GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Isuzu 🢒 2002 🢒 Isuzu T-Series (Truck Line C) 🢒 Body and Accessories 🢒 Body Front End 🢒 Cab Replacement

Removal Procedure

Important: 

  1. Tag all of the following components during removal for proper location during installation:
    2.    • All lines
       • All wires
       • All hoses
       • All harnesses
  2. Block the wheels.

The cab replacement procedure will vary depending upon the optional equipment on the vehicle. Some steps are required due to the optional equipment. Verify which optional equipment has been added to the vehicle in order to perform the applicable steps. The following procedures are intended to be used only as a guide:

  1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
  2. Open the hood.
  3. Remove the grille. Refer to Grille Replacement in Exterior Trim.
  4. Remove the left and the right headlamp assemblies. Refer to Headlamp Replacement in Lighting Systems.
  5. Recover the air conditioning refrigerant. Refer to Refrigerant Recovery and Recharging in Heating, Ventilation and Air Conditioning.
  6. Remove the air conditioning pipes and the brackets. Refer to Air Conditioning Evaporator Hose Assembly Replacement in Heating, Ventilation and Air Conditioning.
  7. Drain the coolant.
  8. Remove the heater pipes. Refer to the following procedures in Heating, Ventilation and Air Conditioning:
    9. •  Heater Inlet Pipe Replacement
    •  Heater Outlet Pipe Replacement
  9. Remove the ground strap.
  10. Remove the main wire harness under the hood.
  11. Remove the clutch fluid pipe, if equipped.
  12. Disconnect the transmission control cables. Refer to Shift Cable Replacement Automatic Transmission-Allison, or to Shift Cable Replacement in Manual Transmission-Isuzu MLD6Q.
  13. Disconnect the parking brake cable. Refer to Park Brake Cable Replacement in Park Brake.
  14. Tilt the cab. Refer to Cab Tilting in General Information.

    15. Object Number: 215795 Size: SH
  15. Remove the air brake hoses, if equipped or the linkage to the brake master cylinder.
  16. Remove the steering shaft at the steering gear. Mark the shaft and the gear in order to aid in reassembly. Refer to Lower Steering Shaft Assembly Replacement in Steering Wheel and Column.
  17. Remove the cab lock cover.
  18. Fasten a rope securely to the cab lock. Use a hoist or chain block in order to keep the cab tilted.
  19. Remove the torsion bar levers.
  20. Remove the cab tilt support.
  21. Lower the cab. Refer to Cab Tilting in General Information.
  22. Remove each center pin by tapping with a hammer, while lowering the cab slowly.

    23. Object Number: 215784 Size: SH

    Notice: When the cab is being removed, ensure that the lifting straps are not wrapped around the door frames. Otherwise, damage to the window channels may occur.

    Important: The trimmed cab weighs about 373 kg (1,000 lbs).

  23. Perform the following procedure in order to remove the cab from the chassis:
    24. 23.1. Use 4 commercial straps that are 152 mm (6 in) wide and about 3 m (10 ft) long in order to lift the cab from the chassis.
    23.2. Open the doors. Pass the straps into the cab through the door opening on each side through the rear of the cab.
    23.3. Connect the straps in the center.
    23.4. Close the doors.
  24. Walk around the cab in order to make sure all components have been disconnected from the chassis.
  25. Raise the cab slowly. Use the aid of a helper in order to guide the cab while the cab is being lifted.

Installation Procedure

    Object Number: 215784 Size: SH
  1. Block the chassis wheels.

    2. Notice: When the cab is being removed, ensure that the lifting straps are not wrapped around the door frames. Otherwise, damage to the window channels may occur.

    Important: The trimmed cab weighs about 373 kg (1,000 lbs).

  2. Perform the following procedure in order to install the cab onto the chassis.
    3. 2.1. Use 4 commercial straps that are 152 mm (6 in) wide and about 3 m (10 ft) long in order to lift the cab from the chassis.
    2.2. Open the doors. Pass the straps into the cab through the door opening on each side through the rear of cab.
    2.3. Connect the straps in the center.
    2.4. Close the doors.

    Object Number: 215820 Size: SH
  3. Apply grease to the following areas of the cab mounts:
    4. • The circumference area of the bracket where the washer comes in contact
    • The bushing inner surface in the side where the sleeve is inserted
    • At least 2 areas on both inside surfaces of the bracket where the washer comes in contact

    Object Number: 215795 Size: SH
  4. Install the left and the right center pins.
  5. Perform the following procedure:
    6. 5.1. Hook a wire to the cab striker.
    5.2. Pull the safety lever.
    5.3. Tilt the cab slowly.
    5.4. Use the wire in order to keep the cab from floating up.

    Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

  6. Extend the cab support and lock it into position.

    7. Tighten
    Tighten the bolts to 68 N·m (50 lb ft).

  7. Perform the following in order to install the torsion bar levers:
    8. 7.1. Locate the left and right identification marks before installation.
    7.2. Match the spline.
    7.3. Install the torsion bar levers.

    Tighten
    Tighten the bolt and nut to 37 N·m (27 lb ft).

  8. Use the match marks made during disassembly as a guide in order to apply grease to the steering shaft.
  9. Insert the steering shaft on the steering unit. Refer to Lower Steering Shaft Assembly Replacement in Steering Wheel and Column.
  10. Tighten the key bolt.

    11. Tighten
    Tighten the bolt to 61 N·m (45 lb ft).

  11. Connect the throttle cable.
  12. Connect the transmission cables. Refer to Shift Cable Replacement Automatic Transmission-Allison, or to Shift Cable Replacement in Manual Transmission-Isuzu MLD6Q.
  13. Connect the air brake hoses, if equipped, or connect the linkage to the brake master cylinder.
  14. Connect the parking brake cable. Refer to Park Brake Cable Replacement in Park Brake.
  15. Lower the cab.
  16. Install the clutch fluid pipe, if equipped.
  17. Install the main wire harness under the hood.
  18. Install the ground strap.
  19. Install the heater pipes. Refer to the following procedures in Heating, Ventilation and Air Conditioning:
    20. •  Heater Inlet Pipe Replacement
    •  Heater Outlet Pipe Replacement
  20. Install the air conditioning pipes and the brackets. Refer to Air Conditioning Evaporator Hose Assembly Replacement in Heating, Ventilation and Air Conditioning.
  21. Install the left and the right headlamp assemblies. Refer to Headlamp Replacement in Lighting Systems.
  22. Install the grille. Refer to Grille Replacement in Exterior Trim.
  23. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
  24. Recharge the air conditioning refrigerant to specification. Refer to Refrigerant Recovery and Recharging and Refrigerant System Capacities in Heating, Ventilation and Air Conditioning.
  25. Refill the engine coolant to proper level. Refer to Fluid and Lubricant Recommendations in Maintenance and Lubrication.
  26. Bleed the clutch system. Refer to Hydraulic Clutch Bleeding in Transmission/Transaxle.