Misalignment of Air Intake Duct When Closing Cab (Install New Duct Guide/Seal)

Some drivers may comment about a misalignment condition between the cab-mounted air intake duct (scoop) and the air cleaner inlet tube when closing the cab.

Install a new guide and seal between the air intake duct and the air duct flapper assembly. Use the following procedure and the part numbers listed below.

1. Remove the upper nut, washers, and bushing that secures the air intake duct to the bracket at the back of the cab.



2. Remove the LH and RH side bolts, washers, and bushings that secure the air intake duct to the bracket at the back of the cab.



3. Remove the air intake duct assembly from the vehicle.




Important: 

•	Do not damage the air intake duct holes when removing the rivets.

•	Do not reuse the existing rivets.

4. Using a drill, carefully remove the existing rivets (total of two) that secure the flapper assembly to the air intake duct. Separate the flapper from the duct assembly.
5. Clean the mating surface of the flapper assembly with alcohol wipes.



6. Install the guide (1), P/N 97500379, and affix the seal (2), P/N 97500378 onto the flapper assembly.
7. Crimp and install the new rivets, P/N 97727861, into the flapper assembly to the original position.

Important: The bonding surface must be dust free.

8. Attach the flapper assembly with the guide and seal to the air intake duct. Match the holes in the guide with the air duct holes. The double-side tape is placed on the bond surface.
9. Install the air intake duct with flapper assembly into position at the back of the cab.
10. Install the air intake duct upper nut and the side bolts with the washers and bushings.

Tighten
Tighten the nut and bolts to 27 N·m (20 lb ft).

11. Test for proper operation by lifting and closing the cab.

Parts are currently available from GMSPO.

For vehicles repaired under warranty, use: