Page 1289 of 2255

FRONT AIR DAM
REMOVAL
(1) Remove Pin-type fasteners attaching air dam
to bottom of front bumper (Fig. 1).
(2) Remove screws attaching air dam to bottom of
front bumper.
(3) Separate air dam from bumper.
INSTALLATION
(1) Position air dam on bumper.
(2) Install screws attaching air dam to bottom of
front bumper.
(3) Install Pin-type fasteners attaching air dam to
bottom of front bumper.
FRONT FASCIA
REMOVAL
(1) Open hood.
(2) Remove fasteners at fender side openings.
(3) Separate fascia from bumper.
INSTALLATION
(1) Position fascia on bumper.
(2) Install front fascia. See fascia adjustment pro-
cedure in this section.
(3) Install fasteners at fender side openings.
ADJUSTMENTS
ADJUSTMENT
(1) Remove the plastic rivet that secures the front
upper fascia to the front lower fascia (Fig. 2).
(2) Position the upper front fascia so that there is
approximately a 19 mm (3/4 in.) gap between the
lower portion of the front fender and the upper por-
tion of the front upper fascia (Fig. 3). The gap should
ideally be 19 mm (3/4 in.), but it is more important to
avoid a V-Gap between the lower portion of the front
fender and the upper portion of the front upper fas-
cia than maintaining the gap. There are ribs in the
front upper fascia and lower fascia that will hold the
front upper fascia in position (Fig. 4).
(3) Attach the front upper fascia to the front lower
fascia using a new plastic rivet.
Fig. 1 Front Bumper Air Dam
1 - BUMPER
2 - SCREW
3 - LOWER AIR DAM
4 - PIN TYPE FASTENER
5 - LOWER FASCIA
Fig. 2 Fascia Rivet
1 - RIVET MUST BE REPLACED AFTER EACH ADJUSTMENT
13 - 2 FRAME & BUMPERSBR/BE
Page 1290 of 2255

FRONT LOWER FASCIA
REMOVAL
(1) Open hood.
(2) Remove fasteners at side fender openings.
(3) Remove lower air dam.(Refer to 13 - FRAMES
& BUMPERS/BUMPERS/FRONT AIR DAM -
REMOVAL)
(4) Disengage clips attaching end of upper fascia to
bumper face bar (Fig. 5).
(5) Disengage clips attaching lower fascia to
bumper face bar.
(6) Separate lower fascia from bumper.
INSTALLATION
(1) Position lower fascia on bumper.
(2) Engage clips attaching lower fascia to bumper
face bar.
(3) Install lower air dam.(Refer to 13 - FRAMES &
BUMPERS/BUMPERS/FRONT AIR DAM - INSTAL-
LATION)
(4) Install fasteners at side fender openings.
FRONT FASCIA - SPORT
REMOVAL
The fascia can be removed from the vehicle without
removing the bumper.
(1) Disconnect wire connectors from fog lamps.
(2) Remove screws attaching rearward edges of
fascia to outer bumper brackets (Fig. 7) .
(3) Remove screws attaching bottom of air deflec-
tor.
(4) Lift top of fascia upward to disengage from
retaining clips on front bumper.
(5) Pull fascia from front bumper and separate
from vehicle.
INSTALLATION
(1) Position fascia on front bumper.
(2) Engage fascia with retaining clips on front
bumper.
Fig. 3 Fascia Gap
1 - GAP Ð 19 mm PARALLELISM MOST IMPORTANT
Fig. 4 Fascia Adjustment Ribs
1 - FRONT UPPER FASCIA
2 - ADJUSTMENT RIBS
3 - FRONT LOWER FASCIA
Fig. 5 Front Bumper Lower Fascia
1 - LOWER FASCIA
2 - RETAINING CLIP
3 - BUMPER
BR/BEFRAME & BUMPERS 13 - 3
FRONT FASCIA (Continued)
Page 1291 of 2255

(3) Install screws attaching bottom of fascia to air
deflector.
(4) Align fascia and wheelhouse liners with outer
bumper brackets and install screws.
(5) Connect harness connectors to fog lamps.
FRONT BUMPER
REMOVAL
(1) Support front bumper on a suitable lifting
device.
(2) Remove bolts attaching front bumper outer
bracket to frame rail (Fig. 6).
(3) Remove nuts and stud plates attaching front
bumper to end of frame rail.
(4) Disengage wire connectors from fog lamps, if
equipped.
(5) Separate front bumper from vehicle.
INSTALLATION
(1) Support front bumper on a suitable lifting
device.
(2) Position front bumper on vehicle.
(3) Engage fog lamp wire connectors, if equipped.
(4) Install nuts and stud plates attaching front
bumper to end of frame rail. Tighten nuts to 94 N´m
(70 ft. lbs.) torque.
(5) Install bolts attaching front bumper outer
bracket to frame rail. Tighten bolts to 94 N´m (70 ft.
lbs.) torque.
Fig. 6 Front Bumper
1 - U-NUT
2 - FRAME
3 - INNER BUMPER BRACKET
4 - FOGLAMP SIGHT SHIELD
5 - BUMPER
6 - 4±WAY CENTER LOCATOR
7 - BLIND PLASTIC RIVET
8 - UPPER FASCIA9 - LOWER FASCIA
10 - AIR DAM
11 - BLIND PLASTIC RIVET
12 - BLIND PLASTIC RIVET
13 - U-NUT
14 - BLIND RIVET
15 - OUTER BUMPER BRACKET
13 - 4 FRAME & BUMPERSBR/BE
FRONT FASCIA - SPORT (Continued)
Page 1292 of 2255

FRONT BUMPER - SPORT
REMOVAL
(1) Disconnect wire connectors from fog lamps.
(2) Remove screws attaching fascia and outer
bumper brackets to wheelhouse liners.
(3) Remove screws and push-in fasteners attaching
bottom of fascia to air deflector.
(4) Support bumper on a suitable lifting device.
(5) Remove nuts attaching bumper to inner
bumper brackets (Fig. 7).
(6) Separate bumper from vehicle.
INSTALLATION
(1) Support bumper on a suitable lifting device.
(2) Position bumper on vehicle.
(3) Install nuts attaching bumper to inner bumper
brackets. Tighten nuts to 94 N´m (70 ft. lbs.) torque.
(4) Install screws and push-in fasteners attaching
bottom of fascia to air deflector.
(5) Align fascia and wheelhouse liners with outer
bumper brackets and install screws. See fascia
adjustment in this section.
(6) Connect wire connectors to fog lamps.
Fig. 7 Front Bumper & Fascia Ð Sport
1 - FASCIA
2 - U-NUT
3 - RETAINING CLIP
4 - OUTER BRACKET
5 - INNER BRACKET
6 - FRAME7 - FASCIA SUPPORT
8 - OUTER BRACKET
9 - PUSH-IN FASTENER
10 - AIR DEFLECTOR
11 - BUMPER
BR/BEFRAME & BUMPERS 13 - 5
Page 1293 of 2255

REAR BUMPER
REMOVAL
(1) Support rear bumper on a suitable lifting
device.
(2) Remove nuts attaching rear bumper to inner
and outer brackets (Fig. 8).
(3) Disengage license plate lamp wire connector
from body wire harness, if equipped.
(4) Separate rear bumper from vehicle.
INSTALLATION
(1) Support rear bumper on a suitable lifting
device.
(2) Position rear bumper on vehicle.
(3) Engage license plate lamp wire connector to
body wire harness, if equipped.
(4) Install nuts attaching rear bumper to inner
and outer brackets. Tighten nuts to 94 N´m (70 ft.
lbs.) torque.
FRAME
DESCRIPTION
DESCRIPTION
The BR/BE frame is the structural center of the
vehicle. In addition to supporting the body and pay-
load, the frame provides a station for the engine and
drivetrain. BR/BE trucks have a ladder type frame
with Box-section front rails, dropped center section,
and open-channel side rails in the rear.
Cross members attach to the side rails with rivets,
welds, or bolts. The cab is isolated from the frame
with rubber load cushions with through bolts. The
cargo box or bed is attached to the frame with bolts.
The frame is designed to absorb and dissipate flex-
ing and twisting due to acceleration, braking, corner-
ing, and road surface variances without bending
when subjected to normal driving conditions.
Fig. 8 Rear Bumper
1 - INNER BRACKET
2 - BUMPER3 - OUTER BRACKET
13 - 6 FRAME & BUMPERSBR/BE
Page 1294 of 2255

FRAME SERVICE
SAFETY PRECAUTIONS AND WARNINGS
WARNING: USE EYE PROTECTION WHEN GRIND-
ING OR WELDING METAL, SERIOUS EYE INJURY
CAN RESULT. BEFORE PROCEEDING WITH FRAME
REPAIR INVOLVING GRINDING OR WELDING, VER-
IFY THAT VEHICLE FUEL SYSTEM IS NOT LEAKING
OR IN CONTACT WITH REPAIR AREA, PERSONAL
INJURY CAN RESULT. DO NOT ALLOW OPEN
FLAME TO CONTACT PLASTIC BODY PANELS.
FIRE OR EXPLOSION CAN RESULT. WHEN
WELDED FRAME COMPONENTS ARE REPLACED,
100% PENETRATION WELD MUST BE ACHIEVED
DURING INSTALLATION. IF NOT, DANGEROUS
OPERATING CONDITIONS CAN RESULT. STAND
CLEAR OF CABLES OR CHAINS ON PULLING
EQUIPMENT DURING FRAME STRAIGHTENING
OPERATIONS, PERSONAL INJURY CAN RESULT.
DO NOT VENTURE UNDER A HOISTED VEHICLE
THAT IS NOT SUPPORTED ON SAFETY STANDS,
PERSONAL INJURY CAN RESULT.
CAUTION: Do not reuse damaged fasteners, quality
of repair would be suspect. Do not drill holes in top
or bottom frame rail flanges, frame rail failure can
result. Do Not use softer than Grade 5 bolts to
replace production fasteners, loosening or failure
can result. When using heat to straighten frame
components do not exceed 566ÉC (1050ÉF), metal
fatigue can result. Welding the joints around riveted
cross members and frame side rails can weaken
frame.
FRAME STRAIGHTENING
When necessary, a conventional frame that is bent
or twisted can be straightened by application of heat.
The temperature must not exceed 566ÉC (1050ÉF).
The metal will have a dull red glow at the desired
temperature. Excessive heat will decrease the
strength of the metal and result in a weakened
frame.
Welding the joints around riveted cross members
and frame side rails is not recommended.
A straightening repair process should be limited to
frame members that are not severely damaged. The
replacement bolts, nuts and rivets that are used to
join the frame members should conform to the same
specifications as the original bolts, nuts and rivets.
FRAME REPAIRS
DRILLING HOLES
Do not drill holes in frame side rail top and bottom
flanges, metal fatigue can result causing frame fail-
ure. Holes drilled in the side of the frame rail must
be at least 38 mm (1.5 in.) from the top and bottom
flanges.
Additional drill holes should be located away from
existing holes.
WELDING
Use MIG, TIG or arc welding equipment to repair
welded frame components.
Frame components that have been damaged should
be inspected for cracks before returning the vehicle
to use. If cracks are found in accessible frame com-
ponents perform the following procedures.
(1) Drill a hole at each end of the crack with a 3
mm (O.125 in.) diameter drill bit.
(2) Using a suitable die grinder with 3 inch cut off
wheel, V-groove the crack to allow 100% weld pene-
tration.
(3) Weld the crack.
(4) If necessary when a side rail is repaired, grind
the weld smooth and install a reinforcement channel
(Fig. 9) over the repaired area.
NOTE: If a reinforcement channel is required, the
top and bottom flanges should be 0.250 inches nar-
rower than the side rail flanges. Weld only in the
areas indicated (Fig. 9).
Fig. 9 Frame Reinforcement
1 - .250 IN FROM EDGE
2 - TOP FLANGE
3 - BOTTOM FLANGE
4 - FRAME RAIL
5 - FRAME REPAIR REINFORCEMENT
BR/BEFRAME & BUMPERS 13 - 7
FRAME (Continued)
Page 1295 of 2255

FRAME FASTENERS
Bolts, nuts and rivets can be used to repair frames
or to install a reinforcement section on the frame.
Bolts can be used in place of rivets. When replacing
rivets with bolts, install the next larger size diameter
bolt to assure proper fit. If necessary, ream the hole
out just enough to sufficiently receive the bolt.
Conical-type washers are preferred over the split-
ring type lock washers. Normally, grade-5 bolts are
adequate for frame repair.Grade-3 bolts or softer
should not be used.Tightening bolts/nuts with thecorrect torque, refer to the Introduction Group at the
front of this manual for tightening information.
SPECIFICATIONS
FRAME DIMENSION
Frame dimensions are listed in Millimeters (mm)
scale. All dimensions are from center to center of
Principal Locating Point (PLP), or from center to cen-
ter of PLP and fastener location (Fig. 10) .
DIMENSIONS FOR DIFFERING WHEELBASES*
WHEELBASE LENGTH
ALENGTH
BLENGTH
C
118 2118.0 3663.6 4185.4
134 2118.0 3994.5 4693.4
138 2626.0 4096.1 4693.4
154 2626.0 4502.5 5201.4
162 2118.0 4705.0 5042.5
*Measurements are in Millimeters (mm).
13 - 8 FRAME & BUMPERSBR/BE
FRAME (Continued)
Page 1296 of 2255
Fig. 10 Frame Dimensions
BR/BEFRAME & BUMPERS 13 - 9
FRAME (Continued)