clean, dry applicator to the rear window glass bonding surface only.
NOTE – If clear glass primer is applied to clear glass surface, glass will haze. Immediately wipe clear
glass primer off bonding surface by following 20 to 25 cm (8 to 10 in.) behind the applicator with a white
or brown paper towel. DO NOT use a cloth shop towel. After completing first application of clear glass
primer, repeat application and removal process.
29
1. 43520A BLACK-OUT GLASS 3. WINDOW GLASS

2. APPLICATOR
11. Shake 43520A black-out glass primer container for at least one minute.
12. Apply 43520A black-out glass primer with a clean, dry applicator to the windshield bonding surface. Allow
primer to dry to a tack-free condition for 6 to 10 minutes minimum after application.
30
CAUTION
To prevent damage to rear window and/or cab 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 43520A black-out glass primer and allow it to dry for 6
to 10 minutes before applying Betaseal Express one-part urethane adhesive .
1. TRIM DIMENSIONS 3. ADHESIVE TUBE

2. CARTRIDGE TIP
31
NOTE – Application of adhesive bead on new rear window glass shall be 0 to 2 mm (0 to 5/64 in.) from
encapsulation edge and be at least 16 to 19 mm (5/8 to 3/4 in.) high and 10 to 13 mm (3/8 to 1/2 in.) wide
maximum.
1. PNEUMATIC OR ELECTRIC 3. ADHESIVE

CAULKING GUN 4. PLASTIC OR WOOD TONGUE
2. CARTRIDGE TIP DEPRESSOR
Figure 34 Applying Adhesive to Rear Window Glass
adhesive at the center of the bottom edge of the rear window glass. Apply a uniform bead all the way
around the rear window glass, overlapping the adhesive at the seam slightly. Use a plastic or wood tongue
depressor to smooth or even out adhesive as required before installing rear window glass.
32
1. TAPE MARKS 5. WINDOW LOCATOR TAB

2. REAR WINDOW GLASS 6. WINDOW LOCATORS ON CAB
3. TAPE MARKS 7. WINDOW SPRING CLIP
4. CAB 8. WINDOW FENCE
Figure 35 Installing Rear Window Glass
16. Align rear window glass with tape marks on rear window and cab. Align window locator tabs between
window locators on cab. Ensure window spring clip is inside the top of the window fence.
17. With the aid of an assistant, gently push on the rear window glass all around the outer edges to seat
it properly against the window fence.
33
1. REAR WINDOW 3. BACKSIDE OF CAB

2. TAPE
Figure 36 Taping Rear Window Glass in Place
18. Tape the rear window to the backside of the cab in four locations while adhesive cures.
19. After the adhesive has cured, remove all pieces of tape and clean the rear window and surrounding areas.
CAUTION
To prevent damage to rear window seal while putting the seats back into the cab, be
careful 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.
20. If rear bench seat was removed, install the rear bench seat (See Rear Bench Seat, page 129).
21. If front seats were removed, install the front seats (See Front Seats, page 127).
34
Rear Window Glass (Obstructed Access) – Removal
NOTE – For proper rear window glass removal you will need:
• Pneumatic or Electric Power Knife with a Short Inside Cutting Blade

• Slide Rail and Suction Cups
1. REAR WINDOW GLASS 3. SPRING CLIP

2. LOCATOR TAB
1. Place protective coverings over areas near the rear window glass inside the cab.
2. Before removing rear window glass, it may be necessary to remove the seats. For removing rear bench
seat (See Rear Bench Seat, page 129).
3. For removing the front seats (See Front Seats, page 127).
35
WARNING
To prevent personal injury or death, wear protective eye wear and work gloves when
removing rear window glass.
1. PLUNGER AND RED INDICATOR 4. BOTTOM RAIL

2. SUCTION CUP 5. SCREW
3. TOP RAIL 6. WING NUT
Figure 38 Slide Rail and Suction Cups
4. Assemble the slide rail by attaching the two top rails to the bottom rail. The three rails are identical and can
be assembled in any one of the three locations. Line up the holes in the two top rails with holes in the
bottom rail. Install three screws and tighten securely with three wing nuts.
CAUTION
To prevent damage to rear window glass and/or vehicle, it is very important that the
area of the van body where the suction cups are being installed is cleaned properly
before the suction cups are attached. If the suction cups come off during the removal
or installation of the rear window glass, the rear window glass will be destroyed and the
vehicle damaged.
5. Clean the area on the van body where the suction cups will be installed to ensure the suction cups will
stick securely.
6. Attach one suction cup to the van body on the driver side and attach the other to the passenger side.
Position both suction cups so that the slide rail (which rests on top of each block) will be just below the
bottom edge of the rear window glass. Repeatedly push the suction cup plungers until the red indicators
are no longer visible; this indicates a good vacuum.
36
NOTE – Periodically check the suction cups to see if the red indicator is starting to appear. If the indicator
is visible on either unit, push the plunger(s) repeatedly until the red indicator is no longer visible.
1. SUCTION CUP 3. SUCTION CUP BLOCK

2. SLIDE RAIL
Figure 39 Installing Slide Rail
7. Place the slide rail on top of each suction cup block.
37
1. SLIDE RAIL 3. SUCTION CUP

2. SUCTION CUP BLOCK 4. PIN
Figure 40 Securing Slide Rail with Pins
8. Starting with the left side, align the hole in the slide rail with the hole in the suction cup block and install
a pin to secure.
9. Moving to the right side, reposition the suction cup to align the slide rail with the suction cup block and
install a pin to secure. Repeatedly push suction cup plunger until the red indicator is not visible.
10. Attach a suction cup to the driver side of the rear window glass.
38
1. POWER KNIFE 3. REAR WINDOW GLASS FENCE

2. SHORT INSIDE CUTTING BLADE
Figure 41 Cutting Rear Window Out
NOTE – When using a power knife to cut around the rear window glass, use a spray bottle filled with
water to lubricate the cutting area. This will prevent burning of the urethane and rebonding of the rear
window glass.
11. From inside the cab, use a power knife with a short inside cutting blade and cut all the way around the rear
window glass until it is free from the window glass fence.
12. Using the suction cup, lift the rear window glass off the fence and set into the slide rail. Lean the top
of the rear window glass against the van body.
39
1. VAN BODY 3. CAB

2. REAR WINDOW GLASS
Figure 42 Removing Rear Window Glass
13. From outside the cab, slide the rear window glass down the slide rail and, with the aid of an assistant,
remove rear window glass and place it out of the way.
14. Remove the suction cup from the rear window glass.
Rear Window Glass (Obstructed Access) – Installation
NOTE – For rear window glass installation, use the Windshield Replacement Kit 2592784C91. A
pneumatic or electric caulking gun is required for application of the adhesive. Windshield Replacement
Kit 2592784C91 is available from Navistar Parts.
40

PRIMER

• Cartridge Tips

• Slide Rail and Suction Cups
41
WARNING
To prevent personal injury or death, wear protective work gloves when handling the rear
window glass. Also, wear appropriate protective gloves when using any of the Betaseal
NOTE –
• Use only heat-treated glass (AS-2 per ANSI Z26.1 - latest revision).
• Before installing new rear window glass, wipe off any water remaining around rear window fence
and surrounding cab area with a lint-free cloth.
• Ensure suction cups and slide rail are still in place on van body from removal procedures. If not,
repeat removal procedures and install suction cups and slide rail before proceeding.
1. REAR WINDOW GLASS 2. SLIDE RAIL

Figure 44 Rear Window Glass on Slide Rail
1. Carefully place rear window glass on the slide rail with the proper side facing the back of the cab.
2. Slide the rear window glass on the slide rail and lean the top of rear window glass against the van body.
3. Attach two suction cups on the rear window glass and repeatedly push the suction cup plungers until the
red indicators are no longer visible. This indicates a good vacuum.
42
NOTE – Periodically check the suction cups to see if the red indicator is starting to appear. If the indicator
is visible on either unit, push the plunger(s) repeatedly until the red indicator is no longer visible.
1. TAPE MARK 5. WINDOW LOCATOR TAB

2. REAR WINDOW GLASS 6. WINDOW LOCATORS ON CAB
3. TAPE MARK 7. WINDOW SPRING CLIP
4. Dry-fit the rear window glass in the window fence to ensure it fits properly. Align window locator tabs
between window locators on the cab and ensure window spring clip is inside the top of the window fence.
5. While the rear window glass is in place, attach a piece of tape (as a reference mark) across the top and
bottom, center portion of the rear window glass and inside the trim panel. Use a utility knife and carefully
cut the tape between the cab and rear window glass.
6. Using the suction cups, lift the rear window glass off the window fence and place it in the slide rail.
7. Slide the rear window glass out of the slide rail and remove. Place rear window glass on a suitable,
padded work stand.
8. Remove the suction cups from the rear window glass.
43
1. OLD ADHESIVE 4. POWER KNIFE WITH SHORT

2. REAR WINDOW FENCE INSIDE CUTTING BLADE
3. UTILITY KNIFE
Figure 46 Removing Old Adhesive
9. Using a utility knife and/or power knife with short inside cutting blade, remove old adhesive from rear
window fence. Leaving a thin layer 2 to 3 mm (5/64 to 1/8 in.) thick of old adhesive is acceptable. While
removing old adhesive, try to maintain a consistent thickness on the windshield fence.
10. Remove any dirt or water remaining from rear window removal with a brush or clean, lint-free cloth.
11. Place strips of tape around the rear window opening to protect the painted surfaces.
44

2. APPLICATOR
12. Shake 43532 body primer container for at least one minute.
13. Apply 43532 body primer with a clean, dry applicator to cover scratches and bare metal on the rear
windshield fence. DO NOT apply 43532 body primer over old urethane adhesive left on rear window fence.
Allow primer to dry for 6 to 10 minutes minimum after application.
14. Remove strips of tape from around the rear window opening.
45

15. Using a razor blade, if necessary, and plastic scrubbing pad, remove any flash from bonding surface of
rear window glass. Clean new, rear window glass thoroughly with Essex® glass cleaner GC800 and dry
thoroughly with paper towels. Ensure rear window glass is completely clean and dry before proceeding.
46

2. APPLICATOR TOWEL
3. REAR WINDOW GLASS 5. BONDING SURFACE
16. Shake 43518 clear glass primer container for at least 1 minute.
17. Apply 43518 clear glass primer with a clean, dry applicator to the rear window glass bonding surface only.
NOTE – If clear glass primer is applied to clear glass surface, glass will haze. Immediately wipe clear
glass primer off bonding surface by following 20 to 25 cm (8 to 10 in.) behind the applicator with a white
or brown paper towel. DO NOT use a cloth shop towel. After completing first application of clear glass
primer, repeat application and removal process.
18. Shake 43520A black-out glass primer container for at least 1 minute.
47
1. 43520A BLACK-OUT GLASS 3. WINDOW GLASS

2. APPLICATOR
CAUTION
To prevent damage to rear window and/or cab 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 43520A black-out glass primer and allow it to dry for 6
to 10 minutes before applying Betaseal Express one-part urethane adhesive .
19. Apply 43520A black-out glass primer with a clean, dry applicator to the rear window glass bonding surface.
Allow primer to dry to a tack-free condition for 6 to 10 minutes minimum after application.
48
1. TRIM DIMENSION 3. ADHESIVE TUBE

2. CARTRIDGE TIP
NOTE – Application of adhesive bead on new rear window glass shall be 0 to 2 mm (0 to 5/64 in.) from
encapsulation edge and be at least 16 to 19 mm (5/8 to 3/4 in.) high and 10 to 13 mm (3/8 to 1/2 in.) wide
maximum.
49
1. PNEUMATIC OR ELECTRIC 3. ADHESIVE

CAULKING GUN 4. PLASTIC OR WOOD TONGUE
2. CARTRIDGE TIP DEPRESSOR
Figure 52 Applying Adhesive to Rear Window Glass
adhesive at the center of the bottom edge of the rear window glass. Apply a uniform bead all the way
around the rear window glass, overlapping the adhesive at the seam slightly. Use a plastic or wood tongue
depressor to smooth or even out adhesive as required before installing rear window glass.
23. Attach two suction cups to the rear window glass and repeatedly push the suction cup plungers until the
red indicators are no longer visible. This indicates a good vacuum.
24. Place rear window glass onto slide rail and slide into position with the window fence.
50
1. TAPE MARKS 5. WINDOW LOCATOR TAB

2. REAR WINDOW GLASS 6. WINDOW LOCATOR ON CAB
3. TAPE MARK 7. WINDOW SPRING CLIP
25. Align rear window with tape marks on rear window glass and cab. Align window locator tabs between
window locators on cab. Ensure window spring clip is inside the top of the window fence.
26. From inside the cab and with the aid of an assistant, carefully pull the rear window glass in against the rear
window fence as evenly as possible.
27. Remove the two suction cups from the rear window glass.
28. From outside the cab, reach in between the back of the cab and the van body and, from both sides, gently
push on rear window glass all around the outer edge to set it properly against the window fence.
51
1. REAR WINDOW 3. BACKSIDE OF CAB

2. TAPE
Figure 54 Taping Rear Window Glass in Place
29. Tape the rear window to the backside of the cab in four locations while adhesive cures.
52
1. SLIDE RAIL 3. SUCTION CUP

2. SUCTION CUP BLOCK 4. PIN
Figure 55 Removing Slide Rail Pins
30. Remove pins from the suction cup blocks and slide rail.
31. Remove the slide rail and suction cups from the van body.
32. If desired, store the slide rail as assembled.
1. PLUNGER AND RED INDICATOR 2. SUCTION CUP
53
3. TOP RAIL 5. SCREW

4. BOTTOM RAIL 6. WING NUT
Figure 56 Slide Rail and Suction Cups
33. To disassemble the slide rail, remove three wing nuts and three screws securing top rails to bottom
rail and store in the removal and installation kit.
34. After the adhesive has cured, remove all pieces of tape and clean the rear window and surrounding areas.
CAUTION
To prevent damage to rear window seal while putting the seats back into the cab, be
careful not to hit the rear window glass while the adhesive is curing. This may cause the
rear window glass to not seal properly and could cause leaking.
35. If rear bench seat was removed, install the rear bench seat (See Rear Bench Seat, page 129).
36. If front seats were removed, install the front seats (See Front Seats, page 127).
54
REAR SIDE WINDOW REMOVAL AND INSTALLATION
2.3. REAR SIDE WINDOW

Rear Side Window – Removal
NOTE – Driver side shown, passenger side removes the same way.
1. If equipped, remove the rear bench seat (See Rear Bench Seat, page 129).
2. Remove the driver front seat (See Front Seats, page 127).
3. Remove scuff plate and seat belt retractor cover (See Scuff Plate and Seat Belt Retractor Cover, page 114).
1. WINDOW LATCH 5. REAR SIDE WINDOW

2. WINDOW SEAL 6. NUT
3. WINDOW FENCE 7. THREADED STUD
4. BOLT 8. WINDOW SEAL SEAM
Figure 57 Rear Side Window
4. Open window latch and remove window seal by pulling it off the window fence.
5. Remove corner and side interior trim panel (See Corner and Side Interior Trim Panel, page 130).
6. Remove two bolts from window latch.
55
REMOVAL AND INSTALLATION REAR SIDE WINDOW
7. Remove two nuts from threaded studs.
8. Carefully pull threaded studs out of mounting holes in window fence.
9. Remove rear side window and place on a padded work surface.
Latch – Removal
1. WINDOW 4. LATCH BAR

2. WINDOW LATCH 5. MOUNTING PEDESTAL SLOT
3. MOUNTING PEDESTAL
Figure 58 Window Latch
1. Rotate window latch clockwise until the latch bar is aligned with the mounting pedestal slot. Lift and
remove latch.
Latch – Installation
NOTE – Driver side shown, passenger side installs the same way.
1. Position latch bar into mounting pedestal slot and rotate window latch counterclockwise until the latch
bar is locked in place on the window (Figure 58).
56
REAR SIDE WINDOW REMOVAL AND INSTALLATION
Rear Side Window – Installation
NOTE – Driver side shown, passenger side installs the same way .
1. Install two threaded studs into mounting holes in window fence (Figure 57, Items 3 and 7).
2. Install two nuts on threaded studs (Figure 57, Items 6 and 7). Tighten nuts to 8 to 11 N•m (71 to 97 lbf-in).
3. Install two bolts on window latch (Figure 57, Items 1 and 4). Tighten bolts to 8 to 11 N•m (71 to 97 lbf-in).
4. Install corner and side interior trim panel (See Corner and Side Interior Trim Panel, page 130).
57
REMOVAL AND INSTALLATION REAR SIDE WINDOW
1. LATCH 4. SEAL INNER GROOVE

2. SEAL 5. WINDOW FENCE
3. SEAL SEAM 6. SEAL OUTER GROOVE
Figure 59 Installing Window Seal
5. Starting at the center of the latch, push inner groove of seal over the flange of the window fence and outer
groove of seal over the side and corner interior trim panel.
6. Install scuff plate and seat belt retractor cover (See Scuff Plate and Seat Belt Retractor Cover, page 114).
7. If equipped, install the rear bench seat (See Rear Bench Seat, page 129).
8. Install the passenger front seat (See Front Seats, page 127).
58
HOOD SEAL REMOVAL AND INSTALLATION
2.4. HOOD SEAL

Hood Seal – Removal
1. HOOD SEAL 2. COWL TRAY

Figure 60 Hood Seal
2. Remove hood seal by pulling it off the cowl tray.
Hood Seal – Installation
1. Check hood seal for cracks and tears (Figure 60, Item 1). If damaged, replace it.
2. Press the hood seal firmly onto the cowl tray until it seats properly (Figure 60).
59
REMOVAL AND INSTALLATION CAB COWL TRAY
2.5. CAB COWL TRAY

Cab Cowl Tray – Removal
2. Remove both driver and passenger side windshield wiper arm and blade assembly (See Windshield Wiper
Arm and Blade Assembly, page 61).
1. SCREW 6. ANTENNA
2. MOUNTING NUT 7. RUBBER SEAL
3. COWL TRAY 8. WIPER PIVOT POST
4. CENTER MOUNTING BRACKET 9. HOOD SEAL
BOLT 10. WASHER HOSE
5. MOUNTING STUD
Figure 61 Cab Cowl Tray
3. Remove washer hose.
4. Remove screw to support bracket.
5. Remove center mounting bolt.
6. Remove two mounting nuts.
7. Pull the cowl tray off the mounting studs and wiper pivot posts.
Cab Cowl Tray – Installation
1. Align cowl tray over mounting studs and wiper pivot posts. (Figure 61, Items 3, 5, and 8).
2. Install two mounting nuts on the cowl tray (Figure 61, Items 2 and 3). Tighten nuts to 22 N•m (16 Lbf-ft),
DO NOT exceed 24 N•m (18 Lbf-ft).
60
WINDSHIELD WIPER ARM AND BLADE ASSEMBLY REMOVAL AND INSTALLATION
3. Install center mounting bracket bolt (Figure 61, Item 4). DO NOT overtighten.
4. Install screw to support bracket (Figure 61, Item 1). DO NOT overtighten.
5. Install washer hose (Figure 61, Item 10).
6. Install both driver and passenger side windshield wiper arm and blade assembly (See Windshield Wiper
8. Turn wipers on high speed, activate windshield washer, and check for proper wiper operation. If required,
adjust windshield wiper arm and blade assembly.
2.6. WINDSHIELD WIPER ARM AND BLADE ASSEMBLY

Windshield Wiper Arm and Blade Assembly – Removal
1. DRIVER SIDE WIPER ARM AND 3. PASSENGER SIDE WIPER ARM

BLADE ASSEMBLY AND BLADE ASSEMBLY
2. WIPER PIVOT POST 4. LOCK LEVER
5. WASHER HOSE
Figure 62 Windshield Wiper Arm and Blade Assembly
NOTE – Before removing wiper arm and blade assembly, mark or note orientation of blade assembly to
wiper pivot post for easier installation.
2. Disconnect washer hose from T-fitting.
3. Lift up on lock lever and remove driver side wiper arm and blade assembly from wiper pivot post.
61
REMOVAL AND INSTALLATION WINDSHIELD WIPER ASSEMBLY
4. Lift up on lock lever and remove passenger side wiper arm and blade assembly.
Windshield Wiper Arm and Blade Assembly – Installation
1. Press passenger side wiper arm and blade assembly onto wiper pivot post until assembly locks in place
(Figure 62, Items 2 and 3).
2. Press driver side wiper arm and blade assembly onto wiper pivot post until assembly locks in place
(Figure 62, Items 1 and 2).
3. Ensure that both lock levers are pressed down (Figure 62, Item 4).
4. Attach washer hose to T-fitting (Figure 62, Item 5).
2.7. WINDSHIELD WIPER ASSEMBLY

Windshield Wiper Assembly – Removal
2. Remove both driver and passenger side windshield wiper arm and blade assembly (See Windshield Wiper
3. Remove the cab cowl tray (See Cab Cowl Tray, page 60).
1. MOUNTING STUD 4. WINDSHIELD WIPER MOTOR

2. MOUNTING NUT 5. WINDSHIELD WIPER ASSEMBLY
3. ELECTRICAL CONNECTOR
Figure 63 Windshield Wiper Assembly
4. If needed, cut wire tie securing wiring harness to windshield wiper motor.
62
WINDSHIELD WIPER ASSEMBLY REMOVAL AND INSTALLATION
5. Disconnect electrical connector from windshield wiper motor.
6. Remove four mounting nuts from the mounting studs.
7. Remove windshield wiper assembly.
Windshield Wiper Assembly – Installation
1. Install windshield wiper assembly onto the four mounting studs and secure with four mounting nuts (Figure
63, Items 1, 2, and 5). Tighten nuts to 22 N•m (16 Lbf-ft), DO NOT exceed 24 N•m (18 Lbf-ft).
2. Connect electrical connector to windshield wiper motor (Figure 63, Items 3 and 4).
3. If removed, secure wiring harness and connector with wire tie.
4. Install the cab cowl tray (See Cab Cowl Tray, page 60).
5. Install driver and passenger side windshield wiper arm and blade assembly (See Windshield Wiper
63
REMOVAL AND INSTALLATION WINDSHIELD WASHER BOTTLE WITH PUMP MOTOR
2.8. WINDSHIELD WASHER BOTTLE WITH PUMP MOTOR

WorkStar® Windshield Washer Bottle With Pump Motor – Removal
NOTE – The washer bottle and pump motor are located under the cab door on the passenger side.
1. MOUNTING BRACKET 6. PUMP MOTOR

2. REMOTE FILL HOSE 7. WASHER BOTTLE
3. PUMP MOTOR ELECTRICAL 8. WINDSHIELD WASHER HOSE
CONNECTOR 9. MOUNTING BOLT
4. LOW FLUID SENSOR 10. SPEED NUT
5. LOW FLUID SENSOR
ELECTRICAL CONNECTOR
Figure 64 WorkStar® Windshield Washer Bottle with Pump Motor
1. Disconnect pump motor electrical connector from pump motor.
2. Disconnect low fluid sensor electrical connector from the low fluid sensor.
3. Disconnect windshield washer hose.
4. Disconnect remote fill hose.
5. Disconnect air vent hose (not shown).
6. Remove four mounting bolts.
7. Remove washer bottle and pump motor.
NOTE – If any of the four speed nuts are damaged, remove and replace them.
64
WINDSHIELD WASHER BOTTLE WITH PUMP MOTOR REMOVAL AND INSTALLATION
WorkStar® Windshield Washer Bottle With Pump Motor – Installation
1. Install washer bottle and pump motor with four mounting bolts (Figure 64, Items 6, 7, and 9). Do not
overtighten.
2. Connect remote fill hose (Figure 64, Item 2).
3. Connect air vent hose (not shown).
4. Connect windshield washer hose (Figure 64, Item 8).
5. Connect low fluid sensor electrical connector to the low fluid sensor (Figure 64, Items 4 and 5).
6. Connect pump motor electrical connector to pump motor (Figure 64, Items 3 and 6 ).
7. Fill washer bottle with windshield washer solvent and check for leaks and proper washer operation (Figure
64, Item 7).
65
REMOVAL AND INSTALLATION WINDSHIELD WASHER BOTTLE WITH PUMP MOTOR
TranStar® Windshield Washer Bottle With Pump Motor – Removal
NOTE – The washer bottle and pump motor are located under the cab door on the driver side.
1. MOUNTING BRACKET 6. WINDSHIELD WASHER HOSE

2. LOW FLUID SENSOR 7. PUMP MOTOR
3. REMOTE FILL HOSE 8. LOW FLUID SENSOR
4. PUMP MOTOR ELECTRICAL ELECTRICAL CONNECTOR
CONNECTOR 9. MOUNTING BOLT
5. WASHER BOTTLE 10. SPEED NUT
Figure 65 TranStar® Windshield Washer Bottle with Pump Motor
1. Disconnect pump motor electrical connector from pump motor.
2. Disconnect low fluid sensor electrical connector from the low fluid sensor.
3. Disconnect windshield washer hose.
4. Disconnect remote fill hose.
5. Disconnect air vent hose (not shown).
6. Remove four mounting bolts.
7. Remove washer bottle and pump motor.
NOTE – If any of the four speed nuts are damaged, remove and replace them.
66
WINDSHIELD WASHER BOTTLE WITH PUMP MOTOR REMOVAL AND INSTALLATION
TranStar® Windshield Washer Bottle With Pump Motor – Installation
1. Install washer bottle and pump motor with four mounting bolts (Figure 65, Items 5, 7, and 9). Do not
overtighten.
2. Connect remote fill hose (Figure 65, Item 3).
3. Connect air vent hose (not shown).
4. Connect windshield washer hose (Figure 65, Item 6).
5. Connect low fluid sensor electrical connector to the low fluid sensor (Figure 65, Items 2 and 8).
6. Connect pump motor electrical connector to pump motor (Figure 65, Items 4 and 7).
7. Fill washer bottle with windshield washer solvent and check for leaks and proper washer operation (Figure
65, Item 5).
67
REMOVAL AND INSTALLATION WINDSHIELD WASHER PUMP MOTOR
2.9. WINDSHIELD WASHER PUMP MOTOR

Windshield Washer Pump Motor – Removal
NOTE –
• The pump motor is removable from the washer bottle without removing the washer bottle. The pump
motor is serviceable and replaced as a unit.
• The WorkStar® pump motor location is under passenger side door, the TranStar® pump motor is
under the driver side door.
1. ELECTRICAL CONNECTOR 3. PUMP MOTOR

2. WASHER BOTTLE 4. WINDSHIELD WASHER HOSE
Figure 66 Windshield Washer Pump Motor
1. Disconnect electrical connector from pump motor.
2. Place a container under the washer bottle to catch the windshield washer fluid.
3. Disconnect windshield washer hose from pump motor.
4. Remove pump motor by carefully pulling it straight out of the washer bottle.
68
ELECTRIC WINDSHIELD WIPER MOTOR REMOVAL AND INSTALLATION
Windshield Washer Pump Motor – Installation
NOTE –
• The pump motor is removable from the washer bottle without removing the washer bottle. The pump
motor is serviceable and replaced as a unit.
• The WorkStar® pump motor location is under passenger side door, the TranStar® pump motor is
under the driver side door.
1. Install the pump motor by carefully pushing the pump motor straight into the washer bottle (Figure 66,
Items 2 and 3).
2. Connect windshield washer hose to pump motor (Figure 66, Items 3 and 4).
3. Connect electrical connector to pump motor (Figure 66, Items 1 and 3).
4. Fill washer bottle with windshield washer solvent and check for leaks and washer operation.
2.10. ELECTRIC WINDSHIELD WIPER MOTOR

Electric Windshield Wiper Motor – Removal
CAUTION
To prevent damage to wiper arms and blades, do not attempt to grasp the wiper blades
or arms while they are in motion. Attempting to stop the arms or blades in motion may
result in component damage. If blades are frozen to the windshield, thaw them out before
attempting to operate.
NOTE – The electric windshield wiper motor has no serviceable parts or adjustments and is replaced as
a complete unit.
2. Turn the ignition key to the ON position and cycle the wiper arm to the end of the sweep cycle (wiper
blades will be in the vertical position). Turn key to OFF position.
69
REMOVAL AND INSTALLATION ELECTRIC WINDSHIELD WIPER MOTOR
1. WIPER LINKAGE 5. ELECTRIC WIPER MOTOR

2. ELECTRICAL CONNECTOR 6. WIPER DRIVE ARM
3. MOUNTING BOLT 7. NUT
4. MOUNTING BRACKET 8. LOCKWASHER
Figure 67 Electric Windshield Wiper Motor
NOTE – Graphic view is from the back side (or cab side) of unit.
3. Disconnect electrical connector from the electric wiper motor. Remove wire ties as needed.
4. Remove nut and lockwasher securing wiper drive arm to electric wiper motor.
5. Remove three mounting bolts securing electric wiper motor to the mounting bracket.
6. Remove electric wiper motor.
Electric Windshield Wiper Motor – Installation
CAUTION
To prevent damage to wiper arms and blades, do not attempt to grasp the wiper blades
or arms while they are in motion. Attempting to stop the arms or blades in motion may
result in component damage. If blades are frozen to the windshield, thaw them out before
attempting to operate.
NOTE – The electric windshield wiper motor has no serviceable parts or adjustments and is replaced as
a complete unit.
1. Install the electric wiper motor on the mounting bracket and secure with three mounting bolts (Figure 67,
Items 3, 4, and 5). Tighten to 10 to 12 N•m (90 to 110 Lbf-in.).
2. Install nut and lockwasher securing wiper drive arm to electric wiper motor (Figure 67). Tighten to 20 to 25
N•m (15 to 18 Lbf-ft).
3. Connect electrical connector to the electric wiper motor. Replace any previously removed wire ties (Figure
67, Items 2 and 5).
70
CAB DOORS REMOVAL AND INSTALLATION
4. Turn the ignition key to the ON position and cycle the wiper arm to the end of the sweep cycle (wiper
blades will be in the horizontal position). Turn key to OFF position.
2.11. CAB DOORS

Cab Doors – Removal
NOTE –
• Removal procedures on passenger side and driver side are the same.
• The cab doors are of welded, all-steel construction and are mounted on hinges located on the hinge
pillars. Door adjustment is provided by enlarged holes in the door hinges. The door check stops
are located just below the upper hinges on the door hinge pillars. The door latch striker pin is also
adjustable on the door lock pillar.
1. WIRING HARNESS RUBBER 2. CAB HINGE PILLAR

BOOT
Figure 68 Wiring Harness Rubber Boot
1. Remove wiring harness rubber boot from the cab hinge pillar.
71
REMOVAL AND INSTALLATION CAB DOORS
1. LIGHTED, HEATED 2. CB RADIO CONNECTOR

OR ELECTRIC MIRROR 3. ELECTRIC WINDOW AND DOOR
CONNECTOR LOCK CONNECTOR
Figure 69 Electrical Connectors
2. Disconnect the three electrical connectors (lighted, heated, or electric mirror; CB radio; and electric
window and door locks), as equipped.
3. Secure a sling or padded chain to the top of the window frame and attach to an overhead hoist to
support the door.
72
CAB DOORS REMOVAL AND INSTALLATION
1. UPPER HINGE 5. LINK

2. STOP PIN 6. BRACKET
3. CAB DOOR 7. LOWER HINGE
4. THREADED STUD 8. MOUNTING NUT WITH WASHER
Figure 70 Cab Door
4. Remove stop pin from link and bracket.
5. Remove four mounting nuts with washers from threaded studs.
6. With cab door supported from overhead hoist, move cab door slightly backward to disengage threaded
studs from upper and lower hinges.
7. Carefully pull the wiring harness and electrical connectors through the cab hinge pillar.
8. Using the overhead hoist, move cab door to a padded workbench.
73
REMOVAL AND INSTALLATION CAB DOORS
Cab Doors – Installation
NOTE – Installation procedures on passenger side and driver side are the same.
1. Secure a sling or padded chain to the top of the window frame and attach to an overhead hoist to support
the cab door (Figure 70, Item 3).
2. Using the overhead hoist, lift and move the cab door near to the cab (Figure 70, Item 3).
3. Carefully pull the wiring harness and electrical connectors into and through the cab hinge pillar (Figure
68, Item 2).
4. Move cab door slightly forward to engage threaded studs into the upper and lower hinges (Figure 70).
5. Install four mounting nuts with washers onto the threaded studs (Figure 70, Items 4 and 8). Tighten
nuts to 19 to 24 N•m (14 to 18 Lbf-ft).
6. Align link into bracket and insert stop pin (Figure 70, Items 2, 5, and 6).
7. Connect the three electrical connectors (lighted, heated, or electric mirror; CB radio; and electric window
and door locks), as equipped. (Figure 69).
8. Push the wiring harness and electrical connectors up under the instrument panel, if applicable.
9. Install wiring harness rubber boot to the cab hinge pillar (Figure 68).
74
DOOR HINGE REMOVAL AND INSTALLATION
2.12. DOOR HINGE

Door Hinge – Removal
NOTE – Removal procedures on passenger side and driver side are the same.
1. UPPER HINGE 4. CAB HINGE PILLAR

2. LOWER HINGE 5. LOCKING BOLT
3. HINGE BOLT
Figure 71 Cab Door Hinge
NOTE – The cab door is mounted on upper and lower hinges located on the cab hinge pillar. Door
adjustment is provided by enlarged holes in the door upper and power hinge mounting holes. If door
hinges are removed from the cab, upper and lower hinges can be interchanged.
1. Remove the cab door from the hinges (See Cab Doors, page 71).
2. Mark upper and lower hinge positions on cab hinge pillar to simplify cab door adjustment during installation.
3. Mark the location of the locking bolt, so it can be installed in the correct location.
4. Remove hinge bolt, locking bolt, and upper hinge from cab hinge pillar.
5. Remove two hinge bolts and lower hinge from cab hinge pillar.
75
REMOVAL AND INSTALLATION DOOR STRIKER PIN
Door Hinge – Installation
1. Align lower hinge with previously made marks on cab hinge pillar (Figure 71, Items 2 and 4).
2. Install lower hinge and secure with two hinge bolts (Figure 71, Items 2 and 3). Tighten bolts to 20 to 24
N•m (15 to 18 Lbf-ft).
3. Align upper hinge with previously made marks on cab hinge pillar (Figure 71, Items 1 and 4).
4. Install upper hinge and secure with hinge bolt and locking bolt (Figure 71, Items 1, 3, and 5). Tighten
bolts to 20 to 24 N•m (15 to 18 Lbf-ft).
5. Install the cab door on the hinges (See Cab Doors, page 71).
2.13. DOOR STRIKER PIN

Door Striker Pin – Removal
1. DOOR LOCK PILLAR 3. STRIKER PIN

2. BOLT
Figure 72 Striker Pin
NOTE – The striker pin provides positive engagement with the cab door latch assembly. Removal and
installation requires a Torx head tool. Enlarged mounting holes in door lock pillar and mounting plate
allow adjustment.
1. Remove two bolts securing striker pin to door lock pillar.
76
DOOR CHECK BRACKET REMOVAL AND INSTALLATION
2. Remove striker pin.
Door Striker Pin – Installation
1. Install striker pin and secure to door lock pillar with two bolts (Figure 72). Tighten bolts to 26 to 33 N•m
(19 to 24 Lbf-ft).
2.14. DOOR CHECK BRACKET

Door Check Bracket – Removal
1. Remove stop pin from link and bracket (Figure 70, Items 2, 5, and 6).
1. CHECK BRACKET 3. CAB HINGE PILLAR

2. BOLT
Figure 73 Check Bracket
2. Remove the two bolts securing the check bracket to the cab hinge pillar.
3. Remove check bracket.
77
REMOVAL AND INSTALLATION DOOR CHECK LINK
Door Check Bracket – Installation
1. Install check bracket and secure to the cab hinge pillar with two bolts (Figure 73). Tighten bolts to 11
to 14 N•m (97 to 124 Lbf-in).
2.15. DOOR CHECK LINK

Door Check Link – Removal
1. Remove door trim panel (See Door Trim Panel, page 80).
2. Remove door vapor barrier (See Door Vapor Barrier, page 82).
3. Remove stop pin from link and bracket (Figure 70, Items 2, 5, and 6).
78
DOOR CHECK LINK REMOVAL AND INSTALLATION
1. NUT 3. CHECK LINK

2. CAB DOOR
Figure 74 Check Link
4. Remove two nuts and remove the check link from the cab door.
Door Check Link – Installation
1. Install check link to cab door with two nuts (Figure 74). Tighten to 9 to 11 N•m (77 to 95 Lbf-in).
3. Install door vapor barrier (See Door Vapor Barrier, page 82).
4. Install door trim panel (See Door Trim Panel, page 80).
79
REMOVAL AND INSTALLATION DOOR TRIM PANEL
2.16. DOOR TRIM PANEL

Door Trim Panel – Removal
1. INNER DOOR PULL CUP SCREW 5. MAP POCKET/GRAB HANDLE

2. INNER DOOR PULL CUP 6. COURTESY LIGHT
3. TRIM PANEL 7. TRIM PANEL FASTENER
4. MAP POCKET/GRAB HANDLE 8. CAB DOOR
SCREW
Figure 75 Door Trim Panel
1. Remove two inner door pull cup screws and remove inner door pull cup.
2. Remove two map pocket/grab handle screws from map pocket.
3. If equipped, remove grab handle.
4. Carefully pull map pocket away from trim panel and disconnect electrical connector from courtesy light, if
applicable.
5. Remove map pocket.
NOTE – If equipped with manual windows and door locks, follow the next step. If equipped with power
windows and door locks, skip this step.
6. Press in on trim panel near window handle shaft, insert proper removal tool, and remove retaining clip
and handle (not shown).
7. Using the interior trim tool, remove nine trim panel fasteners.
80
DOOR TRIM PANEL REMOVAL AND INSTALLATION
1. TRIM PANEL 3. ELECTRIC WINDOW AND DOOR

2. ELECTRICAL CONNECTOR LOCK SWITCH
Figure 76 Trim Panel Electrical Connectors
8. Lift trim panel away from cab door and disconnect electrical connectors, if applicable.
9. Remove trim panel and place on a suitable, padded surface.
Door Trim Panel – Installation
1. Connect electrical connectors to trim panel (Figure 75, Items 1 and 2), if applicable.
NOTE – Ensure electrical connector for courtesy light is pulled through before securing trim panel.
2. Position trim panel in place on cab door and press firmly on each of the nine fasteners to secure trim
panel to cab door (Figure 75, Items 3, 7, and 8).
3. Connect electrical connector to courtesy light, if applicable (Figure 75, Item 6).
4. Install map pocket and grab handle, if equipped, with two map pocket/grab handle screws (Figure 75,
Items 4 and 5). Tighten screws to 2 to 3 N•m (20 to 25 Lbf-in).
5. Install door pull cup with two door pull cup screws (Figure 75, Items 1 and 2). Tighten screws to 2 to 3
N•m. (20 to 25 Lbf-in).
NOTE – If equipped with manual windows and door locks, follow the next step. If equipped with power
windows and door locks, skip this step.
81
REMOVAL AND INSTALLATION DOOR VAPOR BARRIER
6. Install retaining clip and window handle. Press firmly onto window handle until it locks into place (not
shown).
2.17. DOOR VAPOR BARRIER

Door Vapor Barrier – Removal
1. CAB DOOR 3. TRIM PANEL

2. VAPOR BARRIER
Figure 77 Vapor Barrier
2. Note vapor barrier position on the cab door for easier installation. Carefully pull the vapor barrier free
from the cab door and remove.
Door Vapor Barrier – Installation
NOTE – Inspect vapor barrier for damage. If damaged, replace.
1. Position the vapor barrier on the cab door (Figure 77, Items 1 and 2).
82
WINDOW SLIDE BLOCK REMOVAL AND INSTALLATION
2.18. WINDOW SLIDE BLOCK

Window Slide Block – Removal
NOTE –
• Cab door glass does not have to be removed for window slide block removal.
• Lower cab door glass to the bottom before removing trim panel.
1. DOOR 5. WINDOW SLIDE BLOCK

2. TRIM PANEL 6. GLASS
3. REGULATOR ARM 7. VAPOR BARRIER
4. SLIDE RAIL
Figure 78 Window Slide Block
83
REMOVAL AND INSTALLATION DOOR GLASS
3. Using a blunt-tip, flat-blade screwdriver, carefully pry regulator arm from the window slide block.
1. SLIDE RAIL 3. WINDOW SLIDE BLOCK

2. PLASTIC RETAINING TAB 4. DOOR
Figure 79 Plastic Retaining Tab
4. Carefully break off the plastic retaining tab.
5. Slide the window slide block off the slide rail and remove.
Window Slide Block – Installation
NOTE –
• Installation procedures on passenger side and driver side are the same.
• 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.
• Inspect window slide block for wear or damage. If damaged, replace it.
1. Install the window slide block onto the slide rail (Figure 79, Items 1 and 3).
2. Carefully push regulator arm into the window slide block (Figure 78, Items 3 and 5).
2.19. DOOR GLASS

Door Glass – Removal
NOTE –
84
DOOR GLASS REMOVAL AND INSTALLATION
3. Using a blunt-tip, flat-blade screwdriver, carefully pry regulator arm from the window slide block (Figure 78,
Items 3 and 5).
1. CAB DOOR 2. GLASS SEAL AND RUN

CHANNEL
Figure 80 Glass Seal and Run Channel
4. Starting at the upper left side, pull glass seal and run channel free from cab door.
5. Remove glass seal and run channel.
85
REMOVAL AND INSTALLATION DOOR GLASS
1. DOOR GLASS 3. GLASS SEAL AND OUTER BELT

2. CAB DOOR 4. GLASS SEAL AND INNER BELT
Figure 81 Glass Seal and Inner and Outer Belt
NOTE – Modular door hardware assembly purposely not shown in graphic for clarity.
6. Pull glass seal and inner belt free from cab door and remove.
7. Pull glass seal and outer belt free from cab door and remove.
8. From outside the cab door, pull door glass upward and remove.
9. Place door glass on a suitable, padded work surface.
Door Glass – Installation
NOTE –
• Check glass seal, run channels, and inner and outer belts for damage. Replace if needed.
1. From outside the cab door, install the door glass and position into the left and right run channels. Ensure
the door glass is in the run channels and moves freely before proceeding (Figure 80).
2. Lower the door glass to the bottom.
3. Install the glass seal and inner belt and press down firmly into cab door (Figure 81, Items 2 and 4).
86
MODULAR DOOR HARDWARE ASSEMBLY REMOVAL AND INSTALLATION
4. Install the glass seal and outer belt and press down firmly into cab door (Figure 81, Items 2 and 3).
5. Starting at the upper right, begin pressing glass seal and run channel into the cab door. Proceed until
entire glass seal and run channel is firmly seated into cab door (Figure 80).
6. Attach the regulator arm to the window slide block (Figure 78, Items 3 and 5).
NOTE – For manual windows, temporarily attach regulator handle to operate. For electric windows,
temporarily connect electrical connector to operate. Remove regulator handle or disconnect electrical
connector when next step is complete.
7. Raise and lower window to ensure free movement. If binding occurs, find, locate, and correct problem
before continuing.
2.20. MODULAR DOOR HARDWARE ASSEMBLY

Modular Door Hardware Assembly – Removal
NOTE –
• The modular door hardware assembly consists of the window regulator assembly, front and rear
window run channels, inner and outer door handles, and door latch. This assembly is installed and
removed as a module.
3. Remove door glass (See Door Glass, page 84).
87
REMOVAL AND INSTALLATION MODULAR DOOR HARDWARE ASSEMBLY
1. CAB DOOR 3. TRIM BEZEL

2. SCREW 4. OUTER DOOR HANDLE
Figure 82 Door Handle Trim Bezel
4. Using a flat-blade screwdriver covered with a cloth rag to protect the paint, carefully pry door handle
trim bezel away from cab door.
NOTE – The plastic tabs on the door handle trim bezel will likely break off during removal. Replace trim
bezel if tabs get broken.
5. Remove four screws securing outer door handle.
88
1. ASSEMBLY MOUNTING BOLT 4. DOOR LATCH BOLT

2. MOUNTING GUIDE PIN 5. MODULAR DOOR HARDWARE
3. REGULATOR ASSEMBLY ASSEMBLY
Figure 83 Modular Door Hardware Assembly
6. Remove three door latch bolts securing door latch assembly.
7. Remove four assembly mounting bolts securing modular door hardware assembly.
8. Remove mounting guide pin.
9. Slide modular door hardware assembly to the right, lift upward, and pull outward to expose electrical
connectors.
89
REMOVAL AND INSTALLATION MODULAR DOOR HARDWARE ASSEMBLY
1. PUSH-IN FASTENER 4. WINDOW RUN CHANNEL

2. WINDOW MOTOR ELECTRICAL 5. DOOR LATCH ASSEMBLY
CONNECTOR 6. DOOR LATCH ELECTRICAL
3. WINDOW ELECTRIC MOTOR CONNECTOR
Figure 84 Electrical Connectors
10. Disconnect window motor electrical connector from the electric window motor.
11. Remove all push-in fasteners securing the wiring harness.
12. Disconnect door latch electrical connector from the door latch assembly.
13. Remove modular door hardware assembly.
Modular Door Hardware Assembly – Installation
NOTE –
• The modular door hardware assembly consists of the window regulator assembly, front and rear
window run channels, inner and outer door handles, and door latch. This assembly is installed and
removed as a module.
1. Position modular door hardware assembly near the cab door and connect the door latch electrical
connector to the door latch assembly (Figure 84, Items 5 and 6).
2. Install all wiring harness push-in fasteners (Figure 84, Item 1).
90
3. Connect window motor electrical connector to window electric motor (Figure 84, Items 2 and 3).
4. Guide the top of the window run channels up inside cab door and align door latch assembly (Figure 84,
Items 4 and 5).
5. Align modular door hardware assembly and install mounting guide pin (Figure 83, Items 2 and 5).
6. Install modular door hardware assembly with four assembly mounting bolts (Figure 83, Items 1 and
5). Finger-tighten bolts only.
7. Once all four bolts are in place, tighten the bolts to 11 to 14 N•m (97 to 124 Lbf-in).
8. Install door latch assembly with three door latch bolts (Figure 83, Items 3 and 4). Tighten bolts to 11
to 14 N•m (97 to 124 Lbf-in).
9. Install outer door handle with four screws (Figure 82, Items 2 and 4). Tighten screws to 4 to 5 N•m
(35 to 44 Lbf-in.).
NOTE – A new outer door handle trim bezel will need to be installed if the plastic tabs were broken off
during removal.
10. Install trim bezel and carefully push it in place (Figure 82, Item 3).
11. Ensure the door lock, inner and outer door handles, and door latch assembly are all working properly
before proceeding.
12. Install door glass (See Door Glass, page 84).
91
REMOVAL AND INSTALLATION VENT WINDOW, LATCH, AND SEAL
2.21. VENT WINDOW, LATCH, AND SEAL

Vent Window, Latch, And Seal – Removal
1. VENT WINDOW 3. WINDOW LATCH

2. SCREW
Figure 85 Vent Window, Latch, and Seal
1. Open vent window and remove two screws and window latch.
92
VENT WINDOW, LATCH, AND SEAL REMOVAL AND INSTALLATION
1. VENT WINDOW 4. UPPER HINGE PIN

2. LOWER HINGE PIN 5. VENT WINDOW SEAL
3. HINGE 6. CAB DOOR
Figure 86 Vent Window, Hinge Pins, and Seal
2. Lift the hinge off the upper hinge pin.
3. Lift vent window off the hinge and remove.
4. Remove vent window seal from cab door.
Vent Window, Latch, And Seal – Installation
1. Install vent window seal in cab door and push into place (Figure 86, Items 5 and 6).
2. Install vent window and position lower hinge pin into the hinge (Figure 86, Items 1, 2, and 3).
3. Carefully lift up the upper part of the hinge and position upper hinge pin into hinge (Figure 86, Items 3
and 4).
4. Close vent window and install window latch with two screws (Figure 85, Items 2 and 3) . Tighten screws to
6 to 8 N•m (53 to 71 Lbf-in.).
93
REMOVAL AND INSTALLATION DOOR LOCK CYLINDER
2.22. DOOR LOCK CYLINDER

Door Lock Cylinder – Removal
NOTE –
• All door lock cylinders are coded the same as the ignition switch; one key operates both the ignition
switch and the door locks.
1. Using a flat-blade screwdriver covered with a cloth rag to protect the paint, carefully pry door handle trim
bezel away from cab door (Figure 82, Items 1 and 3).
NOTE – The plastic tabs on the door handle trim bezel will likely break off during removal. Replace trim
bezel if tabs get broken.
1. DOOR LOCK CYLINDER 3. RETAINING CLIP

2. DOOR HANDLE 4. CAB DOOR
Figure 87 Door Lock Cylinder
2. Using a flat-blade screwdriver, remove retaining clip from behind door handle.
3. Remove door lock cylinder.
94
DOOR LOCK CYLINDER REMOVAL AND INSTALLATION
Door Lock Cylinder – Installation
NOTE –
• All door lock cylinders are coded the same as the ignition switch; one key operates both the ignition
switch and the door locks.
1. Insert door lock cylinder into door handle (Figure 87, Items 1 and 2).
2. Install retaining clip on door handle (Figure 87, Items 2 and 3).
3. Ensure the door lock cylinder is working properly before proceeding.
NOTE – Replace trim bezel if tabs were broken during removal.
4. Install door handle trim bezel onto cab door and snap into place (Figure 82, Items 1 and 3).
95
REMOVAL AND INSTALLATION WINDOW ELECTRIC MOTOR
2.23. WINDOW ELECTRIC MOTOR

Window Electric Motor – Removal
1. MODULAR DOOR HARDWARE 3. WINDOW ELECTRIC MOTOR

ASSEMBLY 4. MOUNTING NUT AND STUD
2. ELECTRICAL CONNECTOR
Figure 88 Window Electric Motor
3. Disconnect electrical connector from window electric motor.
4. Remove three mounting nuts securing window electric motor to modular door hardware assembly.
5. Remove window electric motor.
Window Electric Motor – Installation
1. Install window electric motor on studs (Figure 88, Items 3 and 4). Ensure unit is aligned properly.
2. Install three mounting nuts (Figure 88, Item 4). Tighten nuts to 7 to 13 N•m (62 to 115 Lbf-in.).
3. Connect electrical connector to window electric motor (Figure 88, Items 2 and 3).
96
REGULATOR ARM ASSEMBLY REMOVAL AND INSTALLATION
2.24. REGULATOR ARM ASSEMBLY

Regulator Arm Assembly – Removal
NOTE –
3. Remove window electric motor (See Window Electric Motor, page 96).
97
REMOVAL AND INSTALLATION REGULATOR ARM ASSEMBLY
1. DOOR 5. WINDOW SLIDE BLOCK

2. TRIM PANEL 6. GLASS
3. REGULATOR ARM 7. VAPOR BARRIER
4. SLIDE RAIL
Figure 89 Window Slide Block
4. Using a blunt-tip, flat-blade screwdriver, carefully pry window regulator arm from the window slide block.
5. Lift glass to the top and secure it in position.
98
1. BOLT 4. DOOR HANDLE

2. DOOR HANDLE RETAINING TAB
3. MODULAR DOOR HARDWARE
ASSEMBLY
Figure 90 Inner Door Handle
6. Remove bolt from door handle.
7. Slide door handle to the left and pull door handle retaining tabs out of the modular door hardware assembly.
99
REMOVAL AND INSTALLATION REGULATOR ARM ASSEMBLY
1. DOOR HANDLE 4. REGULATOR ASSEMBLY COIL

2. REGULATOR ARM ASSEMBLY SPRING
SHAFT 5. MODULAR DOOR HARDWARE
3. RETAINING TAB ASSEMBLY
Figure 91 Regulator Arm Assembly and Coil Spring
8. Rotate door handle counterclockwise until the regulator assembly coil spring is exposed.
100
WARNING
To prevent personal injury or death, be sure to use an appropriate tool. Use care when
removing the window regulator assembly coil spring from behind the retaining tab on
the modular door hardware assembly in the step below (step 9), to prevent bodily injury.
The window regulator assembly coil spring will be in the loaded position during removal.
9. Carefully release regulator assembly coil spring from the retaining tab.
10. Remove regulator assembly coil spring from the regulator arm assembly shaft.
1. REGULATOR ARM ASSEMBLY 3. MODULAR DOOR HARDWARE

SHAFT ASSEMBLY
2. REGULATOR ARM
Figure 92 Regulator Arm and Regulator Arm Assembly Shaft
11. Insert a flat-blade screwdriver in the slot of the regulator arm assembly shaft and rotate it counterclockwise
to the unlocked position.
12. Pull regulator arm assembly shaft straight out and remove.
13. Remove regulator arm from the modular door hardware assembly.
Regulator Arm Assembly – Installation
1. Attach regulator arm by installing the regulator arm assembly shaft through the modular door hardware
assembly into the regulator arm (Figure 92).
2. Insert a flat-blade screwdriver in the slot of the regulator arm assembly shaft and rotate it clockwise to
the locked position (Figure 92, Item 1).
3. Install regulator assembly coil spring into the slot of the regulator arm assembly shaft (Figure 91, Items 2
and 4).
101
REMOVAL AND INSTALLATION OUTER DOOR HANDLE
WARNING
To prevent personal injury or death, be sure to use an appropriate tool. Use care when
removing the window regulator assembly coil spring from behind the retaining tab on
the modular door hardware assembly in the step below (step 4), to prevent bodily injury.
The window regulator assembly coil spring will be in the loaded position during removal.
4. Rotate regulator assembly coil spring clockwise around to the retaining tab on the modular door hardware
assembly and position behind retaining tab (Figure 91, Items 3, 4, and 5).
5. Rotate door handle clockwise until the regulator assembly coil spring is covered (Figure 91, Items 1 and 4).
6. Insert door handle retaining tabs into the slots in the modular door hardware assembly and slide door
handle to the right to secure in place (Figure 90, Items 2, 3, and 4).
7. Install bolt securing door handle to the modular door hardware assembly (Figure 90, Items 1, 3, and 4).
Tighten bolt to 8 to 10 N•m (71 to 88.5 Lbf-in.).
8. Lower glass to the bottom.
9. Attach the regulator arm to the window slide block (Figure 89, Items 3 and 5).
NOTE – For manual windows, temporarily attach regulator handle to operate. For electric windows,
temporarily connect electrical connector to operate. Remove regulator handle or disconnect electrical
connector when next step is complete.
10. Raise and lower window to ensure free movement. If binding occurs, find, locate, and correct problem
before continuing.
11. Install window electric motor (See Window Electric Motor, page 96).
2.25. OUTER DOOR HANDLE

Outer Door Handle – Removal
3. Remove modular door hardware assembly (See Modular Door Hardware Assembly, page 87).
102
OUTER DOOR HANDLE REMOVAL AND INSTALLATION
1. DOOR LATCH 6. WINDOW RUN CHANNEL

2. LOCK LEVER 7. HANGER SUPPORT BRACKET
3. SHORT CONTROL ROD 8. LOCKING TAB
4. LONG CONTROL ROD 9. MODULAR DOOR ASSEMBLY
5. OUTER DOOR HANDLE
Figure 93 Outer Door Handle and Control Rods
4. Press in the locking tab and slide the hanger support bracket to the left and out of the window run channel.
5. Disconnect the long control rod from the lock lever.
6. Rotate outer door handle and disconnect from the short control rod.
103
REMOVAL AND INSTALLATION OUTER DOOR HANDLE
1. T-SHAPED LOCKING TAB 5. DOOR LOCK CYLINDER LEVER

2. HANGER SUPPORT BRACKET 6. DOOR LOCK CONTROL ROD
3. OUTER DOOR HANDLE 7. SHORT CONTROL ROD
4. DOOR LOCK CYLINDER
Figure 94 Outer Door Handle and Hanger Support Bracket
7. Rotate hanger support bracket counterclockwise. Align the slot in the hanger support bracket with the
T-shaped locking tab and remove outer door handle.
8. Remove door lock cylinder (See Door Lock Cylinder, page 94).
9. Remove door lock control rod from door lock cylinder lever.
10. Remove door lock cylinder lever from outer door handle.
Outer Door Handle – Installation
1. Install door lock cylinder lever on outer door handle (Figure 94, Items 3 and 5).
2. Install door lock control rod into door lock cylinder lever (Figure 94, Items 5 and 6).
3. Install door lock cylinder (See Door Lock Cylinder, page 94).
4. Attach the outer door handle by aligning the slot in the hanger support bracket with the T-shaped locking
tab and rotate hanger support bracket clockwise (Figure 94, Items 1, 2, and 3).
104
DOOR LATCH REMOVAL AND INSTALLATION
5. Connect the short control rod to the top of outer door handle. Rotate outer door handle to position it on the
control rod properly (Figure 93, Items 3 and 5).
6. Connect the long control rod to the lock lever (Figure 93, Items 2 and 4).
7. Slide the hanger support bracket in place on the window run channel and ensure the locking tab locks in
place (Figure 93, Items 6, 7, and 8).
8. Install modular door hardware assembly (See Modular Door Hardware Assembly, page 87).
2.26. DOOR LATCH

Door Latch – Removal
1. WINDOW RUN CHANNEL 5. UPPER CONTROL ROD

2. DOOR LATCH 6. LOCKING TAB
3. HANGER SUPPORT BRACKET 7. MODULAR DOOR HARDWARE
4. LOWER CONTROL ROD ASSEMBLY
Figure 95 Door Latch and Control Rods
4. Press in the locking tab and slide the hanger support bracket to the left and out of the window run channel.
5. Disconnect upper and lower control rods from door latch and remove door latch.
105
REMOVAL AND INSTALLATION INNER DOOR HANDLE
Door Latch – Installation
1. Connect upper and lower control rods to door latch (Figure 95, Items 2, 4, and 5).
2. Slide the hanger support bracket in place on the window run channel and ensure the locking tab locks in
2.27. INNER DOOR HANDLE

Inner Door Handle – Removal
NOTE –
• Removal procedures on passenger side and driver side are the same
• Raise cab door glass to the top before removing trim panel.
1. Lift glass to the top and secure it in position.
1. DOOR HANDLE BOLT 3. MODULAR DOOR HARDWARE

2. DOOR HANDLE RETAINING TAB ASSEMBLY
4. INNER DOOR HANDLE
Figure 96 Inner Door Handle
4. Remove door handle bolt from inner door handle.
106
INNER DOOR HANDLE REMOVAL AND INSTALLATION
5. Slide inner door handle to the left and pull door handle retaining tabs out of the modular door hardware
assembly.
1. DOOR HANDLE RETAINING TAB 5. LOWER CONTROL ROD

2. RETAINING CLIP 6. INNER DOOR HANDLE
3. SPRING 7. MODULAR DOOR HARDWARE
4. UPPER CONTROL ROD ASSEMBLY
Figure 97 Inner Cab Door Handle and Control Rods
6. Disconnect inner door handle from upper and lower control rods by rotating it counterclockwise 90 degrees
and pulling to the right.
7. Remove inner door handle.
NOTE – If modular door hardware assembly has been removed, perform the following steps:
8. Remove outer door handle (See Outer Door Handle, page 102).
9. Remove door latch (See Door Latch, page 105).
10. Remove upper and lower control rods, spring, and retaining clip.
11. Remove inner door handle.
Inner Door Handle – Installation
1. Install inner door handle and connect upper and lower control rods (Figure 97, Items 4, 5, and 6).
107
REMOVAL AND INSTALLATION WINDOW RUN CHANNELS
2. Rotate inner door handle 90 degrees clockwise to secure control rods to inner door handle (Figure 97,
Item 6).
3. Insert door handle retaining tabs into the slots in the modular door hardware assembly and slide inner door
4. Install door handle bolt (Figure 96, Item 1). Tighten bolt to 8 to 10 N•m (71 to 89 Lbf-in.).
NOTE – If modular door hardware assembly has been already been removed, follow the next steps.
7. Install upper and lower control rods, spring, and retaining clip (Figure 97).
8. Install inner door handle and connect upper and lower control rods (Figure 97, Items 4, 5, and 6).
9. Rotate inner door handle 90 degrees clockwise to secure control rods to inner door handle.
10. Insert door handle retaining tabs into the slots in the modular door hardware assembly and slide inner door
11. Install door handle bolt (Figure 96, Item 1). Tighten bolt to 8 to 10 N•m (71 to 90 Lbf-in.).
12. Install door latch (See Door Latch, page 105).
13. Install outer door handle (See Outer Door Handle, page 102).
2.28. WINDOW RUN CHANNELS

Window Run Channels – Removal
108
WINDOW RUN CHANNELS REMOVAL AND INSTALLATION
1. DOOR LATCH 4. OUTER DOOR HANDLE

2. DOOR LATCH BRACKET 5. LOCKING TAB
3. OUTER DOOR HANDLE 6. WINDOW RUN CHANNEL
BRACKET 7. LOCKING TAB
Figure 98 Window Run Channel and Brackets
4. Remove outer door handle by pressing the locking tab in and sliding the outer door handle bracket out of
the window run channel.
5. Remove door latch by pressing the locking tab in and sliding the door latch bracket out of the window
run channel.
109
REMOVAL AND INSTALLATION WINDOW RUN CHANNELS
1. WINDOW RUN CHANNEL 3. MODULAR DOOR HARDWARE

2. LOCKING TAB ASSEMBLY
Figure 99 Window Run Channels
6. Depress locking tabs at the top and bottom of the window run channels.
7. Slide window run channels out of the modular door hardware assembly and remove.
Window Run Channels – Installation
1. Install window run channels into modular door hardware assembly. Slide into place and ensure locking
tabs lock in place (Figure 99).
2. Install door latch by sliding the door latch bracket into the window run channel. Ensure locking tabs
lock in place (Figure 98).
3. Install outer door handle by sliding the outer door handle bracket into the window run channel. Ensure
locking tabs lock in place (Figure 98).
110
ELECTRIC WINDOW AND DOOR LOCK SWITCH REMOVAL AND INSTALLATION
2.29. ELECTRIC WINDOW AND DOOR LOCK SWITCH

Electric Window And Door Lock Switch – Removal
1. UNIVERSAL DIN REMOVAL 4. SPRING RETAINING CLIP

TOOL 5. ELECTRIC WINDOW AND DOOR
2. SWITCH BUTTON LOCK SWITCH
3. TRIM PANEL 6. ELECTRICAL CONNECTOR
Figure 100 Electric Window and Door Lock Switch
1. Insert universal DIN removal tools into electric window and door lock switch at a slight angle toward
the switch buttons.
2. Pull removal tools out and away from the switch buttons to release the spring retaining clips.
3. Lift the electric window and door lock switch up from the door trim panel and disconnect electrical
connectors.
4. Remove electric window and door lock switch and removal tools.
111
REMOVAL AND INSTALLATION ELECTRIC MIRROR SWITCH
Electric Window And Door Lock Switch – Installation
1. Connect electrical connectors to electric window and door lock switch (Figure 100, Items 5 and 6).
2. Push electric window and door lock switch down into door trim panel until spring retaining clips lock in
2.30. ELECTRIC MIRROR SWITCH

Electric Mirror Switch – Removal
1. ELECTRIC MIRROR SWITCH 3. DOOR TRIM PANEL

2. ELECTRIC WINDOW AND DOOR 4. RETAINING TAB
LOCK SWITCH 5. ELECTRICAL CONNECTOR
Figure 101 Electric Mirror Switch
1. Using a flat-blade screwdriver, carefully pry electric mirror switch out of the door trim panel.
2. Disconnect electrical connector and remove electric mirror switch.
112
WEATHER SEALS REMOVAL AND INSTALLATION
Electric Mirror Switch – Installation
1. Connect electrical connector to electric mirror switch (Figure 101, Items 1 and 5).
2. Push electric mirror switch down into door trim panel until retaining tabs lock in place (Figure 101, Items 1,
3, and 4).
2.31. WEATHER SEALS

Weather Seals – Removal
1. SECONDARY WEATHER SEAL 3. PRIMARY WEATHER SEAL

2. WEATHER SEAL FLANGE
Figure 102 Weather Seals
2. Remove primary weather seal by carefully pulling off of the weather seal flange.
3. Remove secondary weather seal by carefully pulling off of the weather seal flange.
Weather Seals – Installation
1. Install secondary weather seal onto weather seal flange by pressing into place until seated (Figure 102,
Items 1 and 2).
113
REMOVAL AND INSTALLATION SCUFF PLATE AND SEAT BELT RETRACTOR COVER
2. Install primary weather seal onto weather seal flange by pressing into place until seated (Figure 102,
Items 2 and 3).
2.32. SCUFF PLATE AND SEAT BELT RETRACTOR COVER

Scuff Plate and Seat Belt Retractor Cover – Removal
1. SCREW 4. SEAT BELT RETRACTOR

2. PUSH-IN FASTENER ASSEMBLY
3. SEAT BELT RETRACTOR COVER 5. SCUFF PLATE
Figure 103 Scuff Plate and Seat Belt Retractor Cover
1. Remove four screws and scuff plate.
2. Remove push-in fastener securing seat belt retractor cover to seat belt retractor assembly.
3. Remove seat belt retractor cover.
Scuff Plate and Seat Belt Retractor Cover – Installation
1. Install scuff plate and secure with four screws (Figure 103, Items 1 and 5). Tighten screws to 2 to 3
N•m (20 to 25 Lbf-in.).
2. Install seat belt retractor cover over seat belt retractor assembly and secure with push-in fastener (Figure
103, Items 2, 3, and 4).
114
SUNSHADE REMOVAL AND INSTALLATION
2.33. SUNSHADE
Sunshade – Removal
1. MOUNTING BRACKET 5. MOUNTING BOLTS

2. ELECTRICAL CONNECTOR 6. CLEARANCE LIGHT
3. GASKET 7. SCREWS
4. SUNSHADE
Figure 104 Sunshade
1. Remove 6 screws from left, center, and right clearance lights (See Figure 104, page 115).
2. Pull clearance lights partially out of sunshade to expose mounting bolts.
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.
3. Support sunshade, and remove three mounting bolts from mounting bracket (See Figure 104, page 115).
4. Disconnect electrical connector, and remove sunshade.
Sunshade – Installation
1. Apply Loctite® Blue 242 to mounting bolts.
2. Connect cab electrical cable to sunshade electrical connector (See Figure 104, page 115).
115
REMOVAL AND INSTALLATION SUN VISOR AND CLIP
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.
3. Install sunshade and three new gaskets on mounting bracket with three mounting bolts (See Figure 104,
page 115). 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 104, page 115).
Tighten screws to 2 to 3 N•m (20 to 25 Lbf-in).
2.34. SUN VISOR AND CLIP

Sun Visor and Clip – Removal
1. HEADER CONSOLE PANEL 4. SUN VISOR

2. CLIP 5. SCREW
3. CLIP SCREW
Figure 105 Sun Visor and Clip
1. Remove three screws securing sun visor to the header console panel and remove the sun visor.
NOTE – If the sun visor does not come off, drop the corner of the header console panel down far enough
to remove the retaining washer from the sun visor.
2. Remove the clip screw and clip.
Sun Visor and Clip – Installation
1. Install the clip and secure with clip screw (Figure 105, Items 2 and 3). Tighten screw to 2 to 3 N•m (20 to
25 Lbf-in.).
2. Install sun visor and secure with three screws (Figure 105, Items 4 and 5). Tighten screws to 2 to 3
N•m (20 to 25 Lbf-in.).
116
IGNITION SWITCH AND IGNITION SWITCH CYLINDER REMOVAL AND INSTALLATION
2.35. IGNITION SWITCH AND IGNITION SWITCH CYLINDER

The ignition switch and door locks are coded the same; one key operates both the ignition switch and the door
locks. A plastic bag (kept with the vehicle) is stamped and barcoded with the ignition switch and door lock
cylinder code numbers. This plastic bag is to remain with the vehicle when it is delivered to the customer.
It is very important that this plastic bag (with the code numbers) be kept by the customer in a safe, secure
place for key replacement.
NOTE – The code numbers do not appear on the ignition switch body or the door lock assembly.
Ignition Switch – Removal
1. INSTRUMENT PANEL 3. RUBBER TRIM

2. IGNITION SWITCH 4. NUT
Figure 106 Ignition Switch Trim and Nut
1. Remove nut with a 1-1/8 inch thin-wall socket.
117
REMOVAL AND INSTALLATION IGNITION SWITCH AND IGNITION SWITCH CYLINDER
1. IGNITION SWITCH ELECTRICAL 2. IGNITION SWITCH

CONNECTOR
Figure 107 Ignition Switch and Electrical Connector
2. Push ignition switch through instrument panel and disconnect electrical connector.
3. Remove ignition switch.
Ignition Switch – Installation
1. Connect ignition switch electrical connector to ignition switch (Figure 107).
2. Insert ignition switch through instrument panel (Figure 106, Items 1 and 2).
3. Install nut and tighten with a 1-1/8 inch-thin wall socket (Figure 106, Item 4).
118
IGNITION SWITCH AND IGNITION SWITCH CYLINDER REMOVAL AND INSTALLATION
Ignition Switch Cylinder – Removal
1. RELEASE HOLE 3. IGNITION KEY

2. IGNITION SWITCH 4. IGNITION SWITCH BODY
Figure 108 Ignition Switch Assembly
1. Insert ignition key into ignition switch and rotate key counterclockwise to the ACCESSORY position. This
aligns the key with the release hole.
119
REMOVAL AND INSTALLATION IGNITION SWITCH AND IGNITION SWITCH CYLINDER
1. IGNITION KEY 4. VISE

2. IGNITION SWITCH CYLINDER 5. RELEASE HOLE
3. ROD 6. IGNITION SWITCH BODY
Figure 109 Ignition Switch Cylinder and Body
2. Support ignition switch assembly in a vise with soft jaws.
3. Insert a 2 mm (1/16 in.) diameter rod (paper clip will work) into release hole and depress.
4. Remove ignition switch cylinder from ignition switch body using ignition key and pulling straight out.
NOTE – If vehicle keys are lost, drill out the ignition switch cylinder by using an 8 mm (5/16 in.) drill bit
and drill 13 to 19 mm (1/2 to 3/4 in.) deep. This will permit the tumblers to drop out and allow switch
ignition cylinder removal.
Ignition Switch Cylinder – Installation
NOTE – If the original key is desired when replacing the ignition switch cylinder, code the new ignition
switch using the following steps.
1. Insert the original ignition key in the new ignition switch cylinder (Figure 109, Items 1 and 2).
2. File off any tumblers that protrude from the ignition switch cylinder. Ensure no burrs are left on the
tumblers. Remove the ignition key and blow all filings out with compressed air.
3. Apply a small quantity of powdered graphite to the tumblers and reinsert ignition key into the new ignition
switch cylinder (Figure 109, Items 1 and 2).
120
INSTRUMENT PANEL REMOVAL AND INSTALLATION
4. Rotate ignition key and ignition switch cylinder counterclockwise to the ACCESSORY position (Figure 109,
Items 1 and 2).
5. Insert ignition switch cylinder back into ignition switch body, turn ignition key to OFF position, and remove
ignition key (Figure 108).
2.36. INSTRUMENT PANEL

Gauge Cluster – Removal
NOTE – Always disconnect battery ground before servicing or removing gauge cluster.
1. SHIELD 5. 12-PIN ELECTRICAL

2. RETAINING CLIP CONNECTOR
3. SCREW 6. BACK PLATE
4. GAUGE CLUSTER
Figure 110 Gauge Cluster
1. Remove the shield from the gauge cluster by gently pressing in the seven retaining clips.
2. Remove four screws securing gauge cluster to back plate.
3. Tilt the gauge cluster forward and disconnect the 12-pin electrical connector.
4. Disconnect any remaining auxiliary electrical connectors.
5. Remove the gauge cluster.
121
REMOVAL AND INSTALLATION INSTRUMENT PANEL
Gauge Cluster – Installation
1. Install gauge cluster (Figure 110, Item 4).
2. Connect any auxiliary electrical connectors.
3. Connect the 12-pin electrical connector (Figure 110, Item 5).
4. Install four screws securing gauge cluster to gauge cluster back plate (Figure 110, Items 3, 4, and 6).
Tighten screws to 2 to 3 N•m (20 to 25 Lbf-in.).
5. Install shield to gauge cluster by gently pressing in place until retaining clips snap in place (Figure 110,
Items 1, 2, and 4).
Instrument Panel – Removal
NOTE – Always disconnect battery ground before servicing or removing instrument panel.

PANEL 3. BOLT
1. Remove two bolts from grab handle and remove grab handle.
122

2. CAB A-PILLAR
TRIM PANEL
4. Disconnect ignition switch electrical connector (not shown).
5. Remove courtesy lights (not shown) under the instrument panel.
123
1. BOLT 3. CENTER INSTRUMENT PANEL

2. CENTER INSTRUMENT PANEL
TRIM BEZEL
Figure 113 Instrument Panel
6. Carefully pry the center instrument panel trim bezel out of the center instrument panel.
7. Remove six bolts from the center instrument panel.
8. Remove two steering column bolts (not shown).
9. Remove four air brake control mounting bolts and air brake control (not shown).
124
1. UPPER INSTRUMENT PANEL 3. INSTRUMENT PANEL

BOLT 4. FUSE PANEL COVER
2. LOWER INSTRUMENT PANEL
BOLT
Figure 114 Instrument Panel
10. If equipped with automatic transmission shifter, remove two mounting bracket bolts and remove shifter
(not shown).
11. Remove two lower instrument panel bolts from each side of the lower instrument panel.
12. Remove five upper instrument panel bolts from the front edge of the upper instrument panel.
13. Pull the fuse panel cover away from instrument panel, lift up, and remove.
NOTE – Tag and mark all electrical connectors before disconnecting.
14. Lift instrument panel forward and upward slightly and disconnect all electrical connectors and air ducts.
15. Remove instrument panel.
Instrument Panel – Installation
1. Install instrument panel (Figure 114, Item 3).
2. Connect all electrical connectors and air ducts.
3. Install the fuse panel cover (Figure 114, Item 4).
4. Install five upper instrument panel bolts through the front edge of the instrument panel (Figure 114, Items 1
and 3). Tighten bolts to 10 to 12 N•m (84 to 106 Lbf-in.).
5. Install two lower instrument panel bolts into each side of the instrument panel (Figure 114, Items 2 and
3). Tighten bolts to 22 to 26 N•m (16 to 19 Lbf-ft).
6. If equipped with automatic transmission shifter, install shifter with two mounting bracket bolts (not shown).
Tighten bolts to 20 to 24 N•m (15 to 18 Lbf-ft).
125
7. Install six bolts into the center instrument panel (Figure 113, Items 1 and 2).
8. Carefully snap the center instrument panel trim bezel into the center instrument panel (Figure 113,
Items 2 and 3).
9. Install courtesy lights (not shown) under the instrument panel.
10. Connect ignition switch electrical connector (not shown).
to 11 N•m (77 to 95 Lbf-in.).
14. Reconnect battery ground after servicing or installing instrument panel.
126
FRONT SEATS REMOVAL AND INSTALLATION
2.37. FRONT SEATS

Front Seats – Removal
NOTE – Removal procedures show passenger side; driver side procedures are the same.
1. QUICK DISCONNECT 5. SEAT BELT MOUNTING

CONNECTOR BRACKET
2. AIR LINE 6. BOLT
3. NUT, WASHER, AND MOUNTING 7. OUTER SEAT BELT
STUD 8. BUCKET SEAT
4. INNER SEAT BELT
Figure 115 Bucket Seat
1. Remove bolt and outer seat belt from seat belt mounting bracket.
2. Remove bolt and inner seat belt from seat belt mounting bracket.
3. If equipped, disconnect air line at the quick disconnect connector.
4. Remove four nuts and washers from mounting studs.
127
REMOVAL AND INSTALLATION FRONT SEATS
5. With the aid of an assistant, lift bucket seat off mounting studs and remove.
Front Seats – Installation
NOTE – Use all new mounting hardware when installing seats to ensure proper torque requirements can
be met.
NOTE – Installation procedures show passenger side; driver side procedures are the same.
1. With the aid of an assistant, install bucket seat and set in place on mounting studs (Figure 115, Items 3
and 8).
2. Install four nuts and washers (Figure 115, Item 3). Tighten nuts to 20 to 27 N•m (15 to 20 Lbf-ft).
3. If equipped, connect air line at the quick disconnect connector (Figure 115, Items 1 and 2).
4. Install inner seat belt and secure to seat belt mounting bracket with bolt (Figure 115, Items 4, 5, and
6). Tighten bolt to 34 to 41 N•m (25 to 30 Lbf-ft).
5. Install outer seat belt and secure to seat belt mounting bracket with bolt (Figure 115, Items 5, 6, and
7). Tighten bolt to 34 to 41 N•m (25 to 30 Lbf-ft).
128
REAR BENCH SEAT REMOVAL AND INSTALLATION
2.38. REAR BENCH SEAT

Rear Bench Seat – Removal
1. NUT WITH WASHER 3. MOUNTING STUDS

2. REAR BENCH SEAT 4. SEAT BELT
Figure 116 Rear Bench Seat
1. Remove four nuts with washers from mounting studs.
2. Pull seat belts through upper and lower seat.
3. With the aid of an assistant, lift rear bench seat off mounting studs and remove.
Rear Bench Seat – Installation
NOTE – Use all new mounting hardware when installing seats to ensure proper torque requirements can
be met.
1. With the aid of an assistant, install rear bench seat and set in place on mounting studs (Figure 116,
Items 2 and 3).
129
REMOVAL AND INSTALLATION CORNER AND SIDE INTERIOR TRIM PANEL
2. Install four nuts with washers (Figure 116, Item 1). Tighten nuts to 20 to 24 N•m (15 to 18 Lbf-ft).
3. Push seat belts through from backside of upper and lower seat and pull through to the front side (Figure
116, Item 4).
2.39. CORNER AND SIDE INTERIOR TRIM PANEL

Corner and Side Interior Trim Panel – Removal
2. Remove the front seats (See Front Seats, page 127).
1. PUSH-IN FASTENER 4. CORNER AND SIDE INTERIOR

2. SHOULDER BELT TRIM PANEL
3. BOLT
Figure 117 Corner and Side Interior Trim Panel
4. Remove bolt securing the shoulder belt.
5. Remove push-in fasteners using the ZTSE4839 interior trim tool.
6. Remove corner and side interior trim panel.
Corner and Side Interior Trim Panel – Installation
1. Install corner and side interior trim panel and secure with the push-in fasteners (Figure 117, Items 1 and 4).
2. Install shoulder belt and secure with bolt (Figure 117, Items 2 and 3). Tighten bolt to 27 to 34 N•m (20 to
25 Lbf-ft).
130
REAR INTERIOR TRIM PANEL REMOVAL AND INSTALLATION
5. Install the front seats (See Front Seats, page 127).
2.40. REAR INTERIOR TRIM PANEL

Rear Interior Trim Panel – Removal
1. Remove either corner and side interior trim panels (See Corner and Side Interior Trim Panel, page 130).
1. REAR INTERIOR TRIM PANEL 2. PUSH-IN FASTENER

Figure 118 Rear Interior Trim Panel
2. Remove push-in fasteners using the ZTSE4839 interior trim tool.
3. Remove rear interior trim panel.
Rear Interior Trim Panel – Installation
NOTE – The following procedure describes installing both driver and passenger side corner and side
interior trim panels after installing rear interior trim panel. If one of the corner and side interior trim
panels was not removed during the removal step, then only the side and corner interior trim panel that
was removed needs to be installed.
1. Install rear interior trim panel and secure with push-in fasteners (Figure 118).
2. Ensure floor mat is properly fitted around rear interior trim panel at the bottom.
3. Install both corner and side interior trim panels (See Corner and Side Interior Trim Panel, page 130).
131
REMOVAL AND INSTALLATION HEADER CONSOLE PANEL
2.41. HEADER CONSOLE PANEL

Header Console Panel – Removal

PANEL 3. BOLT
1. Remove two bolts from grab handle and remove handle.
132
HEADER CONSOLE PANEL REMOVAL AND INSTALLATION

2. CAB A-PILLAR
TRIM PANEL
4. Remove sun visor and clip (See Sun Visor and Clip, page 116).
133
REMOVAL AND INSTALLATION HEADER CONSOLE PANEL
1. WIRING HARNESS 4. SPEAKER

2. COURTESY LIGHT SCREW 5. SCREW
3. COURTESY LIGHT ELECTRICAL 6. COURTESY LIGHT
CONNECTOR 7. HEADER CONSOLE PANEL
Figure 121 Header Console Panel
5. Pull courtesy light slightly out of header console panel to expose wiring.
6. Disconnect courtesy light electrical connector from wiring harness and remove.
7. Remove two courtesy light screws inside courtesy light cavity.
8. Remove two screws from each side of header console panel near the speakers.
9. Release the header console panel by pulling down and out.
10. Lower header console panel down and lay it across the instrument panel.
134
HEADER CONSOLE PANEL REMOVAL AND INSTALLATION
1. CONTROL PANEL ELECTRICAL 5. SPEAKER ELECTRICAL

CONNECTOR CONNECTOR
2. CONTROL PANEL 6. HEADER CONSOLE PANEL
3. RETAINING CLIP WITH WIRE TIE 7. PASSENGER SIDE SPEAKER
4. WIRING HARNESS 8. DRIVER SIDE SPEAKER
Figure 122 Header Console Panel Electrical Connections
11. Disconnect control panel electrical connector from control panel, if equipped.
12. Disconnect speaker electrical connectors from driver and passenger speakers.
13. If equipped, pull off six retaining clips with wire ties securing the wiring harness to the header console panel.
14. Remove header console panel.
135
REMOVAL AND INSTALLATION HEADLINER TRIM PANEL (STANDARD CAB)
Header Console Panel – Installation
1. Install six retaining clips with wire ties securing the wiring harness to the header console panel (Figure
122, Items 3, 4, and 6).
2. Connect driver and passenger side speaker electrical connectors to speakers (Figure 122, Items 5,
7, and 8).
3. Connect control panel electrical connector to control panel, if equipped (Figure 122, Items 1 and 2).
4. Install header console panel by pushing up into place until it snaps in place (Figure 121, Item 7).
5. Install two screws to each side of header console panel near the speakers (Figure 121, Items 4, 5, and 7).
6. Install two courtesy light screws inside cavity for courtesy light (Figure 121, Items 2 and 6). Tighten
screws to 2 to 3 N•m (20 to 25 Lbf-in).
7. Connect courtesy light electrical connector to wiring harness (Figure 121, Items 1 and 3).
8. Push courtesy light into header console panel until it snaps into place (Figure 121, Items 6 and 7).
9. Install sun visor and clip (See Sun Visor and Clip, page 116).
to 11 N•m (77 to 95 Lbf-in.).
2.42. HEADLINER TRIM PANEL (STANDARD CAB)

Headliner Trim Panel (Standard Cab) – Removal
1. Remove header console panel (See Header Console Panel, page 132).
136
HEADLINER TRIM PANEL (STANDARD CAB) REMOVAL AND INSTALLATION
1. COAT HOOK 5. PUSH-IN FASTENER

2. COAT HOOK LEVER COVER 6. A-PILLAR
3. COAT HOOK LEVER 7. CORNER AND SIDE INTERIOR
4. HEADLINER TRIM PANEL TRIM PANEL
Figure 123 Headliner Trim Panel on Standard Cab Models
NOTE –
• Use the ZTSE4839 interior trim tool to remove all push-in interior fasteners.
• Passenger side and driver side procedures are the same.
2. Pull coat hook lever cover down.
3. Push coat hook lever down and remove coat hook.
4. Remove two push-in fasteners at the top of each corner and side interior trim panel.
5. Remove two push-in fasteners at the rear of the headliner trim panel.
6. Remove one push-in fastener each in headliner trim panel near each A-pillar above door opening.
7. Remove one push-in fastener from front, center of the headliner trim panel. Support the front of the
headliner trim panel after removing push-in fastener.
137
REMOVAL AND INSTALLATION HEADLINER TRIM PANEL (EXTENDED CAB)
8. Lower the front of the headliner trim panel and slide forward. Carefully pull the headliner trim panel out
from behind corner and side interior trim panels and remove.
Headliner Trim Panel (Standard Cab) – Installation
NOTE – Passenger side and driver side procedures are the same.
1. Insert headliner trim panel in place behind corner and side interior trim panels (Figure 123, Items 4 and 7).
2. Lift up the front, center of the headliner trim panel and install one push-in fastener (Figure 123, Items 4
and 5).
3. Install one push-in fastener each in headliner trim panel near each A-pillar above door opening (Figure
123, Items 4, 5, and 6).
4. Install two push-in fasteners at the rear of the headliner trim panel (Figure 123, Items 4 and 5).
5. Install two push-in fasteners at the top of each corner and side interior trim panel (Figure 123, Items 5
and 7).
6. Install coat hook and press in until it snaps in place (Figure 123, Item 1).
7. Push coat hook lever cover up and press until it snaps in place (Figure 123, Item 2).
8. Install header console panel (See Header Console Panel, page 132).
2.43. HEADLINER TRIM PANEL (EXTENDED CAB)

Headliner Trim Panel (Extended Cab) Front – Removal
1. Remove header console panel (See Header Console Panel, page 132).
138
HEADLINER TRIM PANEL (EXTENDED CAB) REMOVAL AND INSTALLATION
1. CAB HEADER 4. PUSH-IN FASTENER

2. FRONT HEADLINER TRIM 5. CORNER AND SIDE INTERIOR
PANEL TRIM PANEL
3. REAR HEADLINER TRIM PANEL
Figure 124 Headliner Trim Panel, Extended Cab, Front
NOTE – Use the ZTSE4839 interior trim tool to remove all push-in interior fasteners.
2. Remove two push-in fasteners at the top of each corner and side interior trim panel.
3. Remove five push-in fasteners from the back of the front headliner trim panel where both headliners join.
4. Remove one push-in fastener from front, center of the headliner trim panel. Support the front of the front
headliner trim panel after removing push-in fastener.
5. Lower the front of the front headliner trim panel and slide forward.
6. Carefully pull the headliner trim panel out from underneath rear headliner trim panel and remove.
139
Headliner Trim Panel (Extended Cab) Front – Installation
1. Slide back edge of front headliner trim panel in place over the top of the rear headliner trim panel (Figure
124, Items 2 and 3).
2. Lift up the front, center of the front headliner trim panel and install one push-in fastener through trim panel
and into cab header (Figure 124, Items 1, 2, and 4).
3. Install five push-in fasteners into the back of the front headliner trim panel where both headliners join
(Figure 124, Items 2, 3, and 4).
4. Install two push-in fasteners into the top of each corner and side interior trim panel (Figure 124, Items 4
and 5).
5. Install header console panel (See Header Console Panel, page 132).
140
HEADLINER TRIM PANEL (EXTENDED CAB) REMOVAL AND INSTALLATION
Headliner Trim Panel (Extended Cab) Rear – Removal
1. COAT HOOK 5. PUSH-IN FASTENER

2. COAT HOOK LEVER COVER 6. CORNER AND SIDE INTERIOR
3. COAT HOOK LEVER TRIM PANEL
4. REAR HEADLINER TRIM PANEL
Figure 125 Headliner Trim Panel, Extended Cab, Rear
NOTE –
• Use the ZTSE4839 interior trim tool to remove all push-in interior fasteners.
• Passenger side and driver side procedures are the same.
1. Pull coat hook lever cover down.
2. Push coat hook lever down and remove coat hook.
3. Remove four push-in fasteners at the top of each corner and side interior trim panel.
4. Remove two push-in fasteners at the back of rear headliner trim panel.
141
1. CAB HEADER 4. COURTESY LIGHT ELECTRICAL

2. FRONT HEADLINER TRIM CONNECTOR
PANEL 5. REAR HEADLINER TRIM PANEL
3. COURTESY LIGHT 6. PUSH-IN FASTENER
Figure 126 Headliner Trim Panel, Extended Cab, Rear
5. Remove five push-in fasteners securing front headliner trim panel and rear headliner trim panel.
6. Slide front of rear headliner trim panel forward and carefully pull out from behind corner and side interior
trim panels.
7. Lower rear headliner trim panel down and disconnect electrical connector from courtesy light.
8. Remove rear headliner trim panel.
Headliner Trim Panel (Extended Cab) Rear – Installation
NOTE – Passenger side and driver side procedures are the same.
1. Connect electrical connector to courtesy light (Figure 126, Items 3 and 4).
2. Slide rear headliner trim panel into place between corner and side interior trim panels (Figure 125,
Items 4 and 6).
3. Install five push-in fasteners through rear headliner trim panel and front headliner trim panel into the
cab header (Figure 126).
4. Install two push-in fasteners into the back of rear headliner trim panel (Figure 125, Items 4 and 5).
142
ENGINE COVER AND CUP HOLDER REMOVAL AND INSTALLATION
5. Install four push-in fasteners into the top of each corner and side interior trim panel (Figure 125, Items 5
and 6).
6. Install coat hook and press in until it snaps in place (Figure 125, Item 1).
7. Push coat hook lever cover up and press until it snaps in place (Figure 125, Item 2).
2.44. ENGINE COVER AND CUP HOLDER

Cup Holder and Ashtray – Removal
1. CENTER INSTRUMENT PANEL 3. CUP HOLDER

TRIM BEZEL 4. ASHTRAY
2. SCREW 5. CENTER INSTRUMENT PANEL
Figure 127 Cup Holder and Ashtray
1. Using a flat-blade screwdriver, carefully pry the center instrument panel trim bezel out of the center
instrument panel.
2. Remove ashtray from cup holder by lifting ashtray out of cup holder.
3. Remove two screws securing cup holder.
4. Push cup holder rearward to disengage from underside of center instrument panel.
5. Remove cup holder.

Cup Holder and Ashtray – Installation
1. Pull cup holder forward to engage the underside of the center instrument panel (Figure 127, Items 3 and 5).
2. Install two screws through the center instrument panel into the cup holder (Figure 127, Items 2, 3, and 5).
3. Carefully push center instrument panel trim bezel in until it snaps into place (Figure 127, Item 1).
143
REMOVAL AND INSTALLATION CAB
4. Slide ashtray into cup holder (Figure 127, Items 3 and 4).
Engine Cover – Removal
1. ENGINE COVER 2. BOLT

Figure 128 Engine Cover
1. Remove the front seats (See Front Seats, page 127).
2. Remove eight bolts from engine cover as shown.
3. Slide engine cover out and remove.
Engine Cover – Installation
1. Install engine cover with eight bolts as shown and finger-tighten only (Figure 128). Tighten bolts to 9
to 11 N•m (77 to 95 Lbf-in.).
2. Install the front seats (See Front Seats, page 127).
2.45. CAB
Initial Procedures Before Cab Removal
The removal of the cab from the chassis can be performed using an overhead crane and cab lifting fixture.
Removal procedures may vary for various models, depending on the type of equipment and accessories.
144
CAB REMOVAL AND INSTALLATION
WARNING
To prevent personal injury or death when working on or near a vehicle, the following
general precautions should be observed:
• Park the vehicle on a level surface, apply the parking brakes, and always block the
wheels.
• Stop the engine when working around the vehicle.
• Drain the air pressure from all reservoirs before beginning any work on the vehicle.
• Never connect or disconnect a hose or line containing pressure; it may whip. Never
remove a component or plug, unless you are certain all system pressure has been
released.
• Never exceed recommended pressures and always wear safety glasses.
• Do not attempt to install, remove, disassemble, or assemble a component until you have
read and thoroughly understand the recommended procedures. Use only the proper
tools and observe all precautions pertaining to use of those tools.
• Prior to returning the vehicle to service, make certain all components and systems are
restored to their proper operating condition.
• Always turn the ignition key to the OFF position before disconnecting any of the antilock
wiring or connectors. If the key is not off, the EC-15 controller will record the power
interruption as a static fault.
The following steps may be used as a guide:
1. Block wheels of truck and engage parking brake.
2. Tilt or remove hood.
WARNING
To prevent personal injury or death, always disconnect power source before working on
electrical equipment.
3. Disconnect battery ground cable.
WARNING
To prevent personal injury or death, allow the engine to cool down before removing the
pressure cap from the deaeration tank. Always insulate the cap by wrapping it with a
thick, heavy cloth.
145
WARNING
To prevent personal injury or death from scalding water or steam, do not pull the pressure
cap off immediately when it has been loosened to the first notch. Pause momentarily to
allow time for excess pressure to release through the overflow tube.
4. Drain cooling system and disconnect heater hose.
5. Disconnect steering shaft at gear.
6. Disconnect accelerator linkage and cruise control, if so equipped.
7. Disconnect electrical connections and ground wire.
8. Disconnect clutch linkage.
WARNING
To prevent personal injury or death, before any component is serviced or removed from
the air system, be sure the air system is drained.
9. Disconnect brake system (air or hydraulic).
WARNING
To prevent personal injury or death, 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 may cause personal injury or
death.
WARNING
To prevent personal injury or death, 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
To prevent personal injury or death, 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 is required by law.
10. Disconnect air conditioning lines (if so equipped). Refer to HVAC service manual (S16053).
11. Remove shift lever from transmission.
146
12. Detach exhaust system from cab if system is vertical type.
13. Detach any other connections between the cab and frame if required.
14. 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.
15. Partially lift cab so cab weight is supported on lifting fixture.
Cab – Removal
NOTE – Removal procedures for driver side and passenger side are the same.
1. NUT 4. CAB CHASSIS MOUNTING

2. FRONT CAB MOUNTING BRACKET
BRACKET 5. FRONT OF VEHICLE
3. STUD
Figure 129 Front Cab Mounting
1. Remove one nut from the stud of the cab chassis mounting bracket.
147
1. CARRIAGE BOLT 5. NUT

2. CAB UNDERBODY SILL 6. REAR OF VEHICLE
3. CAB MOUNT RETAINING CLIP
4. REAR CAB AIR SUSPENSION
ASSEMBLY
Figure 130 Rear Cab Mounting
2. Remove two nuts from the carriage bolts under the top plate of the rear cab air suspension assembly.
CAUTION
To prevent damage to cab, frame, and/or cab/frame components, inspect all cab-to-frame
attaching points to be sure they are disconnected, or damage can result.
NOTE – The carriage bolts are secured to the cab underbody sill with cab mount retaining clips. The
carriage bolts remain with cab underbody sill when cab is lifted off the rear cab air suspension assembly.
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.
Cab – Installation
CAUTION
To prevent damage to cab and/or cab components, do not put all cab weight on chassis
until all mounting bolts are tightened.
148
CAUTION
To prevent damage to cab, frame, and/or cab/frame components, inspect all cab-to-frame
attaching points to be sure they are aligned properly, or damage can result.
CAUTION
To prevent damage to cab, frame, and/or cab/frame components, refer to Cab Squaring
when installing the cab (See CAB SQUARING, page 165)
NOTE – Installation procedures for driver side and passenger side are the same.
NOTE – The installation of the cab onto the chassis can be performed providing an overhead crane and
cab lifting fixture are available. Installation procedures may vary for various models, depending on type
of equipment and accessories.
1. Using an overhead crane and cab lifting fixture, carefully lower cab onto chassis. Align cab with front and
rear mounting locations while lowering.
2. Install two nuts onto the carriage bolts under the top plate of the rear cab air suspension assembly (Figure
130). Tighten nuts to 119 to 144 N•m (88 to 106 Lbf-ft).
3. Install one nut to the stud of the cab chassis mounting bracket (Figure 129, Items 1, 3, and 4). Tighten nut
to 193 to 237 N•m (142 to 175 Lbf-ft).
4. Remove cab lifting fixture.
Final Procedures After Cab Installation
1. Attach exhaust system if it is the vertical type.
2. Attach shift lever to transmission.
3. Connect the following items:
• Connect air conditioning lines (if so equipped). Refer to HVAC service manual (S16053).
• Brake system (air or hydraulic).
• Clutch linkage
• Electric connections and ground wire
• Accelerator linkage
• Steering shaft at gear
• Heater hose
4. Fill cooling system. Refer to coolant package service manual (S12036).
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.
149
REMOVAL AND INSTALLATION REAR CAB AIR SUSPENSION ASSEMBLY
8. Road test vehicle. Be sure all vehicle components are operating properly before putting vehicle back
into service.
2.46. REAR CAB AIR SUSPENSION ASSEMBLY

Rear Cab Air Suspension Assembly – Removal
1. Drain air from the air system.
2. Disconnect the air line to the rear cab air suspension assembly.
4. If equipped, remove seat belt mounting bolts (not shown) securing seat belts to rear cab floor. Lift up floor
mat to access carriage bolts in cab underbody sill.
NOTE – The carriage bolts are secured to the cab underbody sill with cab mount retaining clips. The
carriage bolts remain with cab underbody sill when cab is lifted off the rear cab air suspension assembly.
1. CARRIAGE BOLT 4. REAR CAB AIR SUSPENSION

2. CAB UNDERBODY SILL ASSEMBLY
3. CAB MOUNT RETAINING CLIP 5. NUT
6. REAR OF VEHICLE
Figure 131 Rear Cab Air Suspension Mounting Carriage Bolts
5. Lift up carriage bolts through cab underbody sill and unscrew from cab mount retaining clips.
6. Remove the carriage bolts.
150
REAR CAB AIR SUSPENSION ASSEMBLY REMOVAL AND INSTALLATION
1. BOLT 3. AIR LINE

2. REAR CAB AIR SUSPENSION 4. FRAME RAIL CROSSMEMBER
ASSEMBLY 5. NUT
Figure 132 Rear Cab Air Suspension Assembly
7. Remove four nuts and four bolts securing rear cab air suspension assembly to frame rail crossmember.
8. Place a suitable lifting device between frame and back of cab.
9. Raise cab and remove rear cab air suspension assembly.
Rear Cab Air Suspension Assembly – Installation
1. Install rear cab air suspension assembly (Figure 132, Item 2).
2. Install four nuts and four bolts securing rear cab air suspension assembly to frame rail crossmember
(Figure 132). Tighten nuts to 119 to 144 N•m (88 to 106 Lbf-ft).
3. Connect the air line to the rear cab air suspension assembly (Figure 132, Items 2 and 3).
4. Lower rear of cab onto rear cab air suspension and remove lifting device (Figure 132, Items 2).
5. Install the carriage bolts through the cab floor and cab underbody sill (Figure 131, Items 1 and 2).
6. Screw cab mount retaining clips onto both carriage bolts until they are against the bottom of the cab
underbody sill (Figure 13, Items 1, 2, and 3).
7. Reposition the floor mat and, if equipped, install seat belt mounting bolts securing seat belts to rear
cab floor (not shown).
151
REMOVAL AND INSTALLATION FRONT CAB MOUNTING BUSHINGS
2.47. FRONT CAB MOUNTING BUSHINGS

Front Cab Mounting Bushings – Removal
1. Place a suitable lifting device on the front of cab.
1. FRONT CAB MOUNTING 5. FRONT CAB MOUNTING

BRACKET BUSHING
2. NUT 6. LOWER CAB CHASSIS
3. UPPER CAB CHASSIS MOUNTING BRACKET
MOUNTING BRACKET 7. FRONT OF VEHICLE
4. BOLT
Figure 133 Front Cab Mounting Bushing
NOTE – Removal procedures show passenger side; driver side procedures are the same.
2. Remove nut securing front cab mounting bracket.
3. Raise front of cab far enough for the front cab mounting bracket to clear upper cab chassis mounting
bracket.
4. Remove bolt from upper cab chassis mounting bracket and lower cab chassis mounting bracket.
5. Remove upper cab chassis mounting bracket.
6. Remove front cab mounting bushing from lower cab chassis mounting bracket.
152
FRONT CAB MOUNTING BUSHINGS REMOVAL AND INSTALLATION
Front Cab Mounting Bushings – Installation
NOTE – Installation procedures show driver side; passenger side procedures are the same.
1. Install front cab mounting bushing into lower cab chassis mount bracket (Figure 133, Items 5 and 6).
2. Install upper cab chassis mounting bracket to lower cab chassis mounting bracket and secure with bolt
(Figure 133, Items 3, 4, and 6). Tighten bolt to 119 to 144 N•m (88 to 106 Lbf-ft).
3. Lower front cab mounting bracket down onto upper cab chassis mounting bracket (Figure 133, Items 1
and 3).
4. Secure front cab mounting bracket to upper cab chassis mounting bracket with nut (Figure 133, Items 1, 2,
and 3). Tighten nut to 119 to 144 N•m (88 to 106 Lbf-ft).
5. Remove lifting device on the front of cab.
153
REMOVAL AND INSTALLATION REAR CAB AIR SUSPENSION SYSTEM

Height Control Valve – Removal
WARNING
To prevent personal injury or death, raise cab and block it about 2.54 cm (1 in.) higher
than design height between bottom of cab mounting plate and crossmember mounting
plate.
NOTE – Attempts to disassemble or adjust fittings on the height control valve will void the warranty.
Contact the rear cab air suspension manufacturer for assistance.
1. SUPPLY AIR LINE 6. HEIGHT CONTROL VALVE

2. MOUNTING BOLT 7. LINKAGE
3. AIR SPRING AIR LINE 8. BALL PIVOT
4. MOUNTING BRACKET 9. COMPRESSION NUT
5. LOCKNUT
Figure 134 Height Control Valve
2. Remove supply air line from height control valve.
3. Loosen compression nut and remove air spring air line.
4. Remove linkage from ball pivot.
154
5. Remove two mounting bolts and locknuts from height control valve.
6. Remove height control valve from mounting bracket.
Height Control Valve – Installation
CAUTION
The cab was raised and blocked about 2.54 cm (1 in.) higher than design height between
bottom of cab mounting plate and crossmember mounting plate. Raise cab and remove
block after servicing is complete and before returning the vehicle to service. Failure to
remove the block may result in damage to vehicle components.
NOTE –
• Attempts to disassemble or adjust fittings on the height control valve will void the warranty. Contact
the rear cab air suspension manufacturer for assistance.
• Inspect height control valve for proper alignment. The drive bearing notch on the rear side of drive
bearing must be on the supply side of the valve labeled SUPP. If not, loosen pan head bearing screw,
but do not remove, and pull height control valve arm loose from drive bearing. Rotate drive bearing
until drive bearing notch is in correct position, then secure height control valve lever by tightening
pan head bearing screw. Tighten screw to 5 to 6 N•m (40 to 50 Lbf-in.).
1. Install height control valve on mounting bracket (Figure 134, Items 4 and 6).
2. Install two mounting bolts and locknuts (Figure 134, Items 2 and 5). Tighten locknuts to 11 to 14 N•m (8 to
10 Lbf-ft).
3. Attach linkage to ball pivot (Figure 134, Items 7 and 8).
4. Attach air spring air line and secure with compression nut (Figure 134, Items 3 and 9). Hand-tighten
compression nut and then turn another 450 to 630 degrees.
5. Attach supply air line to the height control valve by pressing firmly in and ensuring it is locked into position
(Figure 134, Items 1 and 6). Pull on supply air line to verify it is locked securely into the height control valve.
6. Build up air pressure and check for air leaks.
7. Check cab ride height (See Rear Cab Air Suspension, page 169).
155
Shock Absorber – Removal
1. CAB MOUNTING PLATE 4. CROSSMEMBER MOUNTING

2. BOLT PLATE
3. SHOCK ABSORBER 5. LOCKNUT
Figure 135 Shock Absorber
WARNING
plate.
NOTE –
• Both front and rear shock absorbers are removed the same way.
• Some models may have a different configuration from that shown. The procedures are the same.
1. Remove two bolts and two locknuts from the shock absorber.
2. Remove shock absorber from between cab mounting plate and crossmember mounting plate.
156
Shock Absorber – Installation
CAUTION
NOTE –
• Both front and rear shock absorbers are removed the same way.
• Some models may have a different configuration from that shown. The procedures are the same.
1. Install shock absorber between cab mounting plate and crossmember mounting plate (Figure 135, Items 1,
3, and 4).
2. Secure the shock absorber with two bolts and two locknuts (Figure 135, Items 2, 3, and 5). Tighten lock
nuts to 54 to 68 N•m (40 to 50 Lbf-ft).
Suspension Air Spring (Bag) – Removal
WARNING
plate.
157
1. AIR LINE 4. RETAINING RING

2. COMPRESSION NUT 5. AIR SPRING (BAG)
3. FITTING 6. SCREW
Figure 136 Suspension Air Spring (Bag)
2. Loosen compression nuts on fittings and disconnect air lines.
3. Unthread fittings from air springs (bags).
NOTE – Retaining rings will be damaged upon removal. New retaining rings are supplied with the new
air springs (bags).
4. Pry retaining rings from top of air springs (bags) and remove.
5. Remove screw from the bottom of each air spring (bag).
6. Compress air springs (bags) and remove.
158
Suspension Air Spring (Bag) – Installation
CAUTION
NOTE – New retaining rings are supplied with the new air springs (bags).
1. Install air springs (bags) and attach new retaining rings to the top (Figure 136, Items 4 and 5).
2. Install screw to the bottom of each air spring (Figure 136, Items 5 and 6). Tighten screw to 3 to 5 N•m
(27 to 44 Lbf-in).
3. Apply pipe thread sealant to threads of the fittings and reinstall into top of air springs (Figure 136, Items 3
and 5). Hand-tighten the fittings until snug, then turn another 270 to 450 degrees.
4. Connect air lines to fittings (Figure 136, Items 1 and 3). Hand-tighten the compression nuts, then turn
another 450 to 630 degrees.
5. Build up air pressure and check air spring operation. Also check for air leaks. Correct as necessary.
6. Check cab ride height (See Rear Cab Air Suspension, page 169).
Lateral Control Rod – Removal
WARNING
plate.
159
1. LATERAL CONTROL ROD 4. BOLT

2. LOCKNUT 5. CAB MOUNTING PLATE
3. CROSSMEMBER MOUNTING
PLATE
Figure 137 Lateral Control Rod
1. Remove bolt and locknut from lateral control rod and cab mounting plate.
2. Remove bolt and locknut from lateral control rod and crossmember mounting plate.
3. Remove lateral control rod.
Lateral Control Rod – Installation
CAUTION
1. Install lateral control rod (Figure 137, Item 1).
2. Install bolt and locknut through lateral control rod and crossmember mounting plate (Figure 137). Tighten
nut to 95 to 122 N•m (70 to 90 Lbf-ft).
3. Install bolt and locknut through lateral control rod and cab mounting plate (Figure 137). Tighten nut to 95
to 122 N•m (70 to 90 Lbf-ft).
160
Jounce Bumper – Removal
1. CAB MOUNTING PLATE 3. BOLT

2. LOCKNUT 4. JOUNCE BUMPER
Figure 138 Jounce Bumper
1. Remove bolt and locknut from jounce bumper.
2. Remove jounce bumper from underneath cab mounting plate.
Jounce Bumper – Installation
1. Position jounce bumper underneath cab mounting plate (Figure 138, Items 1 and 4).
2. Install bolt and locknut (Figure 138, Items 2 and 3). Tighten locknut to 3 to 5 N•m (27 to 44 Lbf-in).
161
TROUBLESHOOTING ELECTRIC WINDSHIELD WIPER MOTOR
3. TROUBLESHOOTING
3.1. ELECTRIC WINDSHIELD WIPER MOTOR
CONDITION PROBABLE CAUSE REMEDY
Wiper does 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.
6. Stripped gear teeth. 6. Replace motor assembly.
Wiper does not shut off 1. Faulty parking switch 1. Replace motor assembly.
assembly.
2. Faulty manual switch. 2. Replace manual switch.
Wiper continually shut 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.
162
WASHER PUMP MOTOR TROUBLESHOOTING
3.2. WASHER PUMP MOTOR

CONDITION PROBABLE CAUSE REMEDY
Pump does not 1. No voltage to pump motor. 1. Check for open circuit or blown fuse.
operate
2. Defective switch. 2. Replace switch.
3. Defective pump motor. 3. Replace pump/motor assembly.
Pump operates, 1. Hoses loose, kinked, or damaged. 1. Reinstall or replace hose.
but pressure is
2. Nozzles plugged, or dirt in reservoir. 2. Clean nozzles and service reservoir, as
weak
required.
3. Defective motor or pump. 3. Replace pump/motor assembly.
Pump operates, 1. No solution in reservoir. 1. Fill reservoir.
but no washer
2. Hoses loose, kinked, or damaged. 2. Reinstall or replace hoses.
solution delivered.
3. Nozzles plugged, or dirt in reservoir. 3. Clean nozzles and service reservoir, as
required
4. Solution frozen. 4. Thaw out system and replace washer
solvent.
5. Defective pump. 5. Replace pump/motor assembly.

Condition Probable Cause Remedy
Rear cab air suspension 1. Air line is leaking. 1. Replace air line.
system loses air.
2. Air fitting is leaking. 2. Remove fitting and apply fresh
joint compound. Reinstall fitting,
but do not overtighten. Do not use
Teflon tape. Replace if required.
Air springs do not maintain 1. Air springs need to be adjusted. 1. Adjust valve linkage to maintain
proper height. proper air spring height.
Air springs leak. 1. Air springs. 1. Replace leaking air spring.
Air leaks from joint between 1. Height control valve is loose. 1. Tighten four Phillips head
valve halves. screws.
Air springs do not inflate when 1. Height control valve. 1. Replace valve.
weight is added to cab.
Air springs do not deflate when 1. Height control valve. 1. Replace valve.
weight is removed from cab.
Shock absorbers provide 1. Rear cab air suspension shock 1. Replace shock absorber.
insufficient dampening effect. absorber.
Lateral control rod is loose. 1. Nuts on lateral control rod bolts 1. Tighten securely to clamp the
are loose. inner sleeve.
Bushings are worn. 1. Lateral control rod. 1. Replace lateral control rod.
163
LUBRICATION 4,000 MILES (6,000 KM) OR MONTHLY
4. 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 the
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.
4.1. 4,000 MILES (6,000 KM) OR MONTHLY

1. Lubricate door stop, hinges, latches, and strikers with DEXRON II™ oil.
2. Lubricate the hood tilt linkage with Fleetrite® EP Moly grease or equivalent NLGl No. 2 Multi-Purpose
Lithium grease.
4.2. 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 at cab door window slide block, and cab door
window slide rail with Lubriplate 105 grease or equivalent.
164
CAB SQUARING ADJUSTMENTS
5. ADJUSTMENTS
Proper adjustments are critical to the cab structure, as this affects the functioning of other components of the
vehicle. The following adjustments must be performed in the order listed below. Before adjusting the hood or
squaring the cab, refer to Cab section (See Cab, page 144).
5.1. 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. It
is important to properly square the cab to avoid interference between the cab, hood, and sleeper box and to
provide acceptable appearance of the components.
NOTE – Ensure chassis is on a level surface before squaring.
1. CAB 4. FRAME RAIL

2. CAB COWL LINE
3. EQUAL DIMENSION EACH SIDE
OF CAB
Figure 139 Cab Squaring
1. Center cab on frame rail by using equal distance between cab frame rail and cab cowl on each side.
NOTE – There are no adjustments available to make the cab back panel perpendicular to the frame.
165
ADJUSTMENTS CAB DOOR
5.2. CAB DOOR

When the cab door is properly adjusted, it should fit the opening with a 6 to 8 mm (1/4 to 5/16 in.) space all
around the cab door frame. A newspaper sheet should not be able to pass between the weather seal and cab
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.
5.3. DOOR HINGE

NOTE –
• Adjustment procedures show driver side; passenger side procedures are the same.
• Hinge procedures are the same for either front or rear cab doors.
1. UPPER HINGE 4. CAB HINGE PILLAR

2. LOWER HINGE 5. LOCKING BOLT
3. HINGE BOLT
Figure 140 Cab Door Hinge
1. Slightly loosen upper hinge bolts and move cab door, as required, at upper door hinge to obtain proper
cab door position.
166
STRIKER PIN ADJUSTMENTS
2. Hold cab door in place and tighten both upper hinge bolts at the cab hinge pillar location. Tighten bolts to
18 to 20 N•m (13 to 15 Lbf-ft).
3. Slightly loosen lower hinge bolts and move cab door as required at lower door hinge to obtain proper
cab door position.
4. Hold cab door in place and tighten both lower hinge bolts at the cab hinge pillar location. Tighten bolts to
18 to 20 N•m (13 to 15 Lbf-ft).
5. Close cab door and check for proper fit. If further adjustment is required, repeat procedure.
5.4. STRIKER PIN

NOTE –
• Adjustment procedures show driver side; passenger side procedures are the same.
• Striker pin procedures are the same for either front or rear cab doors.
1. DOOR LOCK PILLAR 3. STRIKER PIN

2. BOLT
Figure 141 Striker Pin
1. Slightly loosen bolts securing striker pin to door lock pillar.
2. Move striker pin, as required, at the door lock pillar to obtain proper cab door fit and latching position.
3. Hold striker pin in place and tighten both bolts at the cab door lock pillar. Tighten bolts to 26 to 32 N•m
(19 to 24 Lbf-ft).
4. Close cab door and check for proper fit. If further adjustment is required, repeat procedure.
167
ADJUSTMENTS WINDSHIELD WIPER ARM AND BLADE ASSEMBLY
5.5. WINDSHIELD WIPER ARM AND BLADE ASSEMBLY

NOTE – Spray water on the windshield to determine wiper pattern.
1. Turn wipers on high speed to check wiper pattern on the windshield. Wipers should not run off the glass or
stop lower than the horizontal position of the bottom edge of the glass.
1. WIPER PIVOT POST 5. PASSENGER SIDE WIPER ARM

2. LOCK LEVER AND BLADE ASSEMBLY
3. WASHER HOSE 6. T-FITTING
4. DRIVER SIDE WIPER ARM AND
BLADE ASSEMBLY
Figure 142 Windshield Wiper Arm and Blade Assembly
2. If adjustment is needed, lift up on lock lever and remove wiper arm and blade assembly from wiper
pivot post.
3. Reposition wiper arm and blade assembly so it is horizontal to the bottom edge of windshield.
4. Press wiper arm and blade assembly onto wiper pivot post until assembly locks in place.
5. Turn wipers on high speed and check for proper operation. Repeat adjustment if needed.
168
REAR CAB AIR SUSPENSION ADJUSTMENTS
5.6. REAR CAB AIR SUSPENSION

Ride Height
WARNING
To prevent vehicle damage, personal injury, or possible death, park the vehicle on a level
surface, set the parking brake, chock the wheels, and turn the engine off.
1. JOUNCE BUMPER RATE CUP 3. JOUNCE BUMPER STRIKE

2. MEASURE DISTANCE BETWEEN PLATE
METAL CUP AND STRIKE PLATE
Figure 143 Ride Height Measurement
1. Charge the air system to operating pressure of 6.2 to 7.6 bar (90 to 110 psi).
2. Inspect the suspension and ensure it is not seized or bound up.
3. Measure the space between the Jounce Bumper Strike Plate and the Jounce Bumper Rate Cup (Figure
143, Item 2). Be certain to measure to the metal cup, not the rubber bumper.
4. Gap setting should be 3.81 cm (1 ½-inch).
NOTE – Some technicians use an air wrench socket with an outside diameter equal 3.81 cm (1 ½-inch)
to check this measurement.
NOTE – If the measurement is not correct, continue to step 5 for adjustment.
169
ADJUSTMENTS REAR CAB AIR SUSPENSION
1. JAMNUT 4. HEIGHT CONTROL VALVE

2. LINKAGE SOCKET LINKAGE
3. LINKAGE SOCKET CLIP 5. HEIGHT CONTROL VALVE
Figure 144 Linkage Adjustment
5. Loosen the jamnut on the height control valve linkage and back off the nut several turns.
6. Unlatch the linkage socket clip and lightly pry the linkage socket from the pivot ball.
7. Turn the linkage socket clockwise to shorten the linkage or counterclockwise to lengthen the linkage.
CAUTION
To avoid product damage, there must be a minimum of five (5) full threads of the
adjustment linkage threaded into the linkage socket.
8. Connect the linkage socket to the pivot ball, check the design height (step 4), and adjust as needed.
9. When proper adjustment is achieved, latch the linkage clip and tighten the jamnut.
170
TORQUE
TORQUE
Table 5 Torque
Figure No. (Item No.) Location N•m Lbf-ft/Lbf-in.

Figure 10 (Item 3) Driver Side Grab Handle Bolts 9 to 11 77 to 95 Lbf-in.
Figure 57 (Item 4) Rear Side Window Mounting Bolts 8 to 11 71 to 97 Lbf-in
Figure 57 (Item 6) Rear Side Window Mounting Nuts 8 to 11 71 to 97 Lbf-in
Figure 61 (Item 2) Cowl Tray Mounting Nuts 22 to 24, Do 16 to 18 Lbf-ft,
NOT exceed Do NOT exceed
24 18 Lbf-ft
Figure 61 (Item 5) Cowl Tray Center Mounting Bracket Studs Do NOT Do NOT
overtighten overtighten
Figure 63 (Item 2) Windshield Wiper Assembly Mounting Nuts 22 to 24, Do 16 to 18 Lbf-ft,
NOT exceed Do NOT exceed
24 18 Lbf-ft
Figure 64 (Item 9) WorkStar® Washer Bottle Mounting Bolts Do NOT Do NOT
Figure 65 (Item 9) TranStar® Washer Bottle Mounting Bolts Do NOT Do NOT
Figure 67 (Item 7) Wiper Drive Arm Retaining Nut 20 to 25 15 to 18 Lbf-ft
Figure 67 (Item 3) Wiper Motor Mounting Bolts 5 to 7 44 to 62 Lbf-in.
Figure 70 (Item 8) Cab Door Mounting Nuts 19 to 24 14 to 18 Lbf-ft
Figure 71 (Items 3 Door Hinge Mounting Bolts 20 to 24 15 to 18 Lbf-ft
and 5) Figure 140
(Items 3 and 5)
Figure 72 (Item 2) Striker Pin Mounting Bolts 26 to 33 19 to 24 Lbf-ft
Figure 141 (Item 2)
Figure 73 (Item 2) Check Bracket Mounting Bolts 11 to 14 97 to 124 Lbf-in
Figure 74 (Item 1) Check Link Mounting Nuts 9 to 11 77 to 95 Lbf-in.
Figure 75 (Item 1) Inner Door Pull Cup Screws 2 to 3 20 to 25 Lbf-in.
Figure 75 (Item 4) Door Map Pocket Mounting Screws 2 to 3 20 to 25 Lbf-in.
Figure 82 (Item 2) Outer Door Handle Screws 4 to 5 35 to 44 Lbf-in.
Figure 83 (Item 1) Modular Door Hardware Assembly Bolts 11 to 14 97 to 124 Lbf-in
Figure 83 (Item 4) Door Latch Bolts 11 to 14 97 to 124 Lbf-in
Figure 85 (Item 2) Vent Window Latch Mounting Screws 6 to 8 53 to 71 Lbf-in.
Figure 88 (Item 4) Window Electric Motor Mounting Nuts 7 to 13 62 to 115 Lbf-in.
Figure 96 (Item 1) Inner Door Handle Mounting Bolt 8 to 10 71 to 89 Lbf-in.
Figure 103 (Item 1) Scuff Plate Mounting Screws 2 to 3 20 to 25 Lbf-in.
Figure 104 (Item 4) Sunshade Mounting Screws 46 to 52 34 to 38 Lbf-ft
Figure 104 (Item 6) Sunshade Clearance Light Screws 2 to 3 20 to 25 Lbf-in.
171
TORQUE
Table 5 Torque (cont.)

Figure No. (Item No.) Location N•m Lbf-ft/Lbf-in.
Figure 105 (Item 3) Sun Visor Clip Screws 2 to 3 20 to 25 Lbf-in.
Figure 105 (Item 5) Sun Visor Screws 2 to 3 20 to 25 Lbf-in.
Figure 111 (Item 3) Grab Handle Mounting Bolt 9 to 11 77 to 95 Lbf-in.
Figure 110 (Item 3) Gauge Cluster Screws 2 to 3 20 to 25 Lbf-in.
Figure 114 (Item 1) Upper Instrument Panel Mounting Bolts 10 to 12 84 to 106 Lbf-in.
Figure 114 (Item 2) Lower Instrument Panel Mounting Bolts 22 to 26 16 to 19 Lbf-ft
Figure 115 (Item 3) Seat Mounting Nuts with Washers 20 to 27 15 to 20 Lbf-ft
Figure 115 (Items Seat Belt Mounting Bracket Bolts 34 to 41 25 to 30 Lbf-ft
5 and 6)
Figure 116 (Item 1) Rear Bench Seat Mounting Nuts with Washers 20 to 24 15 to 18 Lbf-ft
Figure 117 (Item 3) Shoulder Belt Mounting Bolt 27 to 34 20 to 25 Lbf-ft
Figure 121 (Item 2) Header Console Panel Courtesy Light Screws 2 to 3 20 to 25 Lbf-in.
Figure 121 (Item 5) Header Console Panel near Speakers Screws 2 to 3 20 to 25 Lbf-in.
Figure 127 (Item 2) Cup Holder and Ash Tray Mounting Screws 2 to 3 20 to 25 Lbf-in.
Figure 128 (Item 2) Engine Cover Mounting Bolts 9 to 11 77 to 95 Lbf-in.
Figure 129 (Item 1) Front Cab Mounting Nuts 193 to 237 142 to 175 Lbf-ft
Figure 130 (Items Rear Cab Air Suspension Assembly Carriage 119 to 144 88 to 106 Lbf-ft
1 and 5) Bolts and Nuts
Figure 132 (Items Rear Cab Air Suspension Assembly Mounting to 119 to 144 88 to 106 Lbf-ft
1 and 5) Crossmember Bolt and Nut
Figure 133 (Item 4) Cab Mounting Bushing Mounting Bolt 119 to 144 88 to 106 Lbf-ft
Figure 134 (Items Height Control Valve Mounting Bolts and Lock 11 to 14 97 to 124 Lbf-in
2 and 5) Nuts
Figure 134 (Item 9) Height Control Valve, SUSP Port, Air Line Hand tighten nut 450 degrees
Compression Nut to 630 degrees
Figure 135 (Items Shock Absorber Bolts and Locknuts 54 to 68 40 to 50 Lbf-ft
2 and 5)
Figure 136 (Item 2) Air Spring (Bag) Air Line Compression Nuts Hand tighten nut 450 degrees
to 630 degrees
Figure 136 (Item 3) Air Line Fittings on Air Springs (Bags) Hand tighten plus 270 degrees
to 450 degrees
Figure 136 (Item 4) Air Spring (Bag) Retaining Rings Securely press on stud of
air spring (bag)
Figure 136 (Item 6) Air Spring (Bag) Mounting Screws 3 to 5 27 to 44 Lbf-in
Figure 137 (Items 2) Lateral Control Rod Locknuts 95 to 122 70 to 90 Lbf-ft
Figure 138 (Items 2) Jounce Bumper Locknuts 3 to 5 27 to 44 Lbf-in
172

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

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

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EPA 10 - US, Canada, Mexico

CAB - TranStar®, WorkStar®

2701 Navistar Drive, Lisle, IL 60532 USA

Section / Location Changes

2. REMOVAL AND INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

TABLE OF CONTENTS (CONT.)

TABLE OF CONTENTS (CONT.)

TABLE OF CONTENTS (CONT.)

Cup Holder and Ashtray – Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143

1. STANDARD CAB 2. EXTENDED CAB

1.2. CAB INTERIOR TRIM PANELS

Figure 2 ZTSE4839 Interior Trim Tool

1.3. VEHICLE IDENTIFICATION NUMBER (VIN) AND COMPLIANCE TAG LOCATIONS

1. COMPLIANCE TAG 4. VIN TAG

1.5. ELECTRIC WINDSHIELD WIPERS

1. WIPER ARM 3. WIPER LINKAGE

1.6. WINDSHIELD WASHER

1. PUMP MOTOR 2. WASHER BOTTLE

1. PUMP MOTOR 2. WASHER BOTTLE

1.7. IGNITION SWITCH CYLINDER

1.8. REAR CAB AIR SUSPENSION SYSTEM

1. AIR SPRING (BAG) 3. SHOCK ABSORBER

2. REMOVAL AND INSTALLATION

To prevent personal injury or death, whenever any component is serviced or removed

1. Park the vehicle on a flat, level surface.

• Short Inside Cutting Blade

1. Unlatch and open the hood.

2. Place protective coverings over areas near windshield.

1. Sunshade 3. MOUNTING BRACKET

1. DRIVER SIDE A-PILLAR TRIM 2. GRAB HANDLE

5. Remove two bolts from grab handle and remove handle.

1. HEADLINER TRIM PANEL 4. INSTRUMENT PANEL

1. UTILITY KNIFE 2. RUBBER TRIM FLANGE

1. POWER KNIFE 4. OUTSIDE CUTTING BLADE

1. 43532 BODY PRIMER 4. BETASEAL EXPRESS ONE-PART

The windshield replacement kit includes the following components:

• 43532 Body Primer

Additional materials needed include the following:

• Essex® GC800 Glass Cleaner

2. Remove windshield and place on a suitable padded work stand.

1. OLD ADHESIVE 3. GASKET CHISEL

1. 43532 BODY PRIMER 3. WINDSHIELD FENCE

5. Shake 43532 body primer container for at least 1 minute.

1. BONDING SURFACE 2. RAZOR BLADE

1. 43518 CLEAR GLASS PRIMER 4. WHITE OR BROWN PAPER

8. Shake 43518 clear glass primer container for at least 1 minute.

1. 43520A BLACK-OUT GLASS 3. WINDSHIELD

1. TRIM DIMENSIONS 3. ADHESIVE TUBE

14. Attach cartridge tip to adhesive tube.

1. PNEUMATIC OR ELECTRIC 3. WINDSHIELD FENCE

15. Load adhesive tube into a pneumatic or electric caulking gun.

1. PNEUMATIC OR ELECTRIC 4. PLASTIC OR WOOD TONGUE

1. WINDSHIELD 3. WINDSHIELD LOCATOR TAB

1. TAPE ON WINDSHIELD 4. WINDSHIELD FENCE

27. Test operation of windshield wipers and washer.

28. Clean windshield and surrounding areas.

29. Close and latch the hood.

2.2. REAR WINDOW GLASS

1. WINDOW GLASS 3. SPRING CLIP