9. REMOVE THE BED ASSEMBLY

a) Using a Tor ® TS5H Tamper Resistant Socket, remove the Torx ® bolts from the bed assembly
Regular Cab: 8 Torx ® bolts
- Access Cab: 6 Torx ® bolts
NOTE:
e Use 4 or more people to remove the bed assembly from the frame.
e Evenly support the bed assembly when removing it.

10

10, MEASURE THE DIMENSIONS OF THE REAR FRAME END

a) Measure and record the distance between the left and right frame rails for the TOP and BOTTOM edges
of the rear frame end as shown.

TOP: a Oy BOTTOM:.

NOTE:

Make sure to measure and record the distances. These measurements will be used for adjustment
purposes after the cross member has been installed.

—T

11. REMOVE THE CLIP

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12, DISCONNECT THE FRAME WIRE HARNESS

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Ci a an a) Remove the 5 wire harness clips.

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LRA Yi k= - ws Sh DO NOT damage the wire harness clip during removal.
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14

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b) Disconnect the ABS connector (if equipped).

13. REMOVE THE SPARE TIRE CARRIER
a) Remove the 4 bolts and the spare tire carrier.
NOTE:

The edge of the spare tire carrier is sharp, take care
« when removing.

14, REMOVE THE EXHAUST PIPE HANGER

a) Remove the exhaust pipe hanger from the frame.

15. REMOVE THE REAR SHOCK ABSORBER LH

a) Remove the 2 nuts, bolt and the rear shock absorber
LH.

12

16. DISCONNECT THE LSPV AND LOAD SENSING SPRING

a) Remove the nut, washer and bolt, and then disconnect
the load sensing spring.

b) Remove the 2 washers and collar from the load
sensing spring to prevent them from falling off.

¢c) Disconnect the brake line clip.
d) Rémove the 3 bolts and disconnect the LSPV
assembly,

NOTE: | m |
-« DO NOT damage the brake line clip during removal.
« Visually inspect the LSPV for any damage of fluid

leakage. Replace the LSPV if damage or fluid
leakage Is found. yi

i

e) Suspend the LSPV with a rope this will protect the
brake lines from damage and deformation.

When using an air.chisel and air hammer wear protective eyewear, ear plugs and
gloves.

Please have ALL personel near the work area wear ear plugs when the air chisel and
air hammer are in use.

13

TOP VIEW BOTTOM VIEW a |

17. REMOVE THE REAR FRAME CROSS MEMBER
a) Using an air chisel cut off the 13 rivet heads.

NOTE:
e Always wear protective eyewear, ear plugs and gloves when using an air chisel and air hammer.
e DONOT allow personnel near the vehicle, as the rivet heads may fly off when cut.

e Cover the cab body to prevent damage from flying debris.

‘a4 Nee

b) Position the air chisel in betwéen the rivet, and side member. DO NOT increase the angle the air chisel,
doing so may damage frame side member.

--¢) When cutting the rivet head, alternate the position of
the air chisel between 3 to 4 different spots.

14

d) Using an air punch remove the 73 rivets.

Air Punch

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The rivet may expand preventing removal with the air punch

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if the rivet is attached only to\the cross member no further action is required.

e = |f the rivet i is attached to the side and cross member, drill a hole in the rivet. Then us a hammer and
-punch fo snk the. nes Qut.|

f) Set the frame expansion bar on the vehicle with the
groove ring on the left side of the vehicle.

NOTE:

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Verify that the threaded section of the frame
expansion bar is properly greased.

If grease is needed, apply disulfide molybdenum
grease to the threaded section before use.

Grooved Ring

15

Side view

g) Push the expansion bar until both guide bars contact
the frame.

h) Using the frame expansion bar, expand the ends of the
frame rails by 4.33 in. (110 mm).

i) Push the rear frame cross member towards the left of
the vehicle as shown.

j) Lower the right side of the rear frame cross member
one netch as shown.

k) From the left side of the vehicle, slightly twist the rear
frame cross member to the right and lift up to remove

as shown,

NOTES:

e Use 2 people to remove the rear frame cross
member.

e DO NOT remove the expansion bar.

16
F. REAR FRAME CROSS MEMBER INSTALLATION

Bottom View

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(2): Avea to be Cleaned : ~ a “=

PREPARE AND CLEAN THE BOLT MOUNTING SURFACE

a) Using 80-grit sandpaper, remove any scratches and uneven areas from where the rivets were removed.
b) Sand the surfaces until they are smooth and even.

NOTE:
« Any unevenness in the surface can cause the bolts to loosen.
* Make sure the surface is completely even before proceeding to the next step.

17

INSTALL THE NEW FRAME REAR CROSS MEMBER

a) From the left side of the vehicte, insert the NEW rear
frame cross member and set the right notches in the
position shown.

NOTES:

Use 2 people to install the NEW rear frame cross
member.

b) Slightly twist the NEW frame rear cross member and
set the leit side in the side member as shown.

c) Push the NEW frame rear cross member towards the
left and set the right side in the side member as shown.

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