02 - (2011) Service Manual (S16054)

SERVICE MANUAL
SERVICE MANUAL SECTION
CAB MANUAL
Model: DuraStar® Vehicle
S16054
February 2011
S16054
© February 2011 NC2 Global LLC All rights reserved
All other trademarks are the property of their respective owners.
TABLE OF CONTENTS
TABLE OF CONTENTS
1. DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1. 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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
1.6. WINDSHIELD WASHER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
1.7. IGNITION SWITCH CYLINDER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
1.8. REAR CAB AIR SUSPENSION SYSTEM.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
2. REMOVAL AND INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

2.1. WINDSHIELD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Windshield – Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Windshield – Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
2.2. REAR WINDOW GLASS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
Rear Window Glass (Unobstructed Access) – Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
Rear Window Glass (Unobstructed Access) – Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
Rear Window Glass (Obstructed Access) – Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
Rear Window Glass (Obstructed Access) – Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
2.3. HOOD SEAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54
Hood Seal – Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54
Hood Seal – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54
2.4. SUN SHADE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55
Sun Shade – Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55
Sun Shade – Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55
2.5. SUN VISOR AND CLIP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56
Sun Visor and Clip – Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56
Sun Visor and Clip – Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57
2.6. IGNITION SWITCH AND IGNITION SWITCH CYLINDER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58
Ignition Switch – Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58
Ignition Switch – Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60
Ignition Switch Cylinder – Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60
Ignition Switch Cylinder – Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61
2.7. INSTRUMENT PANEL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63
Gauge Cluster – Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63
Gauge Cluster – Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63
Instrument Panel – Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64
Instrument Panel – Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68
2.8. CAB DOOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70
Cab Door – Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70
Cab Door – Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .73
2.9. DOOR HINGE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74
Door Hinge – Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74
Door Hinge – Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75
2.10. DOOR STRIKER PIN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75
Door Striker Pin – Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75
Door Striker Pin – Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .76
2.11. DOOR CHECK BRACKET. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .76
Door Check Bracket – Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .76
Door Check Bracket – Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .76
2.12. DOOR CHECK LINK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77
S16054 I
TABLE OF CONTENTS
TABLE OF CONTENTS (CONT.)

Door Check Link – Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77
Door Check Link – Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .78
2.13. CAB DOOR TRIM PANEL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .79
Cab Door Trim Panel with Electric Door Window and Locks – Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .79
Cab Door Trim Panel with Electric Door Window and Locks – Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . .81
Cab Door Trim Panel with Manual Door Window and Locks – Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .82
Cab Door Trim Panel with Manual Door Window and Locks – Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . .83
2.14. INNER DOOR PANEL WATER SHIELD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84
Inner Door Panel Water Shield – Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84
Inner Door Panel Water Shield – Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85
2.15. WINDOW SLIDE BLOCK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85
Window Slide Block – Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85
Window Slide Block – Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87
2.16. CAB DOOR GLASS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87
Cab Door Glass – Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87
Cab Door Glass – Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89
2.17. MODULAR DOOR HARDWARE ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90
Modular Door Hardware Assembly – Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90
Modular Door Hardware Assembly – Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93
2.18. VENT WINDOW, LATCH, AND SEAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .95
Vent Window, Latch, and Seal – Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .95
Vent Window, Latch, And Seal – Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .96
2.19. VENT WINDOW HINGE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .97
Vent Window Hinge – Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .97
Vent Window Hinge – Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .97
2.20. DOOR LOCK CYLINDER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .98
Door Lock Cylinder – Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .98
Door Lock Cylinder – Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .99
2.21. WINDOW ELECTRIC MOTOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .99
Window Electric Motor – Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .99
Window Electric Motor – Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .100
2.22. REGULATOR ARM ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101
Regulator Arm Assembly – Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101
Regulator Arm Assembly – Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .104
2.23. OUTER DOOR HANDLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .105
Outer Door Handle – Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .105
Outer Door Handle – Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .107
2.24. DOOR LATCH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .108
Door Latch – Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .108
Door Latch – Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .109
2.25. INNER DOOR HANDLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .109
Inner Door Handle – Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .109
Inner Door Handle – Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
2.26. WINDOW RUN CHANNELS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .111
Window Run Channels – Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .111
Window Run Channels – Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .113
2.27. ELECTRIC WINDOW AND DOOR LOCK SWITCH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .114
Electric Window And Door Lock Switch – Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .114
Electric Window And Door Lock Switch – Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .114
2.28. ELECTRIC MIRROR SWITCH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .115
Electric Mirror Switch – Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .115
ii S16054
TABLE OF CONTENTS

Electric Mirror Switch – Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .115
2.29. SEATS AND SEAT BELTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .116
Bucket Seat – Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .116
Bucket Seat – Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .116
Two Man Fixed Bench Seat – Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .117
Two Man Fixed Bench Seat and Seat Belt – Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .119
2.30. SCUFF PLATE AND SEAT BELT RETRACTOR COVER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .121
Scuff Plate and Seat Belt Retractor Cover – Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .121
Scuff Plate and Seat Belt Retractor Cover – Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .121
2.31. CORNER AND SIDE INTERIOR TRIM PANEL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .122
Corner and Side Interior Trim Panel – Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .122
Corner and Side Interior Trim Panel – Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .122
2.32. REAR INTERIOR TRIM PANEL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .123
Rear Interior Trim Panel – Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .123
Rear Interior Trim Panel – Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .123
2.33. HEADER CONSOLE PANEL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .124
Header Console Panel – Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .124
Header Console Panel – Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .129
2.34. HEADLINER TRIM PANEL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .130
Headliner Trim Panel – Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .130
Headliner Trim Panel – Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .131
2.35. WEATHER SEALS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .132
Weather Seals – Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .132
Weather Seals – Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .132
2.36. WINDSHIELD WIPER ARM AND BLADE ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .133
Windshield Wiper Arm and Blade Assembly – Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .133
Windshield Wiper Arm and Blade Assembly – Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .133
2.37. CAB COWL TRAY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .134
Cab Cowl Tray – Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .134
Cab Cowl Tray – Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .135
2.38. WINDSHIELD WIPER ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .136
Windshield Wiper Assembly – Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .136
Windshield Wiper Assembly – Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .137
2.39. ELECTRIC WINDSHIELD WIPER MOTOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .137
Electric Windshield Wiper Motor – Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .137
Electric Windshield Wiper Motor – Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .138
2.40. WINDSHIELD WASHER BOTTLE AND PUMP MOTOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .139
Windshield Washer Bottle and Pump Motor – Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .139
Windshield Washer Bottle With Pump Motor – Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .140
2.41. ENGINE COVER, CUP HOLDER, AND ASHTRAY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .140
Cup Holder and Ashtray – Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .140
Cup Holder and Ashtray – Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .141
Engine Cover – Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .141
Engine Cover – Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .142
2.42. CAB. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .143
Initial Procedures Before Cab Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .143
Cab – Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .145
Cab – Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .146
Final Procedures After Cab Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .147
2.43. REAR CAB AIR SUSPENSION ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .148
Rear Cab Air Suspension Assembly – Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .148
S16054 III
TABLE OF CONTENTS
Rear Cab Air Suspension Assembly – Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .149

2.44. FRONT CAB MOUNTING BUSHINGS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .150
Front Cab Mounting Bushings – Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .150
Front Cab Mounting Bushings – Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .152
2.45. 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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .158
Lateral Control Rod – Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .159
Lateral Control Rod – Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .159
Jounce Bumper – Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .160
Jounce Bumper – Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .160
3. TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .161
3.1. ELECTRIC WINDSHIELD WIPER MOTOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .161
3.2. WASHER PUMP MOTOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .161
3.3. REAR CAB AIR SUSPENSION SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .162
4. LUBRICATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .163
4.1. 4,000 MILES (6,000 KM) OR MONTHLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .163
4.2. AS REQUIRED. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .163
5. ADJUSTMENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .164
5.1. CAB SQUARING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .164
5.2. CAB DOOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .165
5.3. DOOR HINGE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .165
5.4. STRIKER PIN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .166
5.5. WINDSHIELD WIPER ARM AND BLADE ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .167
5.6. REAR CAB AIR SUSPENSION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .168
Ride Height. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .168
TORQUE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .170
iv S16054
DESCRIPTION
1. DESCRIPTION
1.1. CAB
Figure 1 Cab Configuration
The cabs for the DuraStar® 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.
A sufficient interior trim removal tool, such as the ZTSE4839 interior trim tool, is required to remove all cab
interior trim panels.
S16054 1
DESCRIPTION VEHICLE IDENTIFICATION NUMBER (VIN) AND COMPLIANCE TAG LOCATIONS
1.3. VEHICLE IDENTIFICATION NUMBER (VIN) AND COMPLIANCE TAG LOCATIONS
1. “ VIN ” TAG 3. CAB DOOR LATCH PILLAR

2. COMPLIANCE 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. VIN and compliance tags are located
on the face of the driver side cab door latch pillar.
2 S16054
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 DuraStar® vehicles. Refer to the removal and
installation procedures in this Service Manual for adhesive and tool information.
1.5. ELECTRIC WINDSHIELD WIPERS
1. WIPER ARM 3. WIPER LINKAGE

2. ELECTRIC WIPER MOTOR
Figure 5 Electric Windshield Wipers
S16054 3
DESCRIPTION WINDSHIELD WASHER
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. WASHER BOTTLE 2. PUMP MOTOR

Figure 6 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 on the wiper arms. The washer bottle and pump
motor are mounted on the right front frame rail behind the bumper.
NOTE – The pump motor is detachable from the washer bottle and can be replaced individually.
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.
NOTE – The code number does not appear on the ignition switch body or door lock assembly.
4 S16054
REAR CAB AIR SUSPENSION SYSTEM DESCRIPTION
1.8. REAR CAB AIR SUSPENSION SYSTEM
1. SHOCK ABSORBER 3. AIR SPRING (BAG)

2. HEIGHT CONTROL VALVE
Figure 7 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 DuraStar® vehicles.
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 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 170) for proper tightening of all fasteners and air line fitting connections.
S16054 5
REMOVAL AND INSTALLATION
2. REMOVAL AND INSTALLATION

WARNING
To prevent personal injury or death, park vehicle on a flat, level surface. Make sure engine
ignition is OFF and transmission is in neutral or park position if vehicle is equipped with
an automatic transmission. Set parking brake, chock wheels, and disconnect batteries
at negative terminal before performing any service procedures on engine or vehicle.
WARNING
To prevent personal injury or death, when any component is serviced or removed from
the air system, parking brake is set and/or chock vehicle wheels to prevent vehicle 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 – Prior to performing any work on cab components, Perform the following basic procedures:
1. Park vehicle on a flat, level surface.

2. Place transmission in neutral.
3. Set parking brake.
4. Turn ignition OFF.
5. Chock wheels.
6. Disconnect batteries.
6 S16054
WINDSHIELD REMOVAL AND INSTALLATION
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 hood.
2. Place protective coverings over exposed areas near windshield.
3. Remove windshield wiper arms. (See WINDSHIELD WIPER ARM AND BLADE ASSEMBLY, page 133).
1. SUN SHADE 3. MOUNTING BRACKET

2. TAPE
Figure 8 Taping the Mounting Brackets
4. If vehicle is equipped with an exterior sun shade, place a piece of tape on bottom side of three mounting
brackets to protect paint. To remove sun shade (See SUN SHADE, page 55).
S16054 7
REMOVAL AND INSTALLATION WINDSHIELD
1. PASSENGER SIDE A-PILLAR 2. GRAB HANDLE

AND TRIM PANEL 3. BOLT
Figure 9 Passenger Side A-Pillar Trim Panel and Grab Handle
5. Remove two bolts and grab handle from passenger side A-pillar.
6. Remove passenger side A-pillar trim panel by beginning at the top and pulling free from cab A-pillar.
8 S16054
1. HEADLINER TRIM PANEL 4. INSTRUMENT PANEL

2. CAB A-PILLAR
3. DRIVER SIDE A-PILLAR TRIM
PANEL
Figure 10 Driver Side A-Pillar Trim Panel
7. Remove driver side A-pillar trim panel by beginning at the top and pulling free from cab A-pillar.
S16054 9
WARNING
To prevent personal injury or death, wear protective eyewear and work gloves when
removing windshield.
1. UTILITY KNIFE 2. RUBBER TRIM FLANGE

Figure 11 Cutting Off Rubber Trim Flange
8. Lift outer flange of encapsulation rubber trim, and with a utility knife, cut rubber trim flange completely off
windshield.
NOTE – When using a power knife to cut around windshield, use a spray bottle filled with water to
lubricate cutting area. This will prevent burning of urethane and rebonding of windshield.
10 S16054
1. POWER KNIFE 4. OUTSIDE CUTTING BLADE

2. SHORT INSIDE CUTTING BLADE 5. LONG-HANDLE UTILITY KNIFE
3. LONG INSIDE CUTTING BLADE
Figure 12 Cutting Windshield Out
9. Using a power knife with a short inside cutting blade (or long inside cutting blade and/or outside cutting
blade), cut completely around windshield until free from cab windshield fence. If windshield will not lift off
cab fence, use a long-handle utility knife to cut through adhesive.
10. With the aid of an assistant, lift windshield off cab fence and place on a padded work bench or stand.
S16054 11
Windshield – Installation
NOTE – For windshield installation, use Windshield Replacement Kit 2592784C91. A pneumatic or
electric caulking gun is required for application of adhesive.
1. 43532 BODY PRIMER 4. BETASEAL EXPRESS ONE-PART

2. 43518 CLEAR GLASS PRIMER URETHANE ADHESIVE
3. 43520A BLACKOUT GLASS 5. CARTRIDGE TIP
PRIMER
Figure 13 Windshield Replacement Kit
The windshield replacement kit includes the following components:
• 43532 Body Primer

• 43518 Clear Glass Primer
• 43520A Blackout Glass Primer
• Betaseal Express One-Part Urethane Adhesive
• Cartridge Tips
NOTE – These materials must be used on or before expiration date marked on container. Refer to
individual containers for expiration dates.
Additional materials required include the following:
• Essex® GC800 Glass Cleaner
12 S16054
• White or Brown Paper Towels

• Pneumatic or Electric Caulking Gun
WARNING
To prevent personal injury or death, wear protective work gloves when handling
windshield. Wear appropriate protective gloves when using any Betaseal system
chemicals from 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).
• Prior to installing new windshield, wipe off any water remaining around windshield fence and
surrounding cab area with a lint-free cloth.
1. With the aid of an assistant, dry-fit new windshield to verify proper fitment. While windshield is in place,
attach a piece of tape as a reference mark across the center, top portion of windshield and cab. Using a
utility knife, cut tape between cab and windshield.
2. With the aid of an assistant, remove windshield off windshield cab fence and place on a padded work
bench or stand.
1. OLD ADHESIVE 3. GASKET CHISEL

2. WINDSHIELD FENCE
Figure 14 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 windshield fence.
4. Remove any dirt or water remaining from windshield removal with a brush or clean, lint-free cloth.
S16054 13
1. 43532 BODY PRIMER 3. WINDSHIELD FENCE

2. APPLICATOR
Figure 15 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 windshield
fence. DO NOT apply 43532 body primer over old urethane adhesive left on windshield fence. Allow primer
to dry for a minimum of 6 to 10 minutes after application.
1. BONDING SURFACE 2. RAZOR BLADE

Figure 16 Removing Flash
7. Using a razor blade and plastic scrubbing pad, remove any flash from bonding surface of new windshield.
Clean windshield thoroughly with Essex® glass cleaner GC800 and dry thoroughly with paper towels.
Ensure windshield is completely clean and dry before proceeding.
14 S16054
NOTE – Read and understand Steps 8 and 9 completely to assure proper application and removal of
43518 clear glass primer.
1. 43518 CLEAR GLASS PRIMER 4. WHITE OR BROWN PAPER

2. APPLICATOR TOWEL
3. WINDSHIELD 5. BONDING SURFACE
Figure 17 Applying Clear Glass Primer
8. Shake 43518 clear glass primer container for at least 1 minute.
NOTE – If clear glass primer is applied to clear glass surface, glass will haze.
9. Apply 43518 clear glass primer with a clean, dry applicator to the rear window glass bonding surface only.
Immediately wipe clear glass primer off bonding surface by following 20 to 25 cm (8 to 10 in.) behind
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.
S16054 15
1. 43520A BLACKOUT GLASS 3. WINDSHIELD

PRIMER 4. BONDING SURFACE
2. APPLICATOR
Figure 18 Applying Blackout Glass Primer
10. Shake 43520A BLACKOUT glass primer container for at least one minute.
11. Apply 43520A blackout glass primer with a clean, dry applicator to windshield bonding surface. Allow
primer to dry to a tack-free condition for a minimum of 6 to 10 minutes after application.
16 S16054
CAUTION
To prevent damage to windshield and cab after priming windshield, there is no contact
with bonding surface, as oil from skin will affect bonding performance. If windshield
is not bonded properly, cab strength and safety will be compromised. If contact with
bonding surface has occurred, repeat cleaning process and reapply 43520A blackout
glass primer and allow it to dry for a minimum of 6 to 10 minutes before applying Betaseal
Express one-part urethane adhesive.
1. TRIM DIMENSIONS 3. ADHESIVE TUBE

2. CARTRIDGE TIP
Figure 19 Adhesive Tube and Cartridge Tip
12. Measure, mark, and trim cartridge tip to trim dimensions shown for proper adhesive application.
13. Attach cartridge tip to adhesive tube.
S16054 17
1. PNEUMATIC OR ELECTRIC 3. WINDSHIELD FENCE

CAULKING GUN
2. BETASEAL ONE-PART
URETHANE ADHESIVE
Figure 20 Applying Adhesive to Weld Seams
14. Load adhesive tube into a pneumatic or electric caulking gun.
15. Apply a small bead of adhesive to weld seams at top and bottom of windshield fence on both sides.
NOTE – Application of adhesive bead on new rear window glass must be 0 to 2 mm (0 to 5/64 in.) from
encapsulation edge and a minimum of 16 to 19 mm (5/8 to 3/4 in.) high and 10 to 13 mm (3/8 to 1/2 in.)
wide maximum.
18 S16054
1. PNEUMATIC OR ELECTRIC 4. PLASTIC OR WOOD TONGUE

CAULKING GUN DEPRESSOR
2. CARTRIDGE TIP 5. LOCATING TAB
3. ADHESIVE
Figure 21 Applying Adhesive to Windshield
16. Holding pneumatic or electric caulking gun as close to a 90° degree angle as possible, begin applying
adhesive at the outer edge of locating tab on bottom of windshield. Apply a uniform bead completely
around rear window glass, overlapping adhesive slightly at the seam . Use a plastic or wood tongue
depressor to smooth and even out adhesive as required before installing rear window glass.
S16054 19
1. WINDSHIELD 3. WINDSHIELD LOCATOR TAB

2. TAPE MARK 4. TAB LOCATOR POST
Figure 22 Positioning Windshield
17. 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 during installation.
20 S16054
1. TAPE ON WINDSHIELD 4. WINDSHIELD FENCE

2. TAPE ON CAB 5. WINDSHIELD ENCAPSULATION
3. WINDSHIELD RUBBER TRIM
Figure 23 Windshield Installation
18. While holding windshield locator tabs in place on cab locator posts, push windshield back against
windshield fence. Check windshield encapsulation rubber trim and make sure it is positioned properly
around windshield opening.
19. With the aid of an assistant, gently push on windshield all around outer edges to seat it properly against
windshield fence. Tabs built in windshield prevent it from being pushed in too far.
20. Remove tape from windshield, cab, and sun shade mounting brackets if applicable.
21. If vehicle is equipped with an exterior sun shade, install sun shade (See SUN SHADE, page 55).
22. Install driver side A-pillar trim panel by aligning trim panel retaining clips with mounting holes and push in
to secure (Figure 10, Item 3).
23. Install passenger side A-pillar trim panel by aligning trim panel retaining clips with mounting holes and
push in to secure (Figure 9, Item 1).
24. Install passenger side grab handle and secure with two bolts (Figure 9, Items 2 and 3). Tighten bolts to
9 to 11 N•m (80 to 97 lbf-in).
25. Install windshield wiper arms and blades (See WINDSHIELD WIPER ARM AND BLADE ASSEMBLY,
page 133).
S16054 21
REMOVAL AND INSTALLATION REAR WINDOW GLASS
26. Test operation of windshield wipers and washer. Adjust as required (See WINDSHIELD WIPER ARM
AND BLADE ASSEMBLY, page 167).
27. Clean windshield and surrounding areas.
28. Close and latch hood.
NOTE – Betaseal Express one-part urethane adhesive should be allowed to cure for 60 minutes before
driving vehicle.
2.2. REAR WINDOW GLASS
1. REAR WINDOW GLASS 3. SPRING CLIP

2. LOCATOR TAB
Figure 24 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 exposed areas near rear window glass inside cab.
2. Before removing rear window glass, it may be necessary to remove the front seats (See SEATS AND
SEAT BELTS, page 116).
22 S16054
REAR WINDOW GLASS REMOVAL AND INSTALLATION
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 rear window glass, use a spray bottle filled with water
and lubricate cutting area. This will prevent burning of urethane and rebonding of rear window glass.
1. POWER KNIFE 3. REAR WINDOW GLASS FENCE

2. SHORT INSIDE CUTTING BLADE
Figure 25 Cutting Rear Window Glass Out
3. From inside cab, use a power knife with a short inside cutting blade and cut completely around rear
window glass until free from rear window glass fence.
4. With the aid of an assistant, remove rear window glass off rear window glass fence and place on a padded
work bench or stand.
S16054 23
Rear Window Glass (Unobstructed Access) – Installation
NOTE – For rear window glass installation, use Windshield Replacement Kit 2592784C91. A pneumatic
or electric caulking gun is required for application of adhesive.

3. 43520A BLACKOUT GLASS 5. CARTRIDGE TIP
PRIMER

• 43520A Blackout Glass Primer
• Cartridge Tips
NOTE – These materials must be used on or before expiration date marked on container. Please refer to
24 S16054

WARNING
To prevent personal injury or death, wear protective work gloves when handling rear
window glass. Wear appropriate protective gloves when using any Betaseal system
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 glass
fence and surrounding cab area with a lint-free cloth.
1. With the aid of an assistant, dry-fit new rear window glass in rear window glass fence to verify proper
fitment. Align window locator tabs between window locators on cab and make sure window spring clip is
inside the top of rear window glass fence.
2. While 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. Using a utility knife, cut tape between cab and rear window
glass.
3. With the aid of an assistant, remove rear window glass off rear window glass fence and place on a padded
work bench or stand.
1. OLD ADHESIVE 3. GASKET CHISEL

2. REAR WINDOW GLASS FENCE
Figure 27 Removing Old Adhesive
4. Using a gasket chisel, remove old adhesive from rear window glass 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 rear window glass fence.
S16054 25
5. Remove any dirt or water remaining from rear window removal with a brush or clean, lint-free cloth.
1. 43532 BODY PRIMER 3. REAR WINDOW GLASS FENCE

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 glass fence.
Allow primer to dry for a minimum of 6 to 10 minutes after application.
26 S16054

8. Using a razor blade and plastic scrubbing pad, remove any flash from bonding surface of new rear window.
Clean rear window thoroughly with Essex® glass cleaner GC800 and dry thoroughly with paper towels.
Ensure rear window is completely clean and dry before proceeding.
NOTE – Read and understand Steps 9 and 10 completely to assure proper application and removal of
43518 clear glass primer.
S16054 27

2. APPLICATOR TOWEL
3. REAR WINDOW GLASS 5. BONDING SURFACE
9. Shake 43518 clear glass primer container for at least one minute.
28 S16054
1. 43520A BLACKOUT GLASS 3. REAR WINDOW GLASS

2. APPLICATOR
11. Shake 43520A blackout glass primer container for at least one minute.
12. Apply 43520A blackout glass primer with a clean, dry applicator to the windshield bonding surface. Allow
primer to dry to a tack-free condition for a minimum of 6 to 10 minutes after application.
S16054 29
CAUTION
To prevent damage to rear window and/or cab after priming rear window glass, there is
no contact with bonding surface, as oil from skin will affect bonding performance. If rear
window glass is not bonded properly, cab strength and safety will be compromised. If
contact with bonding surface has occurred, repeat cleaning process and reapply 43520A
blackout glass primer and allow it to dry for a minimum of 6 to 10 minutes before applying
Betaseal Express one-part urethane adhesive .
1. TRIM DIMENSIONS 3. ADHESIVE TUBE

2. CARTRIDGE TIP
30 S16054
wide maximum.
1. PNEUMATIC OR ELECTRIC 3. ADHESIVE

CAULKING GUN 4. PLASTIC OR WOOD TONGUE
2. CARTRIDGE TIP DEPRESSOR
Figure 33 Applying Adhesive to Rear Window Glass
adhesive at the center, bottom edge of rear window glass. Apply a uniform bead completely around rear
window glass, overlapping adhesive slightly at the seam. Use a plastic or wood tongue depressor to
smooth and even out adhesive as required before installing rear window glass.
S16054 31
1. TAPE MARK 5. WINDOW LOCATOR TAB

2. REAR WINDOW GLASS 6. WINDOW LOCATORS ON CAB
3. TAPE MARK 7. WINDOW SPRING CLIP
4. CAB 8. REAR WINDOW GLASS FENCE
Figure 34 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 rear window glass fence.
17. With the aid of an assistant, gently push on rear window glass all around outer edges to seat it properly
against rear window glass fence.
32 S16054
1. REAR WINDOW GLASS 3. BACKSIDE OF CAB

2. TAPE
Figure 35 Taping Rear Window Glass in Place
18. Tape rear window glass to backside of cab in four locations while adhesive cures.
19. After adhesive has cured, remove all pieces of tape and clean rear window glass and surrounding areas.
CAUTION
To prevent damage to rear window seal, be careful not to hit rear window glass while
adhesive is curing. This may cause rear window glass to not seal properly and result in
water leaks.
20. If front seats were removed, install front seats (See SEATS AND SEAT BELTS, page 116).
driving vehicle.
S16054 33
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 exposed areas near rear window glass inside cab.
2. Before removing rear window glass, it may be necessary to remove the front seats. (See SEATS AND
SEAT BELTS, page 116).
34 S16054
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 37 Slide Rail and Suction Cups
3. Assemble slide rail by attaching two top rails to bottom rail. All three rails are identical and can be
assembled in any one of three locations. Line up holes in top two rails with holes in 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 van body where suction cups are being installed is cleaned properly before suction
cups are attached. If suction cups come off during removal or installation of rear window
glass, rear window glass and vehicle will be damaged.
4. Clean area on van body where suction cups will be installed to suction cups will stick securely.
5. Attach one suction cup to van body on driver side and attach remaining suction cup to passenger side.
Position both suction cups so that slide rail (which rests on top of each block) will be just below the bottom
edge of rear window glass. Repeatedly push suction cup plungers until red indicators are no longer visible.
NOTE – Periodically check suction cups to see if the red indicator is starting to appear. If indicator is
visible on either unit, push plunger(s) repeatedly until red indicator is no longer visible.
S16054 35
1. SUCTION CUP 3. SUCTION CUP BLOCK

2. SLIDE RAIL
Figure 38 Installing Slide Rail
6. Place slide rail on top of each suction cup block.
36 S16054
1. SLIDE RAIL 3. SUCTION CUP

2. SUCTION CUP BLOCK 4. PIN
Figure 39 Securing Slide Rail with Pins
7. Beginning with the left side, align hole in slide rail with hole in suction cup block and install a pin to secure.
8. Moving to the right side, reposition suction cup to align slide rail with suction cup block and install a pin to
secure. Repeatedly push suction cup plunger until red indicator is not visible.
9. Attach a suction cup to the driver side of rear window glass.
S16054 37
1. POWER KNIFE 3. REAR WINDOW GLASS FENCE

2. SHORT INSIDE CUTTING BLADE
Figure 40 Cutting Rear Window Out
NOTE – When using a power knife to cut around rear window glass, use a spray bottle filled with water
to lubricate cutting area. This will prevent burning of urethane and rebonding of rear window glass.
10. From inside cab, use a power knife with a short inside cutting blade and cut completely around rear
window glass until free from rear window glass fence.
11. Using suction cup, lift rear window glass off rear window glass fence and set in slide rail. Lean top of
rear window glass against van body.
38 S16054
1. VAN BODY 3. CAB

2. REAR WINDOW GLASS
Figure 41 Removing Rear Window Glass
12. From outside cab, slide rear window glass down slide rail and, with the aid of an assistant, remove rear
window glass and place on a padded work bench or stand.
13. Remove suction cup from rear window glass.
Rear Window Glass (Obstructed Access) – Installation
NOTE – For rear window glass installation, use Windshield Replacement Kit 2592784C91. A pneumatic
or electric caulking gun is required for application of adhesive. Windshield Replacement Kit 2592784C91
is available from Navistar Parts.
S16054 39

3. 43520A BLACK-OUT GLASS 5. CARTRIDGE TIP
PRIMER

• 43520A Black-Out Glass Primer
• Cartridge Tips
NOTE – These materials must be used on or before expiration date marked on container. Refer to

• Slide Rail and Suction Cups
40 S16054
WARNING
To prevent personal injury or death, wear protective work gloves when handling rear
window glass. Wear appropriate protective gloves when using any Betaseal system
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 43 Rear Window Glass on Slide Rail
1. Carefully place rear window glass on slide rail with proper side facing back of cab.
2. Slide rear window glass on slide rail and lean top of rear window glass against van body.
3. Attach two suction cups on rear window glass and repeatedly push suction cup plungers until red indicators
are no longer visible.
S16054 41
NOTE – Periodically check suction cups to see if red indicator is starting to appear. If indicator is visible
on either unit, push plunger(s) repeatedly until red indicator is no longer visible.
1. TAPE MARK 5. WINDOW LOCATOR TAB

2. REAR WINDOW GLASS 6. WINDOW LOCATORS ON CAB
4. Dry-fit new rear window glass in rear window glass fence to proper fitment. Align window locator tabs
between window locators on cab and window spring clip is inside the top of rear window glass fence.
5. While 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 inside trim panel. Using a utility knife, carefully cut tape between
cab and rear window glass.
6. Using suction cups, lift rear window glass off rear window glass fence and place on slide rail.
7. Slide rear window glass out of slide rail and remove. Place rear window glass on a padded work bench or
stand.
8. Remove suction cups from rear window glass.
42 S16054
1. OLD ADHESIVE 4. POWER KNIFE WITH SHORT

2. REAR WINDOW GLASS FENCE INSIDE CUTTING BLADE
3. UTILITY KNIFE
Figure 45 Removing Old Adhesive
9. Using a utility knife and/or power knife with short inside cutting blade, remove old adhesive from rear
window glass 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 rear window glass 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 rear window opening to protect painted surfaces.
S16054 43
1. 43532 BODY PRIMER 3. APPLICATOR

2. REAR WINDOW GLASS FENCE
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 rear window
glass fence. DO NOT apply 43532 body primer over old urethane adhesive left on rear window glass fence.
Allow primer to dry for a minimum of 6 to 10 minutes after application.
14. Remove strips of tape from around rear window opening.
44 S16054

15. Using a razor blade 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.
NOTE – Read and understand Steps 16 and 17 completely for proper application and removal of 43518
clear glass primer.
S16054 45

2. APPLICATOR TOWEL
3. REAR WINDOW GLASS 5. BONDING SURFACE
16. Shake 43518 clear glass primer container for at least 1 minute.
18. Shake 43520A blackout glass primer container for at least 1 minute.
46 S16054
1. 43520A BLACKOUT GLASS 3. REAR WINDOW GLASS

2. APPLICATOR
CAUTION
To prevent damage to windshield and cab after priming windshield, there is no contact
with bonding surface, as oil from skin will affect bonding performance. If windshield
is not bonded properly, cab strength and safety will be compromised. If contact with
bonding surface has occurred, repeat cleaning process and reapply 43520A blackout
glass primer and allow it to dry for a minimum of 6 to 10 minutes before applying Betaseal
Express one-part urethane adhesive.
19. Apply 43520A blackout glass primer with a clean, dry applicator to rear window glass bonding surface.
Allow primer to dry to a tack-free condition for a minimum of 6 to 10 minutes after application.
S16054 47
1. TRIM DIMENSION 3. ADHESIVE TUBE

2. CARTRIDGE TIP
wide maximum.
48 S16054
1. PNEUMATIC OR ELECTRIC 3. ADHESIVE

CAULKING GUN 4. PLASTIC OR WOOD TONGUE
2. CARTRIDGE TIP DEPRESSOR
Figure 51 Applying Adhesive to Rear Window Glass
adhesive at the center, bottom edge of rear window glass. Apply a uniform bead completely around rear
window glass, overlapping adhesive at seam slightly. Use a plastic or wood tongue depressor to smooth
and even out adhesive as required before installing rear window glass.
23. Attach two suction cups to rear window glass and repeatedly push suction cup plungers until red indicators
are no longer visible.
24. Place rear window glass on slide rail and slide in position with rear window glass fence.
S16054 49
1. TAPE MARKS 5. WINDOW LOCATOR TAB

2. REAR WINDOW GLASS 6. WINDOW LOCATOR ON CAB
25. Align rear window glass with tape marks on rear window opening and cab. Align window locator tabs
between window locators on cab. Ensure window spring clip is inside the top of rear window glass fence.
26. From inside cab and with the aid of an assistant, carefully pull rear window glass in against rear window
glass fence as evenly as possible.
27. Remove two suction cups from rear window glass.
28. From outside cab, reach in between the back of cab and van body and, from both sides, gently push on rear
window glass all around outer edge and properly seat rear window glass against rear window glass fence.
50 S16054
1. REAR WINDOW GLASS 3. BACKSIDE OF CAB

2. TAPE
Figure 53 Taping Rear Window Glass in Place
29. Tape rear window glass to backside of cab in four locations while adhesive cures.
S16054 51
1. SLIDE RAIL 3. SUCTION CUP

2. SUCTION CUP BLOCK 4. PIN
Figure 54 Removing Slide Rail Pins
30. Remove pins from suction cup blocks and slide rail.
31. Remove slide rail and suction cups from van body.
32. If desired, store slide rail as assembled.
52 S16054
1. PLUNGER AND RED INDICATOR 4. BOTTOM RAIL

2. SUCTION CUP 5. SCREW
3. TOP RAIL 6. WING NUT
Figure 55 Slide Rail and Suction Cups
33. To disassemble slide rail, remove three wing nuts and three screws securing top rails to bottom rail and
store in removal and installation kit.
34. After adhesive has cured, remove all pieces of tape and clean rear window glass and surrounding areas.
CAUTION
To prevent damage to rear window seal when installing seats back in cab, be careful not
to hit the rear window glass while adhesive is curing. This may cause rear window glass
to not seal properly and result in water leaks.
35. If front seats were removed, install front seats (See SEATS AND SEAT BELTS, page 116).
driving vehicle.
S16054 53
REMOVAL AND INSTALLATION HOOD SEAL
2.3. HOOD SEAL

Hood Seal – Removal
1. HOOD SEAL 3. WINDSHIELD

2. COWL TRAY
Figure 56 Hood Seal
2. Remove hood seal from cowl tray by pulling hood seal off hood seal flange of cowl tray.
Hood Seal – Installation
1. Check hood seal for cracks and tears (Figure 56, Item 1). Replace hood seal if damaged.
2. Press hood seal firmly on seal flange of cowl tray until properly seated (Figure 56).
54 S16054
SUN SHADE REMOVAL AND INSTALLATION
2.4. SUN SHADE

Sun Shade – Removal
1. SELF-TAPPING SCREW 6. MOUNTING SCREW

2. RIGHT SIDE SUN SHADE 7. SUN SHADE MOUNTING
CLEARANCE LIGHT BRACKET
3. LEFT SIDE SUN SHADE 8. CAB ROOF
CLEARANCE LIGHT 9. WIRING HARNESS
4. CENTER SUN SHADE CONNECTOR
CLEARANCE LIGHT 10. WIRING HARNESS HOLE
5. SUN SHADE 11. SUN SHADE CONNECTOR
Figure 57 Sun Shade and Clearance Lights
1. Remove two self-tapping screws, and right side clearance light from sun shade. Allow right side clearance
light to hang by wiring harness.
2. Remove two self-tapping screws, and left side clearance light from sun shade. Allow left side clearance
3. Remove two self-tapping screws, and center clearance light from sun shade. Allow center clearance
4. Remove three mounting screws attaching sun shade to sun shade mounting bracket.
5. Pull sun shade away from sun shade mounting bracket until wiring harness connector is accessible
through wiring harness hole in sun shade mounting bracket. Disconnect sun shade connector from
wiring harness connector and remove sun shade.
Sun Shade – Installation
1. Connect sun shade connector to wiring harness connector in wiring harness hole on sun shade mounting
bracket (Figure 57).
2. Install sun shade on sun shade mounting bracket and secure with three mounting screws through clearance
light openings (Figure 57, Items 5, 6, and 7). Tighten mounting screws to 46 to 52 N•m (34 to 38 lbf-ft).
S16054 55
REMOVAL AND INSTALLATION SUN VISOR AND CLIP
3. Install center clearance light on sunshade and secure with two self-tapping screws (Figure 57, Items 1
and 4). Tighten self-tapping screws to 2 to 3 N•m (18 to 26.6 lbf-in).
4. Install left side clearance light on sun shade and secure with two self-tapping screws (Figure 57, Items 1
5. Install right side clearance light on sun shade and secure with two self-tapping screws (Figure 57, Items 1
2.5. SUN VISOR AND CLIP

Sun Visor and Clip – Removal
1. SCREW 5. RETAINING WASHER

2. SUN VISOR 6. SCREW
3. HEADER CONSOLE PANEL 7. FRONT EDGE OF SUN VISOR
4. SUN VISOR CLIP CLIP
Figure 58 Sun Visor and Clip
1. Remove three screws and sun visor from sun visor clip and header console panel.
NOTE – If sun visor will not drop down out of header console panel after removing three screws, it may
be necessary to drop the corner of header console panel down far enough to remove retaining washer,
used during assembly. To lower header console panel (See HEADER CONSOLE PANEL, page 124).
2. Remove screw securing sun visor clip to header console panel.
3. Push front edge nearest windshield of sun visor clip in and pull sun visor out of header console panel.
56 S16054
SUN VISOR AND CLIP REMOVAL AND INSTALLATION
Sun Visor and Clip – Installation
1. Install sun visor clip on header console panel and secure with screw (Figure 58, Items 3, 4, and 6).
Tighten screw to 2 to 3 N•m (18 to 26.6 lbf-in).
2. Install sun visor on header console panel and secure with three screws (Figure 58, Items 1, 2, and 3).
Tighten screws to 2 to 3 N•m (18 to 26.6 lbf-in).
S16054 57
REMOVAL AND INSTALLATION IGNITION SWITCH AND IGNITION SWITCH CYLINDER
2.6. IGNITION SWITCH AND IGNITION SWITCH CYLINDER

The ignition switch and door locks are coded the same so that one key operates ignition switch and door locks.
The code number is stamped and bar coded on a plastic bag that the ignition switch and door lock cylinders
are supplied in at the assembly plant. This plastic bag is to remain with the vehicle when it is delivered to
the customer. It is very important that this plastic bag be kept by the customer in a safe, secure place, for
key replacement.
NOTE – The code number does not appear on ignition switch body or door lock assembly.
Ignition Switch – Removal
1. INSTRUMENT PANEL 3. IGNITION SWITCH

2. RUBBER TRIM 4. MOUNTING CAP NUT
Figure 59 Ignition Switch and Rubber Trim
1. Remove rubber trim from instrument panel.
2. Using a 1–1/8 inch thin wall socket, remove mounting cap nut from ignition switch.
3. Reach behind instrument panel and remove ignition switch from instrument panel.
58 S16054
IGNITION SWITCH AND IGNITION SWITCH CYLINDER REMOVAL AND INSTALLATION
1. INSTRUMENT PANEL 2. IGNITION SWITCH

Figure 60 Ignition Switch
4. Disconnect ignition switch electrical connector from back of ignition switch.
1. IGNITION SWITCH 2. IGNITION SWITCH

ELECTRICAL CONNECTOR
Figure 61 Ignition Switch Connector
S16054 59
Ignition Switch – Installation
1. Connect ignition switch electrical connector to ignition switch (Figure 61).
2. Insert ignition switch behind dash panel and insert it in dash panel opening (Figure 60).
3. Using a 1–1/8 inch thin wall socket, install mounting cap nut securely to ignition switch and instrument
panel (Figure 59, Items 1, 3, and 4). Tighten mounting cap nut snugly.
4. Install rubber trim on instrument panel (Figure 59, Items 1 and 2).
Ignition Switch Cylinder – Removal
1. RELEASE HOLE 3. IGNITION KEY

2. IGNITION SWITCH 4. IGNITION SWITCH BODY
Figure 62 Ignition Switch Assembly
1. Insert ignition key in ignition switch and rotate key counterclockwise to ACCESSORY position to align
key with release hole.
60 S16054
IGNITION SWITCH AND IGNITION SWITCH CYLINDER REMOVAL AND INSTALLATION
1. IGNITION KEY 4. VISE

2. IGNITION SWITCH CYLINDER 5. RELEASE HOLE
3. PICK 6. IGNITION SWITCH BODY
Figure 63 Ignition Switch Cylinder and Body
2. Support ignition switch assembly in a soft-jawed vise.
3. Insert a suitable 2 mm (1/16 in.) diameter rod, such as a paper clip or pick, in 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 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 ignition switch
cylinder removal.
Ignition Switch Cylinder – Installation
NOTE – If original key is desired when replacing ignition switch cylinder, code new ignition switch using
the following steps.
1. Insert original ignition key in new ignition switch cylinder (Figure 63, Items 1 and 2).
2. File off any tumblers that protrude from ignition switch cylinder. Ensure no burrs are left on tumblers.
Remove ignition key and blow all filings out with compressed air.
3. Apply a small quantity of powdered graphite to tumblers and reinsert ignition key in new ignition switch
cylinder (Figure 63, Items 1 and 2).
S16054 61
4. Rotate ignition key and ignition switch cylinder counterclockwise to the ACCESSORY position (Figure 63,
Items 1 and 2).
5. Insert ignition switch cylinder in ignition switch body, turn ignition key to the OFF position and remove
ignition key (Figure 62, Items 2, 3, and 4).
62 S16054
INSTRUMENT PANEL REMOVAL AND INSTALLATION
2.7. INSTRUMENT PANEL

Gauge Cluster – Removal
CAUTION
To prevent damage to instrument panel electrical components, disconnect batteries prior

to servicing or removing instrument panel.
1. SHIELD 5. 12-PIN ELECTRICAL

2. RETAINING CLIP CONNECTOR
3. SCREW 6. BACK PLATE
4. GAUGE CLUSTER
Figure 64 Gauge Cluster
1. Remove shield from gauge cluster by gently pressing in seven retaining clips.
2. Remove four screws securing gauge cluster to back plate.
3. Tilt gauge cluster forward and disconnect 12-pin electrical connector from gauge cluster.
4. Disconnect any remaining auxiliary electrical connectors.
5. Remove gauge cluster.
Gauge Cluster – Installation
1. Install gauge cluster (Figure 64, Item 4).
S16054 63
REMOVAL AND INSTALLATION INSTRUMENT PANEL
2. Connect auxiliary electrical connectors.
3. Connect 12-pin electrical connector to gauge cluster (Figure 64, Items 4 an 5).
4. Install gauge cluster on back plate and secure with four screws (Figure 64, Items 3, 4, and 6). Tighten
screws to 2 to 3 N•m (18 to 26.6 lbf-in).
5. Install shield on gauge cluster by carefully pressing until retaining clips snap in place (Figure 64, Items 1,
2, and 4).
Instrument Panel – Removal
WARNING
Batteries expel explosive gases. To prevent personal injury or death, keep sparks,
flames, burning cigarettes, or other ignition sources away from batteries at all times.
Always wear safety glasses and a face shield when working near batteries.
CAUTION

1. INSTRUMENT PANEL 3. PRY POINTS

2. INSTRUMENT PANEL TRIM
BEZEL
Figure 65 Instrument Panel and Trim Bezel
1. Using a flat blade screwdriver wrapped with a cloth rag, gently pry instrument panel trim bezel from
instrument panel at four pry points.
64 S16054
1. BOLT 5. BOLT
2. INSTRUMENT PANEL 6. AIR BRAKE CONTROL UNIT
3. FUSE PANEL ACCESS COVER 7. BOLT
4. BOLT 8. STEERING COLUMN
Figure 66 Instrument Panel
2. Open driver side door and remove two bolts under left end of lower instrument panel.
3. Open passenger side door and carefully pull fuse panel access cover away from instrument panel. Lift fuse
panel access cover up to clear tabs at bottom of fuse panel access cover.
4. Remove two bolts under right end of lower instrument panel.
5. Remove two bolts from bottom of steering column.
6. Remove two bolts from air brake control unit on instrument panel.
7. Remove six bolts from instrument panel.
8. Remove driver side and passenger side courtesy lights under instrument panel (not shown).
9. Disconnect ignition switch electrical connector from ignition switch (Figure 61).
S16054 65
1. BOLT 3. INSTRUMENT PANEL

2. SPEED NUT 4. COWL PANEL
10. Remove five bolts from speed nuts on front edge of upper instrument panel and cowl panel.
66 S16054
1. DRIVER SIDE A-PILLAR TRIM 6. GRAB HANDLE

PANEL 7. HEADER TRIM PANEL
2. HEADER TRIM PANEL 8. CAB A-PILLAR
3. CAB A-PILLAR 9. RETAINING CLIP
4. BOLT
5. PASSENGER SIDE A-PILLAR
TRIM PANEL
Figure 68 Driver and Passenger Side A-Pillar Trim Panels
11. Work your fingers in behind driver side A-pillar trim panel at the top between A-pillar trim panel and header
trim panel. Carefully pull A-pillar trim panel off cab A-pillar.
12. Remove two bolts and passenger side grab handle from passenger side A-pillar trim panel.
13. Work your fingers in behind passenger side A-pillar trim panel at the top between A-pillar trim panel and
header trim panel. Carefully pull A-pillar trim panel off cab A-pillar.
S16054 67
1. INSTRUMENT PANEL 3. STEERING WHEEL

2. WINDSHIELD 4. FUSE PANEL ACCESS COVER
14. Carefully lift instrument panel forward and away from windshield, then upward over steering wheel.
Disconnect any auxiliary wiring harness connectors and air ducts.
15. Remove instrument panel from vehicle.
Instrument Panel – Installation
WARNING
Batteries expel explosive gases. To prevent personal injury or death, keep sparks,
flames, burning cigarettes, or other ignition sources away from batteries at all times.
Always wear safety glasses and a face shield when working near batteries.
CAUTION

1. Install instrument panel by carefully lifting it over the steering wheel. Connect any auxiliary wiring harness
electrical connectors and air ducts (Figure 69, Items 1 and 3).
2. Lower instrument panel forward and then downward against cowl panel (Figure 67, Items 3 and 4).
3. Align instrument panel with five speed nuts on cowl panel and secure with bolts (Figure 67). Tighten
bolts to 9.5 to 12 N•m (84 to 106 lbf-in).
4. Connect ignition switch electrical connector to ignition switch (Figure 61).
5. Install driver side and passenger side courtesy lights under instrument panel (not shown).
68 S16054
6. Install six bolts in instrument panel (Figure 66, Items 2 and 7).
7. Install air brake control unit on instrument panel and secure with two bolts (Figure 66, Items 2, 5, and 6).
8. Install instrument panel trim bezel on instrument panel (Figure 65).
9. Install fuse panel access cover on instrument panel (Figure 69, Items 1 and 4).
10. Install two bolts underneath steering column and secure steering column to instrument panel (Figure
66, Items 2, 4, and 8).
11. Open passenger side door and install two bolts under right end of instrument panel (Figure 66, Items 1 and
2). Tighten bolts to 15.5 to 19 N•m (11 to 14 lbf-ft).
12. Open driver side door open and install two bolts under left end of instrument panel (Figure 66, Items 1 and
2). Tighten bolts to 15.5 to 19 N•m (11 to 14 lbf-ft).
13. Align passenger side A-pillar trim panel retaining clips with mounting holes in cab A-pillar and push in
to secure (Figure 68, Items 8 and 9).
14. Install passenger side grab handle on passenger side A-pillar trim panel and secure with two bolts (Figure
68, Items 4, 5, and 6). Tighten bolts to 9 to 11 N•m (80 to 97 lbf-in).
15. Align driver side A pillar trim panel retaining clips with mounting holes in cab A-pillar and push in to
secure (Figure 68, Items 3 and 9).
16. Reconnect battery ground cables after servicing or installing instrument panel.
S16054 69
REMOVAL AND INSTALLATION CAB DOOR
2.8. CAB DOOR

Cab Door – 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 70 Wiring Harness Rubber Boot
1. Remove wiring harness rubber boot from cab hinge pillar.
70 S16054
CAB DOOR REMOVAL AND INSTALLATION
1. LIGHTED, HEATED OR 2. CB RADIO CONNECTOR

ELECTRIC MIRROR 3. ELECTRIC WINDOW AND DOOR
CONNECTOR LOCK CONNECTOR
Figure 71 Electrical Connectors
2. Disconnect 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 window frame and attach to an overhead hoist to support cab
door.
S16054 71
REMOVAL AND INSTALLATION CAB DOOR
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 72 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 wiring harness and electrical connectors through cab hinge pillar.
8. Using overhead hoist, move cab door to a padded workbench.
72 S16054
CAB DOOR REMOVAL AND INSTALLATION
Cab Door – 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
cab door (Figure 72, Item 3).
2. Using the overhead hoist, lift and move cab door near cab (Figure 72, Item 3).
3. Carefully pull wiring harness and electrical connectors through cab hinge pillar (Figure 70, Item 2).
4. Move cab door slightly forward to engage threaded studs in upper and lower hinges (Figure 72).
5. Install four mounting nuts with washers on threaded studs (Figure 72, Items 4 and 8). Tighten nuts to
20 to 24 N•m (15 to 18 lbf-ft).
6. Align link in bracket and insert stop pin (Figure 72, Items 2, 5, and 6).
7. Connect three electrical connectors (lighted, heated, or electric mirror; CB radio; and electric window and
door locks), as equipped. (Figure 71).
8. Secure wiring harness and electrical connectors under instrument panel, if applicable.
9. Install wiring harness rubber boot to cab hinge pillar (Figure 70).
S16054 73
REMOVAL AND INSTALLATION DOOR HINGE
2.9. DOOR HINGE

Door Hinge – Removal
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. UPPER HINGE 4. CAB HINGE PILLAR

2. LOWER HINGE 5. LOCKING BOLT
3. HINGE BOLT
Figure 73 Cab Door Hinge
1. Remove cab door from hinges (See Cab Door, page 70).
2. Matchmark upper and lower hinge positions on cab hinge pillar to aid in cab door adjustment during
installation.
3. Mark location of locking bolt, to installation 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.
74 S16054
DOOR STRIKER PIN REMOVAL AND INSTALLATION
Door Hinge – Installation
1. Align lower hinge with matchmark on cab hinge pillar made during removal (Figure 73, Items 2 and 4).
2. Install lower hinge and secure with two hinge bolts (Figure 73, Items 2 and 3). Tighten bolts to 20 to
24 N•m (15 to 18 lbf-ft).
3. Align upper hinge with matchmark on cab hinge pillar made during removal (Figure 73, Items 1 and 4).
4. Install upper hinge and secure with hinge bolt and locking bolt (Figure 73, Items 1, 3, and 5). Tighten
bolts to 20 to 24 N•m (15 to 18 lbf-ft).
5. Install cab door on hinges (See Cab Door, page 70).
2.10. DOOR STRIKER PIN

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

2. BOLT
Figure 74 Striker Pin
S16054 75
REMOVAL AND INSTALLATION DOOR CHECK BRACKET
1. Remove two bolts and striker pin from door lock pillar.
Door Striker Pin – Installation
1. Install striker pin on door lock pillar and secure with two bolts (Figure 74). Tighten bolts to 20 to 24 N•m
(15 to 18 lbf-ft).
2.11. DOOR CHECK BRACKET

Door Check Bracket – Removal
NOTE – Removal procedures on passenger side and driver side are the same.
1. Remove stop pin from link and bracket (Figure 72, Items 2, 5, and 6).
1. CHECK BRACKET 3. CAB HINGE PILLAR

2. BOLT
Figure 75 Check Bracket
2. Remove two bolts and check bracket from cab hinge pillar.
Door Check Bracket – Installation
76 S16054
DOOR CHECK LINK REMOVAL AND INSTALLATION
1. Install check bracket on cab hinge pillar and secure with two bolts (Figure 75). Tighten bolts to 11 to 14
N•m (97 to 124 lbf-in).
2.12. DOOR CHECK LINK

Door Check Link – Removal
1. Remove cab door trim panel (See CAB DOOR TRIM PANEL, page 79).
2. Remove inner door panel water shield (See INNER DOOR PANEL WATER SHIELD, page 84).
3. Remove stop pin from link and bracket (Figure 72, Items 2, 5, and 6).
S16054 77
REMOVAL AND INSTALLATION DOOR CHECK LINK
1. NUT 3. CHECK LINK

2. CAB DOOR
Figure 76 Door Check Link
4. Remove two nuts and check link from cab door.
Door Check Link – Installation
1. Install check link on cab door and secure with two nuts (Figure 76). Tighten to 9 to 11 N•m (80 to 97 lbf-in).
3. Install inner door panel water shield (See INNER DOOR PANEL WATER SHIELD, page 84).
4. Install cab door trim panel (See CAB DOOR TRIM PANEL, page 79).
78 S16054
CAB DOOR TRIM PANEL REMOVAL AND INSTALLATION
2.13. CAB DOOR TRIM PANEL

Cab Door Trim Panel with Electric Door Window and Locks – Removal
1. SCREW 4. SCREW
2. INNER DOOR PANEL PULL CUP 5. MAP POCKET
3. CAB DOOR TRIM PANEL 6. PUSH-IN FASTENER
Figure 77 Cab Door Trim Panel Fasteners
1. Remove two screws and inner door panel pull cup from cab door trim panel.
2. Remove two screws recessed in map pocket of cab door trim panel.
NOTE – Center portion of push-in fasteners may fall inside cab door if pushed in too far. Center portion
may be retrieved after removal of cab door trim panel.
3. Using a small blunt screwdriver, push in center portion of eight push-in fasteners until they click, and
remove push-in fasteners from cab door trim panel.
S16054 79
REMOVAL AND INSTALLATION CAB DOOR TRIM PANEL
1. CAB DOOR TRIM PANEL 2. CAB DOOR

Figure 78 Cab Door Trim Panel
4. Lift cab door trim panel up and away from cab door.
80 S16054
1. CAB DOOR TRIM PANEL 4. ELECTRIC WINDOW AND

2. CAB DOOR DOOR LOCK SWITCH
3. ELECTRICAL CONNECTOR 5. ELECTRICAL CONNECTOR
Figure 79 Cab Door Trim Panel Electrical Connectors
CAUTION
To prevent damage to wiring harness and components, do not allow cab door trim panel
to hang by wires.
5. While holding cab door trim panel away from cab door, disconnect electric window and door lock switch
and electrical connector from electric mirror switch if equipped.
Cab Door Trim Panel with Electric Door Window and Locks – Installation
1. While holding cab door trim panel away from cab door, connect two electrical connectors on electric
window and door lock switch and electrical connector on electric mirror switch if equipped (Figure 79).
2. Install cab door trim panel on cab door and secure with eight push-in fasteners. Ensure push-in fasteners
are in the locked position. (Figure 77, Items 3 and 6).
3. Install inner door panel pull cup on cab door trim panel and secure with two screws (Figure 77, Items 2, 3,
and 4). Tighten screws to 2 to 3 N•m (18 to 26.6 lbf-in).
4. Install two screws recessed in map pocket of cab door trim panel (Figure 77, Items 3, 4, and 5). Tighten
S16054 81
REMOVAL AND INSTALLATION CAB DOOR TRIM PANEL
Cab Door Trim Panel with Manual Door Window and Locks – Removal
1. SCREW 5. MAP POCKET

2. INNER DOOR PANEL PULL CUP 6. WINDOW REGULATOR HANDLE
3. CAB DOOR TRIM PANEL 7. PUSH-IN FASTENER
4. SCREW
Figure 80 Cab Door and Trim Panel Fasteners
1. Remove two screws inner door panel pull cup from cab door trim panel.
2. Remove two screws recessed in map pocket of cab door trim panel.
3. Push cab door trim panel in at window regulator handle shaft and using suitable removal tool, remove
retaining clip and window regulator handle from window regulator handle shaft (See INNER DOOR PANEL
WATER SHIELD, page 84) (Figure 81).
NOTE – Center portion of push-in fasteners may fall inside cab door if pushed in too far. Center portion
may be retrieved after removal of cab door trim panel.
4. Using a small blunt screwdriver, push in center portion of eight push-in fasteners until they click, and
remove push-in fasteners from cab door trim panel.
5. Lift cab door trim panel up and away from cab door (Figure 78).
82 S16054
Cab Door Trim Panel with Manual Door Window and Locks – Installation
1. Install cab door trim panel on cab door and secure with eight push-in fasteners. Ensure push-in fasteners
are in the locked position (Figure 80, Items 3 and 7).
2. Install inner door panel pull cup on cab door trim panel and secure with two screws (Figure 80, Items 1, 2,
and 3). Tighten screws to 2 to 3 N•m (18 to 26.6 lbf-in).
3. Install two screws recessed in map pocket of cab door trim panel (Figure 80, Items 4 and 5). Tighten
4. Install window regulator handle on window regulator shaft, and secure with retaining clip. Ensure retaining
clip seats in groove on window regulator handle shaft (See INNER DOOR PANEL WATER SHIELD,
page 84) (Figure 81, Items 6, 7, and 12).
S16054 83
REMOVAL AND INSTALLATION INNER DOOR PANEL WATER SHIELD
2.14. INNER DOOR PANEL WATER SHIELD

Inner Door Panel Water Shield – Removal
NOTE –
• Removal procedures for passenger side and driver side are the same.
Note position of inner door panel water shield prior to removal to aid in proper installation.
1. CAB DOOR TRIM PANEL 8. CAB DOOR ACCESS OPENING

2. INNER DOOR PANEL WATER 9. BLUNT TIP FLAT BLADE SCREW
SHIELD DRIVER
3. CAB DOOR 10. WINDOW REGULATOR ARM
4. CAB DOOR GLASS 11. CAB DOOR WINDOW SLIDE
5. ELECTRIC WINDOW SWITCH BLOCK
PANEL 12. CAB DOOR WINDOW SLIDE
6. WINDOW REGULATOR HANDLE RAIL
7. WINDOW REGULATOR HANDLE 13. RETAINING CLIP
SHAFT
Figure 81 Cab Door Inner Door Panel Water Shield
2. Carefully remove inner door panel water shield from cab door.
84 S16054
WINDOW SLIDE BLOCK REMOVAL AND INSTALLATION
Inner Door Panel Water Shield – Installation
NOTE –
• Installation procedures for passenger side and driver side are the same.
Install inner door panel water shield as noted prior to removal.
• Inspect inner door panel water shield for damage that will impair operation. Replace if damaged.
1. Install inner door panel water shield on cab door. Ensure inner door panel water shield is properly
positioned prior to installing cab door trim panel (Figure 81, Items 1, 2, and 3).
2.15. 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 bottom of cab door before removing trim panel.
S16054 85
REMOVAL AND INSTALLATION WINDOW SLIDE BLOCK
1. CAB DOOR 5. WINDOW SLIDE BLOCK

2. TRIM PANEL 6. DOOR GLASS
3. REGULATOR ARM 7. INNER DOOR PANEL WATER
4. SLIDE RAIL SHIELD
Figure 82 Window Slide Block
3. Using a blunt-tip, flat-blade screwdriver, carefully pry regulator arm from window slide block.
86 S16054
CAB DOOR GLASS REMOVAL AND INSTALLATION
1. SLIDE RAIL 3. WINDOW SLIDE BLOCK

2. PLASTIC RETAINING TAB 4. CAB DOOR
Figure 83 Plastic Retaining Tab
4. Carefully break off plastic retaining tab.
5. Slide window slide block off 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 plastic retaining tab broken off during removal of cab door window
slide block from cab door window slide rail.
• Inspect window slide block for wear or damage that will impair operation. Replace If damaged.
1. Install window slide block on slide rail (Figure 83, Items 1 and 3).
2. Carefully push regulator arm in window slide block (Figure 82, Items 3 and 5).
2.16. CAB DOOR GLASS

Cab Door Glass – Removal
NOTE –
• Lower cab door glass to the bottom of cab door before removing trim panel.
S16054 87
REMOVAL AND INSTALLATION CAB DOOR GLASS
2. Remove inner door panel water shield(See INNER DOOR PANEL WATER SHIELD, page 84).
3. Using a blunt-tip, flat-blade screwdriver, carefully pry regulator arm from window slide block (Figure 83,
Items 3 and 5).
1. CAB DOOR 2. GLASS SEAL AND RUN

CHANNEL
Figure 84 Glass Seal and Run Channel
4. Beginning at the upper left side, pull glass seal and run channel from cab door.
5. Remove glass seal and run channel.
88 S16054
CAB DOOR GLASS REMOVAL AND INSTALLATION
1. CAB DOOR GLASS 3. GLASS SEAL AND OUTER BELT

2. CAB DOOR 4. GLASS SEAL AND INNER BELT
Figure 85 Glass Seal and Inner and Outer Belt
NOTE – Modular door hardware assembly not shown in graphic for clarity.
6. Pull glass seal and inner belt from cab door.
7. Pull glass seal and outer belt from cab door.
8. From outside cab door, pull cab door glass upward and remove.
9. Place cab door glass on a suitable, padded work surface.
Cab Door Glass – Installation
NOTE –
• Inspect glass seal, run channels, and inner and outer belts for damage that will impair operation.
Replace if damaged.
1. From outside cab door, install door glass and position in left and right run channels. Ensure cab door glass
is in run channels and moves freely before proceeding (Figure 85, Items 1 and 2).
2. Lower cab door glass to the bottom of cab door (Figure 85, Items 1 and 2).
3. Install glass seal and inner belt and press down firmly in cab door (Figure 85, Items 2 and 4).
S16054 89
REMOVAL AND INSTALLATION MODULAR DOOR HARDWARE ASSEMBLY
4. Install glass seal and outer belt and press down firmly in cab door (Figure 85, Items 2 and 3).
5. Beginning at the upper right, press glass seal and run channel in cab door. Proceed until entire glass seal
and run channel is firmly seated in cab door (Figure 85).
6. Attach regulator arm to window slide block (Figure 82, Items 3 and 5).
NOTE – For manual windows, temporarily attach regulator handle to operate window. For electric
windows, temporarily connect electrical connector to operate window. Remove regulator handle or
disconnect electrical connector after completing Step 7.
7. Raise and lower window to free movement. If binding occurs, find, locate, and correct problem before
continuing.
2.17. 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 removed as
a module.
• Lower cab door glass to the bottom cab door before removing trim panel.
1. Remove door trim panel (See CAB DOOR TRIM PANEL, page 79).
3. Remove cab door glass (See CAB DOOR GLASS, page 87).
90 S16054
MODULAR DOOR HARDWARE ASSEMBLY REMOVAL AND INSTALLATION
1. CAB DOOR 3. TRIM BEZEL

2. SCREW 4. OUTER DOOR HANDLE
Figure 86 Door Handle Trim Bezel
NOTE – Plastic tabs on door handle trim bezel may break off during removal. Replace trim bezel if tabs
break.
4. Using a flat-blade screwdriver wrapped with a cloth rag to protect paint, carefully pry door handle trim
bezel away from cab door.
5. Remove four screws securing outer door handle to cab door.
S16054 91
1. ASSEMBLY MOUNTING BOLT 4. DOOR LATCH BOLT

2. MOUNTING GUIDE PIN 5. MODULAR DOOR HARDWARE
3. REGULATOR ASSEMBLY ASSEMBLY
Figure 87 Modular Door Hardware Assembly
6. Remove three door latch bolts securing door latch assembly to cab door.
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 access electrical
connectors.
92 S16054
MODULAR DOOR HARDWARE ASSEMBLY REMOVAL AND INSTALLATION
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 88 Electrical Connectors
10. Disconnect window motor electrical connector from electric window motor.
11. Remove all push-in fasteners securing wiring harness.
12. Disconnect door latch electrical connector from 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 as a
module.
1. Position modular door hardware assembly near cab door and connect door latch electrical connector to
door latch assembly (Figure 88, Items 5 and 6).
2. Install all wiring harness push-in fasteners (Figure 88, Item 1).
S16054 93
3. Connect window motor electrical connector to window electric motor (Figure 88, Items 2 and 3).
4. Guide the top of window run channels up inside cab door and align door latch assembly (Figure 88,
Items 4 and 5).
5. Align modular door hardware assembly and install mounting guide pin (Figure 87, Items 2 and 5).
6. Install modular door hardware assembly with four assembly mounting bolts (Figure 87, Items 1 and
5). Finger-tighten bolts.
7. Tighten mounting bolts to 11 to 14 N•m (97 to 124 lbf-in).
8. Install door latch assembly on cab door with three door latch bolts (Figure 87, Items 3 and 4). Tighten
bolts to 11 to 14 N•m (97 to 124 lbf-in).
9. Install outer door handle on cab door with four screws (Figure 86, 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 plastic tabs were broken off during
removal.
10. Install trim bezel on cab door and carefully push in place (Figure 86, Item 3).
11. Make sure the door lock, inner and outer door handles, and door latch assembly are all working properly
before proceeding.
12. Install cab door glass (See CAB DOOR GLASS, page 87).
14. Install door trim panel (See CAB DOOR TRIM PANEL, page 79).
94 S16054
VENT WINDOW, LATCH, AND SEAL REMOVAL AND INSTALLATION
2.18. VENT WINDOW, LATCH, AND SEAL

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

2. SCREW 4. CAB DOOR
Figure 89 Vent Window Latch
1. Open vent window and remove two screws and vent window latch from cab door.
S16054 95
REMOVAL AND INSTALLATION VENT WINDOW, LATCH, AND SEAL
1. VENT WINDOW 4. UPPER HINGE PIN

2. LOWER HINGE PIN 5. VENT WINDOW SEAL
3. HINGE 6. CAB DOOR
Figure 90 Vent Window, Hinge Pins, and Seal
2. Lift hinge off upper hinge pin.
3. Lift and remove vent window from hinge.
4. Remove vent window seal from cab door.
Vent Window, Latch, And Seal – Installation
1. Install vent window seal on cab door and press firmly in place (Figure 90, Items 5 and 6).
2. Install vent window and position lower hinge pin in hinge (Figure 90, Items 1, 2, and 3).
3. Carefully lift upper part of hinge and position upper hinge pin in hinge (Figure 90, Items 3 and 4).
4. Close vent window and install vent window latch on cab door with two screws (Figure 89, Items 2, 3, and
4). Tighten screws to 6 to 8 N•m (53 to 71 lbf-in).
96 S16054
VENT WINDOW HINGE REMOVAL AND INSTALLATION
2.19. VENT WINDOW HINGE

Vent Window Hinge – Removal
1. Remove vent window (See VENT WINDOW, LATCH, AND SEAL, page 95).
1. SCREW 4. VENT WINDOW SEAL

2. VENT WINDOW HINGE 5. LOCATING PIN
3. VENT WINDOW FRAME
Figure 91 Vent Window Hinge
2. Remove two screws and vent window hinge from vent window frame.
Vent Window Hinge – Installation
1. Align two locating pins with holes in vent window frame and install vent window hinge on vent window
frame with two screws (Figure 91). Tighten to 6 to 8 N•m (53 to 71 lbf-in).
2. Install vent window (See VENT WINDOW, LATCH, AND SEAL, page 95).
S16054 97
REMOVAL AND INSTALLATION DOOR LOCK CYLINDER
2.20. DOOR LOCK CYLINDER

Door Lock Cylinder – Removal
NOTE –
• All door lock cylinders are coded the same as ignition switch; one key operates both ignition switch
and door locks.
• Plastic tabs on door handle trim bezel may break off during removal. Replace trim bezel if tabs break.
1. Using a flat-blade screwdriver wrapped with a cloth rag to protect paint, carefully pry door handle trim
bezel away from cab door (Figure 86, Items 1 and 3).
1. DOOR LOCK CYLINDER 3. RETAINING CLIP

2. DOOR HANDLE 4. CAB DOOR
Figure 92 Door Lock Cylinder
2. Using a flat-blade screwdriver, remove retaining clip from behind door handle.
3. Remove door lock cylinder from door handle.
98 S16054
WINDOW ELECTRIC MOTOR REMOVAL AND INSTALLATION
Door Lock Cylinder – Installation
NOTE –
• All door lock cylinders are coded the same as ignition switch; one key operates both ignition switch
and door locks.
1. Insert door lock cylinder in door handle (Figure 92, Items 1 and 2).
2. Install retaining clip on door handle (Figure 92, Items 2 and 3).
3. Ensure door lock cylinder operates properly before continuing.
NOTE – Replace trim bezel if tabs were broken during removal.
4. Install trim bezel on cab door and carefully push in place (Figure 86, Item 3).
2.21. WINDOW ELECTRIC MOTOR

Window Electric Motor – Removal
1. Remove door trim panel (See CAB DOOR TRIM PANEL, page 79).
S16054 99
REMOVAL AND INSTALLATION WINDOW ELECTRIC MOTOR
1. MODULAR DOOR HARDWARE 3. WINDOW ELECTRIC MOTOR

ASSEMBLY 4. MOUNTING NUT AND STUD
2. ELECTRICAL CONNECTOR
Figure 93 Window Electric Motor
3. Disconnect electrical connector from window electric motor.
4. Remove three mounting nuts from studs.
5. Remove window electric motor from modular door hardware assembly and studs.
Window Electric Motor – Installation
1. Install window electric motor on modular door hardware assembly and studs (Figure 93, Items 3 and 4).
Make sure window electric motor is aligned properly.
2. Install three mounting nuts on studs (Figure 93, Item 4). Tighten nuts to 7 to 13 N•m (62 to 115 lbf-in).
3. Connect electrical connector to window electric motor (Figure 93, Items 2 and 3).
5. Install door trim panel (See CAB DOOR TRIM PANEL, page 79).
100 S16054
REGULATOR ARM ASSEMBLY REMOVAL AND INSTALLATION
2.22. REGULATOR ARM ASSEMBLY

Regulator Arm Assembly – Removal
NOTE –
• Lower cab door glass to bottom of cab door before removing trim panel.
3. Remove window electric motor (See Window Electric Motor, page 99).
1. CAB DOOR 5. WINDOW SLIDE BLOCK

2. TRIM PANEL 6. CAB DOOR GLASS
3. REGULATOR ARM 7. INNER DOOR PANEL WATER
4. SLIDE RAIL SHIELD
Figure 94 Window Slide Block
S16054 101
REMOVAL AND INSTALLATION REGULATOR ARM ASSEMBLY
4. Using a blunt-tip, flat-blade screwdriver, carefully pry window regulator arm from window slide block.
5. Lift cab door glass to the top of cab door and secure.
1. BOLT 4. INNER DOOR HANDLE

2. DOOR HANDLE RETAINING TAB
3. MODULAR DOOR HARDWARE
ASSEMBLY
Figure 95 Inner Door Handle
6. Remove bolt from inner door handle.
7. Slide inner door handle to the right and pull two door handle retaining tabs from modular door hardware
assembly
102 S16054
REGULATOR ARM ASSEMBLY REMOVAL AND INSTALLATION
1. INNER DOOR HANDLE 4. REGULATOR ASSEMBLY COIL

2. REGULATOR ARM ASSEMBLY SPRING
SHAFT 5. MODULAR DOOR HARDWARE
3. RETAINING TAB ASSEMBLY
Figure 96 Regulator Arm Assembly and Coil Spring
8. Rotate inner door handle counterclockwise until regulator assembly coil spring is exposed.
WARNING
To prevent personal injury or death, be sure to use an appropriate tool when releasing
regulator coil spring tension. Use care when removing window regulator assembly coil
spring from behind retaining tab on modular door hardware assembly. The window
regulator assembly coil spring will be in the loaded position during removal.
S16054 103
REMOVAL AND INSTALLATION REGULATOR ARM ASSEMBLY
9. Carefully release regulator assembly coil spring tension from retaining tab.
10. Remove regulator assembly coil spring from regulator arm assembly shaft.
1. REGULATOR ARM ASSEMBLY 3. MODULAR DOOR HARDWARE

SHAFT ASSEMBLY
2. REGULATOR ARM
Figure 97 Regulator Arm and Regulator Arm Assembly Shaft
11. Insert a flat-blade screwdriver in the slot of regulator arm assembly shaft and rotate counterclockwise to
the unlocked position.
12. Pull regulator arm assembly shaft straight out and remove.
13. Remove regulator arm from modular door hardware assembly.
Regulator Arm Assembly – Installation
1. Attach regulator arm by installing regulator arm assembly shaft through modular door hardware assembly
in regulator arm (Figure 97).
2. Insert a flat-blade screwdriver in the slot of the regulator arm assembly shaft and rotate it clockwise to
the locked position (Figure 97, Item 1).
3. Install regulator assembly coil spring in the slot of regulator arm assembly shaft (Figure 96, Items 2 and 4).
WARNING
To prevent personal injury or death, be sure to use an appropriate tool when installing
regulator coil spring. Use care when installing window regulator assembly coil spring
behind retaining tab on modular door hardware assembly.
4. Rotate regulator assembly coil spring clockwise to retaining tab on modular door hardware assembly and
secure behind retaining tab (Figure 96, Items 3, 4, and 5).
104 S16054
OUTER DOOR HANDLE REMOVAL AND INSTALLATION
5. Rotate inner door handle clockwise until regulator assembly coil spring is covered (Figure 96, Items 1
and 4).
6. Insert two inner door handle retaining tabs in slots in modular door hardware assembly and slide inner
door handle to the right to secure in place (Figure 95, Items 2, 3, and 4).
7. Install bolt and secure inner door handle to modular door hardware assembly (Figure 95, Items 1, 3, and
4). Tighten bolt to 8 to 10 N•m (71 to 89 lbf-in).
8. Lower cab door glass to the bottom of cab door.
9. Attach regulator arm to window slide block (Figure 94, Items 3 and 5).
NOTE – For manual windows, temporarily attach regulator handle to operate window. For electric
windows, temporarily connect electrical connector to operate window. Remove regulator handle or
disconnect electrical connector after completing Step 10.
10. Raise and lower window to free movement. If binding occurs, find, locate, and correct problem before
continuing.
11. Install window electric motor (See Window Electric Motor, page 99).
12. Install cab door inner door panel water shield (See INNER DOOR PANEL WATER SHIELD, page 84).
2.23. OUTER DOOR HANDLE

Outer Door Handle – Removal
3. Remove modular door hardware assembly (See MODULAR DOOR HARDWARE ASSEMBLY, page 90).
S16054 105
REMOVAL AND INSTALLATION OUTER DOOR HANDLE
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 98 Outer Door Handle and Control Rods
4. Depress locking tab and slide hanger support bracket to the left and out of window run channel.
5. Disconnect long control rod from lock lever.
6. Rotate outer door handle and disconnect short control rod.
106 S16054
OUTER DOOR HANDLE REMOVAL AND INSTALLATION
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 99 Outer Door Handle and Hanger Support Bracket
7. Rotate hanger support bracket counterclockwise. Align slot in hanger support bracket with T-shaped
locking tab and remove outer door handle.
8. Remove door lock cylinder (See Door Lock Cylinder, page 98).
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 99, Items 3 and 5).
2. Install door lock control rod on door lock cylinder lever (Figure 99, Items 5 and 6).
3. Install door lock cylinder (See Door Lock Cylinder, page 98).
4. Attach outer door handle by aligning slot in hanger support bracket with T-shaped locking tab and rotate
hanger support bracket clockwise (Figure 99, Items 1, 2, and 3).
S16054 107
REMOVAL AND INSTALLATION DOOR LATCH
5. Connect short control rod to the top of outer door handle. Rotate outer door handle to proper position on
control rod (Figure 98, Items 3 and 5).
6. Connect long control rod to lock lever (Figure 98, Items 2 and 4).
7. Slide hanger support bracket in place on window run channel and locking tab locks in place (Figure
98, Items 6, 7, and 8).
8. Install modular door hardware assembly (See MODULAR DOOR HARDWARE ASSEMBLY, page 90).
2.24. 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 100 Door Latch and Control Rods
4. Depress locking tab and slide hanger support bracket to the left and out of window run channel.
5. Disconnect upper and lower control rods from door latch.
108 S16054
INNER DOOR HANDLE REMOVAL AND INSTALLATION
Door Latch – Installation
1. Connect upper and lower control rods to door latch (Figure 100, Items 2, 4, and 5).
2. Slide hanger support bracket in place on window run channel and locking tab locks in place (Figure
100, Items 1, 3, and 6).
2.25. INNER DOOR HANDLE

Inner Door Handle – Removal
4. Remove outer door handle (See Outer Door Handle, page 105) .
5. Remove door latch (See Door Latch, page 108) .
1. MODULAR DOOR HARDWARE 3. SPRING

ASSEMBLY 4. RETAINING CLIP
2. INNER DOOR HANDLE 5. INNER DOOR HANDLE
CONTROL ROD CONTROL ROD
Figure 101 Inner Door Handle and Control Rods
S16054 109
REMOVAL AND INSTALLATION INNER DOOR HANDLE
6. Remove inner door handle control rod with spring from retaining clip.
7. Remove bolt from inner door handle Figure 95, Items 1, 3, and 4 .
8. Slide inner door handle to the right and pull two door handle retaining tabs from modular door hardware
assembly Figure 95, Items 2, 3, and 4 .
9. Lift inner door handle up and over window regulator assembly and slide it to the right until inner door
handle control rods clear opening in modular door hardware assembly.
1. INNER DOOR HANDLE 3. INNER DOOR HANDLE

2. INNER DOOR HANDLE CONTROL ROD
CONTROL ROD 4. SPRING
Figure 102 Inner Door Handle and Control Rods
10. Remove inner door handle control rod from inner door handle.
11. Remove inner door handle control rod with spring from slotted hole of inner door handle.
Inner Door Handle – Installation
1. Install inner door handle control rod with spring in slotted hole of inner door handle (Figure 102, Items 1,
3, and 4).
2. Install inner door control rod on inner door handle (Figure 102, Items 1 and 2).
110 S16054
WINDOW RUN CHANNELS REMOVAL AND INSTALLATION
3. Install inner door handle control rods through opening in front side of modular door hardware assembly
and slide inner door handle to the left until inner door handle is positioned over window regulator assembly
(Figure 102, Items 2, 5, and 6).
4. Insert two inner door handle retaining tabs in slots in modular door hardware assembly and slide inner
door handle to the right to secure in place (Figure 95, Items 2, 3, and 4).
5. Install bolt and secure inner door handle to modular hardware assembly (Figure 95, Items 1, 3, and
4). Tighten bolt to 8 to 10 N•m (71 to 89 lbf-in).
6. Install inner door control rod with spring in retaining clip (Figure 101, Items 2, 3, and 4).
7. Install door latch (See Door Latch, page 108).
8. Install outer door handle (See Outer Door Handle, page 105).
2.26. WINDOW RUN CHANNELS

Window Run Channels – Removal
S16054 111
REMOVAL AND INSTALLATION WINDOW RUN CHANNELS
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 103 Window Run Channel and Brackets
4. Remove outer door handle by pressing locking tab in and sliding outer door handle bracket out of window
run channel.
5. Remove door latch by pressing locking tab in and sliding door latch bracket out of window run channel.
112 S16054
WINDOW RUN CHANNELS REMOVAL AND INSTALLATION
1. WINDOW RUN CHANNEL 3. MODULAR DOOR HARDWARE

2. LOCKING TAB ASSEMBLY
Figure 104 Window Run Channels
6. Depress locking tabs at top and bottom of window run channels.
7. Slide window run channels out of modular door hardware assembly.
Window Run Channels – Installation
1. Install window run channels in modular door hardware assembly. Ensure locking tabs lock in place (Figure
104).
2. Install door latch by sliding door latch bracket in window run channel. Ensure locking tabs lock in place
(Figure 104).
3. Install outer door handle by sliding outer door handle bracket in window run channel. Ensure locking
tabs lock in place (Figure 104).
5. Install cab door inner door panel water shield (See INNER DOOR PANEL WATER SHIELD, page 84).
S16054 113
REMOVAL AND INSTALLATION ELECTRIC WINDOW AND DOOR LOCK SWITCH
2.27. 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. CAB DOOR TRIM PANEL 6. ELECTRICAL CONNECTOR
Figure 105 Electric Window and Door Lock Switch
1. Insert universal DIN removal tools in electric window and door lock switch at a slight angle toward switch
buttons.
2. Pull universal DIN removal tools out and away from switch buttons to release spring retaining clips.
3. Lift electric window and door lock switch up from cab door trim panel and disconnect electrical connectors.
Electric Window And Door Lock Switch – Installation
1. Connect electrical connectors to electric window and door lock switch (Figure 105, Items 5 and 6).
114 S16054
ELECTRIC MIRROR SWITCH REMOVAL AND INSTALLATION
2. Push electric window and door lock switch in cab door trim panel until spring retaining clips lock in place
2.28. ELECTRIC MIRROR SWITCH

Electric Mirror Switch – Removal
1. ELECTRIC MIRROR SWITCH 3. RETAINING TAB

2. CAB DOOR TRIM PANEL 4. ELECTRICAL CONNECTOR
Figure 106 Electric Mirror Switch
1. Using a flat-blade screwdriver, carefully pry electric mirror switch from cab door trim panel.
2. Disconnect electrical connector from electric mirror switch.
Electric Mirror Switch – Installation
1. Connect electrical connector to electric mirror switch (Figure 106, Items 1 and 4).
2. Push electric mirror switch in cab door trim panel until retaining tabs lock in place (Figure 106, Items 1,
2, and 3).
S16054 115
REMOVAL AND INSTALLATION SEATS AND SEAT BELTS
2.29. SEATS AND SEAT BELTS

Bucket Seat – Removal
WARNING
To prevent injury or death to personnel, fully drain air system prior to disconnecting or
servicing air system components.
1. Drain air system.
1. BUCKET SEAT 4. MOUNTING STUDS

2. FLOOR 5. QUICK DISCONNECT FITTING
3. NUTS 6. AIR LINE
Figure 107 Bucket Seat and Air Line
2. If equipped, disconnect air line at quick disconnect fitting.
3. Remove four nuts from mounting studs.
4. With the aid of an assistant, remove bucket seat from mounting studs and floor.
Bucket Seat – Installation
NOTE – Use new mounting hardware when installing seats so that proper torque requirements can be
met.
116 S16054
SEATS AND SEAT BELTS REMOVAL AND INSTALLATION
1. With the aid of an assistant, install bucket seat on four mounting studs and floor and secure with nuts
(Figure 107). Tighten nuts to 20 to 27 N•m (15 to 20 lbf-ft).
2. If equipped, connect air line to quick disconnect fitting (Figure 107, Items 5 and 6).
Two Man Fixed Bench Seat – Removal
1. NUTS 3. TWO MAN FIXED BENCH SEAT

2. FLOOR 4. MOUNTING STUDS
Figure 108 Two Man Fixed Bench Seat
1. Remove four nuts from mounting studs.
2. With the aid of an assistant, remove two man fixed bench seat from mounting studs and floor.
NOTE – If removing seat belts and buckles, perform Steps 3 and 4.
S16054 117
1. BOLT 4. BOLT
2. OUTSIDE SEAT BELT 5. OUTSIDE SEAT BELT BUCKLE
3. FLOOR 6. INSIDE SEAT BELT BUCKLE
Figure 109 Outside Seat Belt and Buckles
3. Remove bolt and outside seat belt from floor.
4. Remove bolt and inside and outside seat belt buckles from floor.
NOTE – If removing seat belt and retractor, perform Steps 5 through 8.
118 S16054
SEATS AND SEAT BELTS REMOVAL AND INSTALLATION
1. BOLT 5. SEAT BELT

2. FLOOR 6. BOLT
3. BOLT 7. SEAT BELT SUPPORT
4. SEAT BELT RETRACTOR 8. BOLT
Figure 110 Seat Belt, Retractor, and Seat Belt Support
5. Remove seat belt retractor cover from seat belt retractor (See SCUFF PLATE AND SEAT BELT
RETRACTOR COVER, page 121).
6. Remove bolt from seat belt and floor.
7. Remove bolt securing seat belt retractor to cab (not shown).
8. Remove bolt and seat belt from seat belt support.
NOTE – If removing seat belt support, perform Steps 9 and 10.
9. Remove passenger side corner and side interior trim panel (See CORNER AND SIDE INTERIOR TRIM
PANEL, page 122).
10. Remove two bolts and seat belt support from cab (not shown).
Two Man Fixed Bench Seat and Seat Belt – Installation
NOTE – If installing seat belt support, perform Steps 1 and 2.
S16054 119
1. Install seat belt support on cab (not shown) and secure with two bolts (Figure 110, Items 6 and 7). Tighten
bolts to 34 to 47.5 N•m (25 to 35 lbf-ft).
2. Install passenger side corner and side interior trim panel (See CORNER AND SIDE INTERIOR TRIM
PANEL, page 122).
NOTE –
• If installing seat belt and retractor, perform Steps 3 through 6.

• Use new mounting hardware when installing seats so that proper torque requirements can be met.
3. Install seat belt on seat belt support and secure with bolt (Figure 110, Items 5, 7, and 8). Tighten bolt to 34
to 47.5 N•m (25 to 35 lbf-ft).
4. Install seat belt retractor on cab (not shown) and secure with bolt (Figure 110, Items 3 and 4). Tighten
bolt to 34 to 47.5 N•m (25 to 35 lbf-ft).
5. Install seat belt on floor and secure with bolt (Figure 110, Items 1, 2, and 5). Tighten bolt to 34 to 47.5 N•m
(25 to 35 lbf-ft).
6. Install seat belt retractor cover on seat belt retractor (See SCUFF PLATE AND SEAT BELT RETRACTOR
COVER, page 121).
NOTE –
• If installing seat belts and buckles, perform Steps 7 and 8.

• Use new mounting hardware when installing seats so that proper torque requirements can be met.
7. Install inside and outside seat belt buckles on floor and secure with bolt (Figure 109). Tighten bolt to 34
to 47.5 N•m (25 to 35 lbf-ft).
8. Install outside seat belt on floor and secure with bolt (Figure 109, Items 1, 2 and 3). Tighten bolt to 34
to 47.5 N•m (25 to 35 lbf-ft).
9. With the aid of an assistant, install two man fixed bench seat on four mounting studs and floor and secure
with nuts (Figure 108). Tighten nuts to 20 to 27 N•m (15 to 20 lbf-ft).
120 S16054
SCUFF PLATE AND SEAT BELT RETRACTOR COVER REMOVAL AND INSTALLATION
2.30. SCUFF PLATE AND SEAT BELT RETRACTOR COVER

Scuff Plate and Seat Belt Retractor Cover – Removal
1. SCREW 5. SCUFF PLATE

2. PUSH-IN FASTENER 6. FLOOR
3. SEAT BELT RETRACTOR COVER
4. SEAT BELT RETRACTOR
ASSEMBLY
Figure 111 Scuff Plate and Seat Belt Retractor Cover
1. Remove four screws and scuff plate from floor.
2. Remove push-in fastener and seat belt retractor cover from seat belt retractor.
Scuff Plate and Seat Belt Retractor Cover – Installation
1. Install scuff plate on floor and secure with four screws (Figure 111, Items 1,5 and 6). Tighten screws to 2
to 3 N•m (18 to 26.6 lbf-in).
2. Install seat belt retractor cover on seat belt retractor assembly and secure with push-in fastener (Figure
111, Items 2, 3, and 4).
S16054 121
REMOVAL AND INSTALLATION CORNER AND SIDE INTERIOR TRIM PANEL
2.31. CORNER AND SIDE INTERIOR TRIM PANEL

Corner and Side Interior Trim Panel – Removal
1. Remove seats (See SEATS AND SEAT BELTS, page 116).
2. Remove scuff plate and seat belt retractor cover (See SCUFF PLATE AND SEAT BELT RETRACTOR
COVER, page 121).
1. PUSH-IN FASTENER 4. CORNER AND SIDE INTERIOR

2. SEAT BELT TRIM PANEL
3. BOLT 5. CAB
Figure 112 Corner and Side Interior Trim Panel
3. Remove bolt and seat belt from seat belt support.
4. Using ZTSE4839 interior trim tool, remove seven push-in fasteners and corner and side interior trim
panel from cab.
Corner and Side Interior Trim Panel – Installation
1. Install corner and side interior trim panel in cab and secure with seven push-in fasteners (Figure 112,
Items 1,4, and 5).
2. Install seat belt on seat belt support and secure with bolt (Figure 112, Items 2, 3, and 5). Tighten bolt to 34
to 47.5 N•m (25 to 35 lbf-ft).
3. Install scuff plate and seat belt retractor cover (See SCUFF PLATE AND SEAT BELT RETRACTOR
COVER, page 121).
4. Install seats (See SEATS AND SEAT BELTS, page 116).
122 S16054
REAR INTERIOR TRIM PANEL REMOVAL AND INSTALLATION
2.32. REAR INTERIOR TRIM PANEL

Rear Interior Trim Panel – Removal
1. Remove either passenger side or driver side corner and side interior trim panel (See CORNER AND SIDE
INTERIOR TRIM PANEL, page 122).
1. REAR INTERIOR TRIM PANEL 2. PUSH-IN FASTENER

Figure 113 Rear Interior Trim Panel
2. Using ZTSE4839 interior trim tool, remove five push-in fasteners and rear interior trim panel from cab.
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 corner and side interior trim panels was
not removed during removal step, then only the side and corner interior trim panel that was removed
needs to be installed.
1. Install rear interior trim panel in cab and secure with five push-in fasteners (Figure 113).
2. Make sure floor mat is properly fitted around the bottom of rear interior trim panel.
3. Install passenger side or driver side corner and side interior trim panels (See CORNER AND SIDE
INTERIOR TRIM PANEL, page 122).
S16054 123
REMOVAL AND INSTALLATION HEADER CONSOLE PANEL
2.33. HEADER CONSOLE PANEL

Header Console Panel – Removal
1. PASSENGER SIDE A-PILLAR 2. GRAB HANDLE

AND TRIM PANEL 3. BOLT
Figure 114 Passenger Side Grab Handle
1. Remove two bolts and grab handle from passenger side A-pillar.
2. Remove passenger side A-pillar trim panel by beginning at the top and carefully pulling away from A-pillar.
124 S16054
HEADER CONSOLE PANEL REMOVAL AND INSTALLATION
1. DRIVER SIDE A-PILLAR TRIM 3. DRIVER SIDE A-PILLAR

PANEL 4. INSTRUMENT PANEL
2. A-PILLAR
Figure 115 Driver Side A-Pillar Trim Panel
3. Remove driver side A-pillar trim panel by beginning at the top and carefully pulling away from A-pillar.
4. Remove sun visor and clip (See SUN VISOR AND CLIP, page 56).
CAUTION
To prevent damage to electrical connectors and tachograph pins, do not allow

tachograph to hang by electrical connectors. If tachograph is allowed to hang by
electrical connectors, wires may be pulled from electrical connectors, or tachograph
pins may be bent/broken.
NOTE – Do not open, or attempt to disassemble tachograph. Tachograph is to be serviced by an

authorized dealer only. If seal on tachograph housing is broken, tachograph can not be legally installed
in vehicle.
S16054 125
1. HEADER CONSOLE PANEL 3. SCREW

2. TACHOGRAPH 4. BEZEL
Figure 116 Tachograph
5. Using universal DIN removal tool, remove tachograph from header console panel enough to access bezel
and two electrical connectors (not shown) on rear of tachograph.
6. Remove screw and bezel from rear of tachograph.
7. Disconnect two electrical connectors (not shown) from rear of tachograph and remove tachograph from
header console panel.
126 S16054
1. WIRING HARNESS 4. SPEAKER

2. COURTESY LIGHT SCREW 5. SCREW
3. COURTESY LIGHT ELECTRICAL 6. COURTESY LIGHT
CONNECTOR 7. HEADER CONSOLE PANEL
Figure 117 Header Console Panel
8. Pull courtesy light slightly out of header console panel to expose wiring.
9. Disconnect courtesy light electrical connector from wiring harness and remove.
10. Remove two courtesy light screws from courtesy light cavity.
11. Remove two screws from each side of header console panel near speakers.
12. Release header console panel by pulling down and out.
13. Lower header console panel down and lay it across instrument panel.
S16054 127
1. ELECTRICAL CONNECTOR 3. ELECTRICAL CONNECTOR

2. BUZZER 4. ANTI-THEFT MODULE
Figure 118 Anti-Theft and Buzzer Electrical Connectors
14. Disconnect electrical connector from buzzer.
15. Disconnect electrical connector from anit-theft module.
1. DRIVER SIDE SPEAKER 5. WIRING HARNESS

2. HEADER CONSOLE PANEL 6. SPEAKER ELECTRICAL
3. RETAINING CLIP WITH WIRE TIE CONNECTOR
4. PASSENGER SIDE SPEAKER
Figure 119 Header Console Panel Electrical Connections
16. Disconnect speaker electrical connectors from driver side and passenger side speakers.
128 S16054
17. If equipped, remove six retaining clips with wire ties securing wiring harness to header console panel.
18. Remove header console panel.
Header Console Panel – Installation
1. If removed, Install six retaining clips with wire ties and secure wiring harness to header console panel
2. Connect driver side and passenger side speaker electrical connectors to speakers (Figure 119, Items 1,
4, and 6).
3. Connect electrical connector to anti-theft module (Figure 118, Items 1 and 4).
4. Connect electrical connector to buzzer (Figure 118, Items 2 and 3).
5. Install header console panel by pushing up and snapping in place (Figure 117, Item 7).
6. Install two screws on each side of header console panel near speakers (Figure 117, Items 4, 5, and 7).
Tighten screws to 2 to 3 N•m (18 to 26.6 lbf-in).
7. Install two courtesy light screws inside cavity of courtesy light (Figure 117, Items 2 and 6). Tighten screws
to 2 to 3 N•m (18 to 26.6 lbf-in).
8. Connect courtesy light electrical connector to wiring harness (Figure 117, Items 1 and 3).
9. Install courtesy light in header console panel by pushing up and snapping in place (Figure 117, Items 6
and 7).
10. Connect two electrical connectors (not shown) to rear of tachograph (Figure 116, Item 2).
11. Install bezel on rear of tachograph and secure with screw (Figure 116, Items 2, 3 and 4).
12. Install tachograph in header console by firmly pushing until tachograph locks in place (Figure 116,
Items 1 and 2).
13. Install sun visor and clip (See SUN VISOR AND CLIP, page 56).
14. Install driver side A-pillar trim panel by aligning trim panel retaining clips with mounting holes and push in
to secure (Figure 115, Item 10).
15. Install passenger side A-pillar trim panel by aligning trim panel retaining clips with the mounting holes and
push in to secure (Figure 115, Item 1).
16. Install passenger side grab handle and secure with two bolts (Figure 114, Items 2 and 3). Tighten bolts to
9 to 11 N•m (80 to 97 lbf-in).
S16054 129
REMOVAL AND INSTALLATION HEADLINER TRIM PANEL
2.34. HEADLINER TRIM PANEL

Headliner Trim Panel – Removal
1. Remove header console panel (See HEADER CONSOLE PANEL, page 124).
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 120 Headliner Trim Panel
2. Pull coat hook lever cover down.
3. Push coat hook lever down and remove coat hook.
4. Using ZTSE4839 interior trim tool, 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 headliner trim panel.
6. Remove one push-in fastener each in headliner trim panel near each A-pillar above door opening.
130 S16054
HEADLINER TRIM PANEL REMOVAL AND INSTALLATION
7. Support the front of headliner trim panel and remove one push-in fastener from front, center of headliner
trim panel.
8. Lower front of headliner trim panel and slide forward. Carefully pull headliner trim panel out from behind
corner and side interior trim panels.
Headliner Trim Panel – 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 120, Items 4 and 7).
2. Lift front, center of headliner trim panel and install one push-in fastener (Figure 120, Items 4 and 5).
3. Install one push-in fastener each in headliner trim panel near each A-pillar above door opening (Figure
120, Items 4, 5, and 6).
4. Install two push-in fasteners at the rear of headliner trim panel (Figure 120, Items 4 and 5).
5. Install two push-in fasteners at the top of each corner and side interior trim panel (Figure 120, Items 5
and 7).
6. Install coat hook and snap in place (Figure 120, Item 1).
7. Push coat hook lever cover up and snap in place (Figure 120 , Item 2).
8. Install header console panel (See HEADER CONSOLE PANEL, page 124).
S16054 131
REMOVAL AND INSTALLATION WEATHER SEALS
2.35. WEATHER SEALS

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

2. WEATHER SEAL FLANGE
Figure 121 Weather Seals
1. Remove scuff plate and seat belt retractor cover (See SCUFF PLATE AND SEAT BELT RETRACTOR
COVER, page 121).
2. Remove primary weather seal by carefully pulling off of weather seal flange.
3. Remove secondary weather seal by carefully pulling off of weather seal flange.
Weather Seals – Installation
1. Install secondary weather seal on weather seal flange by pressing in place until seated (Figure 121,
Items 1 and 2).
2. Install primary weather seal on weather seal flange by pressing in place until seated (Figure 121, Items 2
and 3).
3. Install scuff plate and seat belt retractor cover (See SCUFF PLATE AND SEAT BELT RETRACTOR
COVER, page 121).
132 S16054
WINDSHIELD WIPER ARM AND BLADE ASSEMBLY REMOVAL AND INSTALLATION
2.36. WINDSHIELD WIPER ARM AND BLADE ASSEMBLY

Windshield Wiper Arm and Blade Assembly – Removal
NOTE – Note orientation of blade assembly to wiper pivot post prior to removal to aid in installation.
1. PASSENGER SIDE WIPER ARM 3. DRIVER SIDE WIPER ARM AND

AND BLADE ASSEMBLY BLADE ASSEMBLY
2. WIPER PIVOT POST 4. LOCK LEVER
5. WASHER HOSE
Figure 122 Windshield Wiper Arm and Blade Assembly
2. Disconnect washer hose from T-fitting.
3. Lift lock lever up and remove driver side wiper arm and blade assembly from wiper pivot post.
4. Lift lock lever up and remove passenger side wiper arm and blade assembly from wiper pivot post.
Windshield Wiper Arm and Blade Assembly – Installation
1. Press passenger side wiper arm and blade assembly on wiper pivot post and lock in place (Figure 122,
Items 1 and 2).
2. Press driver side wiper arm and blade assembly on wiper pivot post and lock in place (Figure 122,
Items 2 and 3).
3. Ensure both lock levers are pressed down and secure (Figure 122, Item 4).
4. Attach washer hose to T-fitting (Figure 122, Item 5).
S16054 133
REMOVAL AND INSTALLATION CAB COWL TRAY
6. Turn wipers on high speed, activate windshield washer, and verify proper wiper operation. Adjust as
required (See WINDSHIELD WIPER ARM AND BLADE ASSEMBLY, page 167).
2.37. CAB COWL TRAY

Cab Cowl Tray – Removal
1. NUT 4. HYDRAULIC CLUTCH

2. SCREW AND WASHER RESERVOIR
3. CAB COWL TRAY
Figure 123 Slave Cylinder and Cab Cowl Tray
2. Remove two nuts, screws, washers, and hydraulic clutch reservoir from cab cowl tray. Set hydraulic
clutch reservoir aside in a secure, upright position.
3. Remove driver and passenger side windshield wiper arm and blade assemblies (See WINDSHIELD
WIPER ARM AND BLADE ASSEMBLY, page 133).
134 S16054
CAB COWL TRAY REMOVAL AND INSTALLATION
1. MOUNTING STUD 6. MOUNTING NUT

2. CENTER MOUNTING BRACKET 7. BRACKET
BOLT 8. COWL TRAY
3. RUBBER SEAL 9. WIPER PIVOT POST
4. ANTENNA 10. WASHER HOSE
5. SCREW
Figure 124 Cab Cowl Tray
4. Remove washer hose from under cowl tray.
5. Remove rubber seal from antenna.
6. Remove screw from bracket.
7. Remove center mounting bracket bolt from cowl tray.
8. Remove two mounting nuts from cowl tray.
9. Lift cowl tray up off antenna, mounting studs, and wiper pivot posts.
Cab Cowl Tray – Installation
1. Install cowl tray over antenna, mounting studs, and wiper pivot posts (Figure 124).
2. Install two mounting nuts on cowl tray (Figure 124, Items 6 and 8). Tighten nuts to 22 N•m (16 lbf-ft); DO
NOT exceed 24 N•m (18 lbf-ft).
3. Install center mounting bracket bolt on cowl tray (Figure 124, Items 2 and 8). DO NOT overtighten.
4. Install screw in bracket (Figure 124, Items 5 and 7). DO NOT overtighten.
5. Install rubber seal on antenna (Figure 124, Items 3 and 4).
S16054 135
REMOVAL AND INSTALLATION WINDSHIELD WIPER ASSEMBLY
6. Install washer hose under cowl tray (Figure 124, Items 8 and 10).
7. Install both driver and passenger side windshield wiper arm and blade assemblies (See WINDSHIELD
8. Install hydraulic clutch reservoir on cab cowl tray and secure with two screws, washers, and nuts (Figure
123). DO NOT overtighten.
10. Turn wipers on high speed, activate windshield washer, and verify proper wiper operation. Adjust as
required (See WINDSHIELD WIPER ARM AND BLADE ASSEMBLY, page 167).
2.38. WINDSHIELD WIPER ASSEMBLY

Windshield Wiper Assembly – Removal
2. Remove driver and passenger side windshield wiper arm and blade assemblies (See WINDSHIELD
3. Remove cab cowl tray (See CAB COWL TRAY, page 134).
1. MOUNTING STUD 4. WINDSHIELD WIPER MOTOR

2. MOUNTING NUT 5. WINDSHIELD WIPER ASSEMBLY
3. ELECTRICAL CONNECTOR
Figure 125 Windshield Wiper Assembly
4. If required, remove wire tie securing wiring harness to windshield wiper motor (not shown).
5. Disconnect electrical connector from windshield wiper motor.
6. Remove four mounting nuts and windshield wiper assembly from mounting studs.
136 S16054
ELECTRIC WINDSHIELD WIPER MOTOR REMOVAL AND INSTALLATION
Windshield Wiper Assembly – Installation
1. Install windshield wiper assembly on four mounting studs and secure with mounting nuts (Figure 125,
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 125, Items 3 and 4).
3. If removed, secure wiring harness and connector with wire tie (not shown).
4. Install cab cowl tray (See CAB COWL TRAY, page 134).
5. Install driver and passenger side windshield wiper arm and blade assemblies (See WINDSHIELD WIPER
ARM AND BLADE ASSEMBLY, page 133).
7. Turn wipers on high speed, activate windshield washer, and verify proper wiper operation. Adjust
windshield wiper arm and blade assemblies if required (See WINDSHIELD WIPER ARM AND BLADE
ASSEMBLY, page 167).
2.39. ELECTRIC WINDSHIELD WIPER MOTOR

Electric Windshield Wiper Motor – Removal
CAUTION
To prevent damage to wiper arms and blades, do not attempt to stop wiper blades or
arms while they are in motion. Attempting to stop wiper arms or blades in motion may
result in component damage. If wiper arms or blades are frozen to the windshield, thaw
them out before attempting to operate.
NOTE – Electric windshield wiper motor has no serviceable parts or adjustments and is replaced as a
complete unit.
2. Turn ignition key to the ON position and cycle wiper arms to the end of sweep cycle (wiper blades will be in
the vertical position). Turn key to the OFF position.
S16054 137
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 126 Electric Windshield Wiper Motor
NOTE – Graphic view is shown from the rear of electric windshield wiper motor.
3. Disconnect electrical connector from electric wiper motor.
4. If required, remove wire tie securing wiring harness to windshield wiper motor and/or mounting bracket.
5. Remove nut and lockwasher securing wiper drive arm to electric wiper motor.
6. Remove three mounting bolts and electric windshield wiper motor from mounting bracket.
Electric Windshield Wiper Motor – Installation
CAUTION
To prevent damage to wiper arms and blades, do not attempt to stop wiper blades or
arms while they are in motion. Attempting to stop wiper arms or blades in motion may
result in component damage. If wiper arms or blades are frozen to the windshield, thaw
them out before attempting to operate.
NOTE – Electric windshield wiper motor has no serviceable parts or adjustments and is replaced as a
complete unit.
1. Install electric wiper motor on mounting bracket and secure with three mounting bolts (Figure 126, Items 3,
4, and 5). Tighten bolts to 10 to 12 N•m (89 to 106 lbf-in).
2. Install wiper drive arm to electric wiper motor and secure with lockwasher and nut (Figure 126). Tighten
nut to 20 to 25 N•m (15 to 18 lbf-ft).
3. Connect electrical connector to electric wiper motor. Replace any previously removed wire ties (Figure
126, Items 2 and 5).
138 S16054
WINDSHIELD WASHER BOTTLE AND PUMP MOTOR REMOVAL AND INSTALLATION
4. Turn ignition key to the ON position and cycle wiper arms to the end of sweep cycle (wiper blades will be in
the horizontal position). Turn key to OFF position.
6. Turn wipers on high speed, activate windshield washer, and verify proper wiper operation. Adjust
windshield wiper arm and blade assemblies if required.
2.40. WINDSHIELD WASHER BOTTLE AND PUMP MOTOR

Windshield Washer Bottle and Pump Motor – Removal
NOTE – The windshield washer bottle with pump motor is mounted on the right front frame rail behind
the bumper.
1. MOUNTING BOLT AND WASHER 5. WIRING HARNESS ELECTRICAL

2. WASHER BOTTLE CONNECTOR
3. PUMP MOTOR 6. WASHER HOSE
4. WASHER BOTTLE BRACKET
Figure 127 Windshield Washer Bottle and Pump Motor
2. Disconnect wiring harness electrical connector from pump motor.
3. Using a suitable container to catch washer fluid, remove washer hose from pump motor and allow fluid to
drain.
4. Remove three mounting bolts, washers, and washer bottle from washer bottle bracket.
5. Carefully remove pump motor from washer bottle.
S16054 139
REMOVAL AND INSTALLATION ENGINE COVER, CUP HOLDER, AND ASHTRAY
Windshield Washer Bottle With Pump Motor – Installation
1. Install pump motor on washer bottle (Figure 127, Items 2 and 3).
2. Install washer bottle on washer bottle bracket and secure with three mounting bolts and washers (Figure
127, Items 1, 2, and 4). Do not overtighten.
3. Connect washer hose to pump motor (Figure 127, Items 3 and 6).
4. Connect wiring harness electrical connector to pump motor (Figure 127, Items 3 and 5 ).
5. Fill washer bottle with windshield washer fluid. Check for leaks and proper washer operation (Figure
127, Item 2).
2.41. ENGINE COVER, CUP HOLDER, AND ASHTRAY

Cup Holder and Ashtray – Removal
1. INSTRUMENT PANEL TRIM 4. SCREW

BEZEL 5. CUP HOLDER
2. INSTRUMENT PANEL 6. PRY POINTS
3. ASHTRAY
Figure 128 Cup Holder and Ashtray
1. Using a flat blade screwdriver wrapped with a cloth rag, gently pry instrument panel trim bezel from
instrument panel at four pry points.
2. Remove ashtray from cup holder by lifting ashtray out of cup holder.
3. Remove two screws securing cup holder to instrument panel.
4. Push cup holder rearward to disengage from underside of instrument panel and remove.
140 S16054
ENGINE COVER, CUP HOLDER, AND ASHTRAY REMOVAL AND INSTALLATION
Cup Holder and Ashtray – Installation
1. Pull cup holder forward to engage in underside of instrument panel (Figure 128, Items 2 and 5).
2. Install two screws and secure cup holder to instrument panel (Figure 128, Items 2, 4, and 5). Tighten
3. Carefully push instrument panel trim bezel on instrument panel and snap in place (Figure 128, Items 1
and 2).
4. Insert ashtray in cup holder (Figure 128, Items 3 and 5).
Engine Cover – Removal
1. RUBBER BOOT 4. TRANSMISSION SHIFT LEVER

2. GEAR SHIFT LEVER SHAFT
3. ALLEN SCREW
Figure 129 Gear Shift Lever and Rubber Boot
1. Remove rubber boot from floor around gear shift lever.
2. Holding rubber boot up, remove allen screw and gear shift lever from transmission shift lever shaft.
S16054 141
REMOVAL AND INSTALLATION ENGINE COVER, CUP HOLDER, AND ASHTRAY
1. TSS WIRING HARNESS 5. ENGINE COVER

2. TSS ELECTRICAL CONNECTOR 6. BOLTS
3. MOUNTING STUD AND NUT 7. FLOOR MAT
4. TSS MODULE
Figure 130 Engine Cover
3. Disconnect TSS electrical connector from TSS wiring harness.
4. Remove four nuts and TSS module from mounting studs.
5. Pull aside floor mat and remove eight bolts from around engine cover.
6. Carefully remove engine cover from under instrument panel by lifting front end of engine cover up and over
transmission shift lever shaft.
Engine Cover – Installation
1. Install engine cover by lifting front end of engine cover up and over transmission shift lever shaft and sliding
engine cover under instrument panel (Figure 130, Item 2).
2. Pull floor mat aside and position engine cover on floor. Loosely install eight bolts around engine cover
(Figure 130). Tighten bolts to 8.7 to 10.7 N•m (77 to 95 lbf-in).
3. Install TSS module on four mounting studs and secure with nuts (Figure 130, Items 3 and 4). Tighten nuts
to 12.3 to 17.6 N•m (109 to 156 lbf-in).
4. Connect TSS electrical connector to TSS wiring harness (Figure 130, Items 1 and 2).
5. Holding rubber boot up, install gear shift lever on transmission shift lever shaft with allen screw (Figure 129).
6. Secure rubber boot on floor around gear shift lever (Figure 129, Items 1 and 2).
142 S16054
CAB REMOVAL AND INSTALLATION
2.42. 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, depending on the type of equipment and accessories.
WARNING
To prevent personal injury or death when working on or near a vehicle, the following
general precautions should be observed:
• Park vehicle on a level surface, apply parking brakes, and always block wheels.
• Stop the engine when working around vehicle.
• Drain the air pressure from all reservoirs before beginning any work on vehicle.
• Never connect or disconnect a hose or line containing pressure. Never remove a

component or plug, unless 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 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. Chock wheels 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 engine to cool down before removing pressure
cap from deaeration tank. Always insulate cap by wrapping it with a thick, heavy cloth.
S16054 143
REMOVAL AND INSTALLATION CAB
WARNING
To prevent personal injury or death from hot water or steam, do not remove pressure
cap immediately when loosened to the first notch. Pause momentarily and allow time for
excess pressure to release through overflow tube.
4. Drain cooling system and disconnect heater hose. Refer to coolant package service manual (S12038).
5. Disconnect steering shaft at gear.
6. Disconnect accelerator linkage and cruise control, if equipped.
7. Disconnect electrical connections and ground wire.
8. Disconnect clutch linkage.
WARNING
To prevent personal injury or death, air system is drained prior to removing or servicing
any component on air system.
9. Disconnect air brake system.
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 system is pressurized 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 equipped. Refer to HVAC service manual (S16055).
11. Remove shift lever from transmission.
12. Detach exhaust system from cab if system is vertical type.
144 S16054
13. Detach any other connections between the cab and frame if required.
14. Install cab lifting fixture. Ensure fixture is padded to prevent damage to cab.
NOTE – Use an overhead crane and cab lifting fixture when removing cab from chassis. Pad 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 131 Front Cab Mounting Bracket
1. Remove one nut from stud of cab chassis mounting bracket.
S16054 145
REMOVAL AND INSTALLATION CAB
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 132 Rear Cab Mounting
2. Remove seat belt mounting bolts securing seat belts to cab floor (See SEATS AND SEAT BELTS, page
116). Lift up floor mat to access carriage bolts in cab underbody sill.
3. Remove two nuts from carriage bolts under top plate of rear cab air suspension assembly.
NOTE – Carriage bolts are secured to cab underbody sill with cab mount retaining clips. Carriage bolts
will remain with cab underbody sill when cab is lifted off rear cab air suspension assembly.
4. Using an overhead crane and cab lifting fixture, carefully lift cab from chassis. If removing cab from
overhead crane, set cab on a suitable surface to protect painted surfaces.
Cab – Installation
CAUTION
To prevent damage to cab and/or cab components, do not allow full cab weight on chassis
until all mounting bolts are tightened.
146 S16054
CAUTION
To prevent damage to cab, frame, and/or cab/frame components, inspect all cab-to-frame
attaching points and they are aligned properly.
CAUTION
To prevent damage to cab, frame, and/or cab/frame components, refer to Cab Squaring
when installing the cab (See CAB SQUARING, page 164).
NOTE –
• Installation procedures for driver side and passenger side are the same.
• Installation of cab on 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 on chassis. Align cab with front and
rear mounting locations while lowering.
2. Install two nuts on carriage bolts under top plate of rear cab air suspension assembly (Figure 132, Items 1,
4, and 5). Tighten nuts to 119 to 144 N•m (88 to 106 lbf-ft).
3. Install seat belts on cab floor and secure with mounting bolts (See SEATS AND SEAT BELTS, page
116). Properly reposition floor mat on cab floor.
4. Install nut on stud of cab chassis mounting bracket (Figure 131, Items 1 and 4). Tighten nut to 193 to
237 N•m (142 to 175 lbf-ft).
5. Remove cab lifting fixture from cab.
Final Procedures After Cab Installation
1. Attach exhaust system if vertical type.
2. Attach shift lever to transmission.
3. Connect the following items:
• Connect air conditioning lines if equipped. Refer to HVAC service manual (S16055).
• 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 (S12038).
5. Connect battery ground cable.
S16054 147
REMOVAL AND INSTALLATION REAR CAB AIR SUSPENSION ASSEMBLY
6. Reattach any other connections between cab and frame, if required.
7. Replace or lower hood, remove wheel chocks, and release parking brake.
8. Road test vehicle. Ensure all vehicle components are operating properly before putting vehicle back
in service.
2.43. REAR CAB AIR SUSPENSION ASSEMBLY

Rear Cab Air Suspension Assembly – Removal
2. Disconnect air line to rear cab air suspension assembly.
3. Remove seat belt mounting bolts securing seat belts to cab floor (See SEATS AND SEAT BELTS, page
116). Lift up floor mat to access carriage bolts in cab underbody sill.
NOTE – Carriage bolts are secured to cab underbody sill with cab mount retaining clips. Carriage bolts
remain with cab underbody sill when cab is lifted off 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 133 Rear Cab Air Suspension Mounting Carriage Bolts
4. Remove two nuts from carriage bolts under top plate of rear cab air suspension assembly.
148 S16054
REAR CAB AIR SUSPENSION ASSEMBLY REMOVAL AND INSTALLATION
5. Lift two carriage bolts through cab underbody sill and unscrew from cab mount retaining clips.
6. Remove two carriage bolts from cab floor and underbody sill.
1. BOLT 3. AIR LINE

2. REAR CAB AIR SUSPENSION 4. FRAME RAIL CROSSMEMBER
ASSEMBLY 5. NUT
Figure 134 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 on frame rail crossmember and secure with four nuts and bolts.
(Figure 134). Tighten nuts to 119 to 144 N•m (88 to 106 lbf-ft).
2. Connect air line to rear cab air suspension assembly (Figure 134, Items 2 and 3).
3. Lower rear of cab on rear cab air suspension and remove lifting device (Figure 134, Item 2).
4. Install two nuts on carriage bolts under top plate of rear cab air suspension assembly (Figure 133).
Tighten nuts to 119 to 144 N•m (88 to 106 lbf-ft).
5. Screw cab mount retaining clips on two carriage bolts until they set against bottom of cab underbody sill
S16054 149
REMOVAL AND INSTALLATION FRONT CAB MOUNTING BUSHINGS
6. Install seat belts on cab floor and secure with mounting bolts (See SEATS AND SEAT BELTS, page
116). Properly reposition floor mat on cab floor.
2.44. FRONT CAB MOUNTING BUSHINGS

Front Cab Mounting Bushings – Removal
NOTE – Removal procedures for passenger side and driver side are the same. Passenger side shown.
1. Place a suitable lifting device on the front of cab.
1. FRONT CAB MOUNTING 4. BOLT

BRACKET 5. FRONT OF VEHICLE
2. NUT 6. LOWER CAB CHASSIS
3. UPPER CAB CHASSIS MOUNTING BRACKET
MOUNTING BRACKET
Figure 135 Front Cab Mounting Bushing
2. Remove nut securing front cab mounting bracket.
3. Raise front of cab far enough for 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.
NOTE – Use ZTSE4928 cab mount bushing press for front cab mounting bushing removal Steps 6 through
14.
150 S16054
FRONT CAB MOUNTING BUSHINGS REMOVAL AND INSTALLATION
1. C-FRAME SCREW 5. PULLING BRIDGE

2. C-FRAME 6. REMOVAL CAP
3. SET SCREW 7. FRONT CAB MOUNTING
4. LOWER CAB CHASSIS BUSHING
MOUNTING BRACKET
NOTE – All removal caps are the same. There is no specific order in which they are used.
6. Remove set screw from c-frame if not already removed.
7. Install removal cap on rear of front cab mounting bushing and lower cab chassis mounting bracket.
8. Install c-frame and pulling bridge on lower cab chassis mounting bracket and removal cap.
WARNING
To prevent personal injury or death, safety glasses must be worn when using impact gun.
NOTE – Make sure c-frame is held at the 12:00 o’clock position during removal process.
9. Using a 13mm (0.5 in.) drive impact gun and socket, tighten c-frame screw until c-frame bottoms out.
10. Loosen c-frame screw and install second removal cap.
12. Loosen c-frame screw and install third removal cap.
13. Using a 13mm (0.5 in.) drive impact gun and socket, tighten c-frame screw until c-frame bottoms out to
finish pressing out front cab mounting bushing.
S16054 151
REMOVAL AND INSTALLATION FRONT CAB MOUNTING BUSHINGS
14. Remove c-frame, pulling bridge, front cab mounting bushing and three removal caps from lower cab
mounting chassis bracket.
Front Cab Mounting Bushings – Installation
NOTE –
• Installation procedures for passenger side and driver side are the same. Passenger side shown.
• Use ZTSE4928 cab mount bushing press for front cab mounting bushing installation Steps 1 through
6.
• Front cab mounting bushing is dry-fit only. DO NOT grease. If cab mounting chassis bracket has
burrs, contamination, or any other imperfections, clean with fine emery paper. Care must be taken
not to increase hole diameter.
1. C-FRAME SCREW 4. REAR INSTALL CAP

2. C-FRAME 5. FRONT CAB MOUNTING
3. LOWER CAB CHASSIS BUSHING
MOUNTING BRACKET 6. BUSHING INSTALL CAP
1. Start front cab mounting bushing evenly in lower cab chassis mounting bracket with a soft-faced mallet
or dead blow hammer.
2. Install rear install cap on c-frame and secure with set screw (not shown).
3. Install bushing install cap on c-frame screw.
4. Install c-frame over front cab mounting bushing and lower cab chassis mounting bracket.
152 S16054
FRONT CAB MOUNTING BUSHINGS REMOVAL AND INSTALLATION
WARNING
To prevent personal injury or death, safety glasses must be worn when using impact gun.
NOTE – Make sure c-frame is held at the 12:00 o’clock position during removal process.
6. Loosen c-frame screw and remove c-frame, bushing install cap and rear install cap from lower cab chassis
mounting bracket.
7. Check that front cab mounting bushing is properly installed in lower cab chassis mounting bracket. If
bushing is loose, or can be rotated in bracket, then bushing and bracket must be replaced as a unit.
8. Install upper cab chassis mounting bracket to lower cab chassis mounting bracket and secure with bolt
(Figure 135, Items 3, 4, and 6). Tighten bolt to 119 to 144 N•m (88 to 106 lbf-ft).
9. Lower front cab mounting bracket down on upper cab chassis mounting bracket (Figure 135, Items 1 and 3).
10. Secure front cab mounting bracket to upper cab chassis mounting bracket with nut (Figure 135, Items 1, 2,
and 3). Tighten nut to 193 to 237 N•m (142 to 175 lbf-ft).
11. Remove lifting device from the front of cab.
S16054 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 rear cab air suspension manufacturer for assistance.
1. AIR SPRING AIR LINE 6. HEIGHT CONTROL VALVE

2. QUICK DISCONNECT 7. AIR SUPPLY LINE
3. MOUNTING BOLT 8. BALL PIVOT
4. QUICK DISCONNECT 9. LINKAGE
5. LOCKNUT 10. MOUNTING BRACKET
Figure 138 Height Control Valve
2. Remove air supply line from height control valve at quick disconnect fitting.
3. Remove air spring air line at quick disconnect fitting.
4. Remove linkage from ball pivot.
5. Remove two mounting bolts and locknuts from height control valve.
6. Remove height control valve from mounting bracket.
154 S16054
REAR CAB AIR SUSPENSION SYSTEM REMOVAL AND INSTALLATION
Height Control Valve – Installation
CAUTION
To prevent damage to cab and vehicle components, raise cab and remove block after
servicing is complete and before returning vehicle to service.
NOTE –
• Attempts to disassemble or adjust fittings on height control valve will void warranty. Contact rear
cab air suspension manufacturer for assistance.
• Inspect height control valve for proper alignment. The drive bearing notch on 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. 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 and secure with two mounting bolts and locknuts (Figure
138). Tighten locknuts to 11 to 14 N•m (8 to 10 lbf-ft).
2. Attach linkage to ball pivot (Figure 138, Items 8 and 9).
3. Connect air spring air line securely at quick disconnect fitting (Figure 138, Items 1 and 4). Pull on supply
air spring air line and verify it is locked securely in quick disconnect fitting.
4. Connect air supply line to height control valve at quick disconnect fitting (Figure 138, Items 2, 6, and 7).
Pull on supply air supply line and verify it is locked securely in quick disconnect fitting.
5. Pressurize air system and check for air leaks.
6. Check cab ride height (See REAR CAB AIR SUSPENSION, page 168).
S16054 155
Shock Absorber – Removal
1. CAB MOUNTING PLATE 4. CROSSMEMBER MOUNTING

2. BOLT PLATE
3. SHOCK ABSORBER 5. LOCKNUT
Figure 139 Shock Absorber
WARNING
plate.
NOTE –
• Removal procedures for both front and rear shock absorbers are the same way.
• Some models may have a different configuration from that shown. Removal procedures are the
same.
1. Remove two bolts and two locknuts from shock absorber.
2. Remove shock absorber from between cab mounting plate and crossmember mounting plate.
156 S16054
Shock Absorber – Installation
CAUTION
NOTE –
• Installation procedures for both front and rear shock absorbers are the same way.
• Some models may have a different configuration from that shown. Installation procedures are the
same.
1. Install shock absorber between cab mounting plate and crossmember mounting plate and secure with two
bolts and locknuts (Figure 139). Tighten locknuts to 54 to 68 N•m (40 to 50 lbf-ft).
Suspension Air Spring (Bag) – Removal
WARNING
plate.
1. FITTING 5. SCREW
2. QUICK DISCONNECT 6. AIR SPRING (BAG)
3. AIR LINE 7. RETAINING RING
4. FITTING
Figure 140 Suspension Air Spring (Bag)
S16054 157
2. Disconnect air lines at three quick disconnect fittings.
NOTE – Note location and position of fittings prior to removal to aid installation.
3. Remove two fittings from air springs (bags).
NOTE – Retaining rings will be damaged upon removal. New retaining rings are supplied with new air
springs (bags).
4. Pry retaining rings and remove from top of air springs (bags).
5. Remove screw from bottom of each air spring (bag).
6. Compress and remove two air springs (bags).
Suspension Air Spring (Bag) – Installation
CAUTION
NOTE – New retaining rings are supplied with new air springs (bags).
1. Install two air springs (bags) and secure with new retaining rings. (Figure 140, Items 6 and 7).
2. Install screw in bottom of each air spring (Figure 140, Items 5 and 6). Tighten screw to 3 to 5 N•m (26.6
to 44 lbf-in).
NOTE – Install fittings as noted prior to removal.
3. Apply pipe thread sealant to threads of two fittings and install fittings on air springs (Figure 140, Items 1, 4,
and 6). Hand-tighten fittings until snug, then turn another 270° to 450° degrees.
4. Connect air line at three quick disconnect fittings (Figure 140).
5. Pressurize air system. Check for air leaks and verify proper air spring (bag) operation. Correct as
necessary.
6. Check cab ride height (See REAR CAB AIR SUSPENSION, page 168).
158 S16054
Lateral Control Rod – Removal
WARNING
plate.
1. LATERAL CONTROL ROD 4. BOLT

2. LOCKNUT 5. CAB MOUNTING PLATE
3. CROSSMEMBER MOUNTING
PLATE
Figure 141 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 from crossmember mounting plate and cab mounting plate.
Lateral Control Rod – Installation
CAUTION
1. Install lateral control rod on cab mounting plate and crossmember mounting plate (Figure 141, Items 1,
3, and 5).
2. Install bolt and locknut through lateral control rod and crossmember mounting plate (Figure 141). Tighten
nut to 95 to 122 N•m (70 to 90 lbf-ft).
S16054 159
3. Install bolt and locknut through lateral control rod and cab mounting plate (Figure 141). Tighten nut to 95
to 122 N•m (70 to 90 lbf-ft).
Jounce Bumper – Removal
1. CAB MOUNTING PLATE 3. BOLT

2. LOCKNUT 4. JOUNCE BUMPER
Figure 142 Jounce Bumper
1. Remove bolt, locknut, and jounce bumper from cab mounting plate.
Jounce Bumper – Installation
1. Install jounce bumper on cab mounting plate and secure with bolt and locknut (Figure 142). Tighten
locknut to 3 to 5 N•m (26.6 to 44 lbf-in).
160 S16054
TROUBLESHOOTING
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 manual 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.
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.
3.2. WASHER PUMP MOTOR

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. 3. Replace pump 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.
S16054 161
TROUBLESHOOTING REAR CAB AIR SUSPENSION SYSTEM

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.

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 inspect for
damage. Reapply pipe thread
sealing compound. Reinstall
fitting, but do not overtighten. Do
not use Teflon tape.
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.
2. Height control valve linkage. 2. Inspect height control valve
linkage for damage or missing
components. If disconnected,
reconnect. Replace if damaged.
Air springs do not deflate when 1. Height control valve. 1. Replace valve.
weight is removed from cab.
2. Height control valve linkage. 2. Inspect height control valve
linkage for damage or missing
components. If disconnected,
reconnect. Replace if damaged.
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 inner
are loose. sleeve.
Bushings are worn. 1. Lateral control rod. 1. Replace lateral control rod.
162 S16054
LUBRICATION
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 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.
S16054 163
ADJUSTMENTS
5. ADJUSTMENTS
Proper adjustments are critical to the cab structure, as this affects the functionality 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 143).
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 – Make sure 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 143 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 frame.
164 S16054
CAB DOOR ADJUSTMENTS
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 excessive effort.
3. Door should not rattle when vehicle is moving.
5.3. DOOR HINGE

NOTE – Adjustment procedures on passenger side and driver side are the same. Driver side shown.
1. UPPER HINGE 4. CAB HINGE PILLAR

2. LOWER HINGE 5. LOCKING BOLT
3. HINGE BOLT
Figure 144 Cab Door Hinge
1. Slightly loosen upper hinge bolt and locking bolt. Move cab door, as required, at upper door hinge to
obtain proper cab door position.
2. Hold cab door in place and tighten locking bolt and upper hinge bolt at the cab hinge pillar location. Tighten
bolts to 20 to 24 N•m (15 to 18 lbf-ft).
S16054 165
ADJUSTMENTS STRIKER PIN
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
20 to 24 N•m (15 to 18 lbf-ft).
5. Close cab door and check for proper fit. If further adjustment is required, repeat Steps 1 through 4.
5.4. STRIKER PIN

NOTE – Adjustment procedures on passenger side and driver side are the same. Driver side shown.
1. DOOR LOCK PILLAR 3. STRIKER PIN

2. BOLT
Figure 145 Striker Pin
1. Slightly loosen two bolts securing striker pin to door lock pillar.
2. Move striker pin, as required, at door lock pillar to obtain proper cab door fit and latching position.
3. Hold striker pin in place and tighten two bolts at 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 Steps 1 through 3.
166 S16054
WINDSHIELD WIPER ARM AND BLADE ASSEMBLY ADJUSTMENTS
5.5. WINDSHIELD WIPER ARM AND BLADE ASSEMBLY

1. Spray water on windshield and operate wipers on high speed to check wiper pattern on windshield. Wipers
should not run off glass or stop lower than the horizontal position of the bottom edge of 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 146 Windshield Wiper Arm and Blade Assembly
2. If adjustment is needed, lift 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 on wiper pivot post until assembly locks in place.
5. Turn wipers on high speed and check for proper wiper operation. If further adjustment is required, repeat
Steps 1 through 4.
S16054 167
ADJUSTMENTS REAR CAB AIR SUSPENSION
5.6. REAR CAB AIR SUSPENSION

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

2. MEASURE DISTANCE BETWEEN PLATE
METAL CUP AND STRIKE PLATE
Figure 147 Ride Height Measurement
1. Pressurize air system to operating pressure of 6.2 to 7.6 bar (90 to 110 psi).
2. Inspect suspension and verify proper operation.
3. Measure space between jounce bumper strike plate and jounce bumper rate cup. Be certain to measure
to the metal cup, not rubber bumper.
4. Gap setting should be 3.81 cm (1 ½ in).
NOTE –
• Technicians may use an air wrench socket with an outside diameter equal 3.81 cm (1 ½-inch) to
check this measurement.
• If measurement is not correct, perform Steps 5 through 7 for adjustment.
168 S16054
REAR CAB AIR SUSPENSION ADJUSTMENTS
1. HEIGHT CONTROL VALVE 3. LINKAGE SOCKET CLIP

2. HEIGHT CONTROL VALVE 4. LINKAGE SOCKET
LINKAGE
Figure 148 Linkage Adjustment
5. Unlatch linkage socket clip and disconnect height control valve linkage from linkage socket.
CAUTION
To prevent damage to linkage, there must be a minimum of five (5) full threads of height
control valve linkage threaded in linkage socket.
6. Reconnect height control valve linkage with desired amount of threads in linkage socket.
7. Secure linkage socket clip to linkage socket by snapping in place and recheck design height gap (refer to
step 4). Adjust as required.
S16054 169
TORQUE
TORQUE
Table 4 Torque
Figure No. (Item No.) Location N•m lbf-ft / lbf-in

Figure 9 (Item 3), Figure Passenger Side Grab Handle Bolts 9 to 11 80 to 97 lbf-in
68 (Item 4), Figure
114 (Item 3)
Figure 57 (Item 1) Clearance Light Self-Tapping Screws 2 to 3 18 to 26.6 lbf-ft
Figure 57 (Item 6) Sun Shade Mounting Screws 46 to 52 34 to 38 lbf-in
Figure 58 (Items 1 and 6) Sun Visor Clip Screw and Sun Visor Screws 2 to 3 18 to 26.6 lbf-in
Figure 64 (Item 3) Gauge Cluster Screws 2 to 3 18 to 26.6 lbf-in
Figure 66 (Item 1) Instrument Panel Bolts 15.5 to 19 11 to 14 lbf-ft
Figure 67 (Item 1) Instrument Panel Bolts 9.5 to 12 84 to 106 lbf-in
Figure 72 (Item 8) Threaded Stud Mounting Nuts 20 to 24 15 to 18 lbf-ft
Figure 73 (Items 3 and Upper and Lower Hinge Bolts and Locking Bolt 20 to 24 15 to 18 lbf-ft
5), Figure 144 (Items
3 and 5)
Figure 74 (Item 2), Door Striker Pin Bolts 20 to 24 15 to 18 lbf-ft
Figure 145 (Item 2)
Figure 75 (Item 2) Check Bracket Bolts 11 to 14 97 to 124 lbf-in
Figure 76 (Item 1) Check Link Nuts 9 to 11 80 to 97 lbf-in
Figure 77 (Item 1), Inner Door Panel Pull Cup Screws 2 to 3 18 to 26.6 lbf-in
Figure 80 (Item 1)
Figure 77 (Item 4), Door Map Pocket Mounting Screws 2 to 3 18 to 26.6 lbf-in
Figure 80 (Item 4)
Figure 86 (Item 2) Outer Door Handle Screws 4 to 5 35 to 44 lbf-in
Figure 87 (Items 1 and 4) Door Latch Bolts and Assembly Mounting Bolts 11 to 14 97 to 124 lbf-in
Figure 89 (Item 2) Vent Window Latch Screws 6 to 8 53 to 71 lbf-in
Figure 91 (Item 1) Vent Window Hinge Screws 6 to 8 53 to 71 lbf-in
Figure 93 (Item 4) Window Electric Motor Nuts 7 to 13 62 to 115 lbf-in
Figure 95 (Item 1) Inner Door Handle Bolt 8 to 10 71 to 89 lbf-in
Figure 107 (Item 3) Bucket Seat Nuts 20 to 27 15 to 20 lbf-ft
Figure 108 (Item 1) Two Man Fixed Bench Seat Nuts 20 to 27 15 to 20 lbf-ft
Figure 109 (Items 1 Outside Seat Belt and Inside Seat Belt Buckle 34 to 47.5 25 to 35 lbf-ft
and 4) Bolts
Figure 110 (Items 1 Seat Belt Bolts 34 to 47.5 25 to 35 lbf-ft
and 8)
Figure 110 (Item 6) Seat Belt Support Bolts 34 to 47.5 25 to 35 lbf-ft
170 S16054
TORQUE
Table 4 Torque (cont.)

Figure No. (Item No.) Location N•m lbf-ft / lbf-in
Figure 110 (Item 6) Seat Belt Retractor Bolt 34 to 47.5 25 to 35 lbf-ft
Figure 111 (Item 1) Scuff Plate Screws 2 to 3 18 to 26.6 lbf-in
Figure 112 (Item 3) Seat Belt Bolt 34 to 47.5 25 to 35 lbf-ft
Figure 117 (Items 2 Courtesy Light Screws and Header Console 2 to 3 18 to 26.6 lbf-in
and 5) Panel Screws
Figure 124 (Items 6) Cowl Tray Mounting Nuts 22 to 24 16 to 18 lbf-ft
Figure 125 (Item 2) Windshield Wiper Assembly Mounting Nuts 22 to 24 16 to 18 lbf-ft
Figure 126 (Item 3) Electric Wiper Motor Mounting Bolts 10 to 12 90 to 110 lbf-ft
Figure 126 (Item 7) Wiper Drive Arm Nut 20 to 25 15 to 18 lbf-ft
Figure 128 (Item 4) Cup Holder Screws 2 to 3 18 to 26.6 lbf-in
Figure 130 (Item 1) Engine Cover Bolts 8.7 to 10.7 77 to 95 lbf-in
Figure 130 (Item 3) TSS Module Nuts 12.3 to 17.6 109 to 156 lbf-in
Figure 131 (Item 1) Front Cab Mounting Bracket Nut 193 to 237 142 to 175 lbf-ft
Figure 132 (Item 1), Rear Cab Mount Carriage Bolt Nuts 119 to 144 88 to 106 lbf-ft
Figure 131 (Item 5)
Figure 134 (Item 5) Rear Cab Air Suspension Assembly Nuts 119 to 144 88 to 106 lbf-ft
Figure 135 (Items 2 Front Cab Mounting Nut 193 to 237 142 to 175 lbf-ft
and 4)
Figure 135 (Item 4) Front Cab Mounting Bolt 119 to 144 88 to 106 lbf-ft
Figure 138 (Item 5) Height Control Valve Locknuts 11 to 14 8 to 10 lbf-ft
Figure 139 (Item 5) Rear Cab Air Suspension Shock Absorber 54 to 68 40 to 50 lbf-ft
Locknuts
Figure 140 (Item 5) Air Spring Screws 3 to 5 26.6 to 44 lbf-in
Figure 141 (Item 2) Lateral Control Rod Locknuts 95 to 122 70 to 90 lbf-ft
Figure 142 (Item 2) Jounce Bumper Locknut 3 to 5 26.6 to 44 lbf-in
S16054 171

02 - (2011) Service Manual (S16054)

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

02 - (2011) Service Manual (S16054)

Uploaded by

Copyright:

Available Formats

SERVICE MANUAL

SERVICE MANUAL SECTION

Model: DuraStar® Vehicle

2. REMOVAL AND INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

TABLE OF CONTENTS (CONT.)

TABLE OF CONTENTS (CONT.)

TABLE OF CONTENTS (CONT.)

Rear Cab Air Suspension Assembly – Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .149

Figure 1 Cab Configuration

1.2. CAB INTERIOR TRIM PANELS

Figure 2 ZTSE4839 Interior Trim Tool

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

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

1.5. ELECTRIC WINDSHIELD WIPERS

1. WIPER ARM 3. WIPER LINKAGE

1.6. WINDSHIELD WASHER

1. WASHER BOTTLE 2. PUMP MOTOR

1.7. IGNITION SWITCH CYLINDER

1.8. REAR CAB AIR SUSPENSION SYSTEM

1. SHOCK ABSORBER 3. AIR SPRING (BAG)

2. REMOVAL AND INSTALLATION

1. Park vehicle on a flat, level surface.

• Short Inside Cutting Blade

1. Unlatch and open hood.

2. Place protective coverings over exposed areas near windshield.

1. SUN SHADE 3. MOUNTING BRACKET

1. PASSENGER SIDE A-PILLAR 2. GRAB 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 required include the following:

• Essex® GC800 Glass Cleaner

• White or Brown Paper Towels

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 BLACKOUT GLASS 3. WINDSHIELD

1. TRIM DIMENSIONS 3. ADHESIVE TUBE

13. Attach cartridge tip to adhesive tube.

1. PNEUMATIC OR ELECTRIC 3. WINDSHIELD FENCE

14. 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. Clean windshield and surrounding areas.

28. Close and latch hood.

2.2. REAR WINDOW GLASS

1. REAR WINDOW GLASS 3. SPRING CLIP

Rear Window Glass (Unobstructed Access) – Removal

1. POWER KNIFE 3. REAR WINDOW GLASS FENCE

Rear Window Glass (Unobstructed Access) – Installation

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

The windshield replacement kit includes the following components:

• 43532 Body Primer

Additional materials required include the following:

• Essex® GC800 Glass Cleaner

• White or Brown Paper Towels

1. OLD ADHESIVE 3. GASKET CHISEL