Page 4697 of 5267
4. Install the roller bushings (1) onto the rollers (2).
5. Install the roller axle rods (3) and install the rollers
(4) onto the support bracket (2).
6. Install the clips (1).
7. Store the winch hook on the most outboard loop of
the tow hook.
8. Engage the clutch lever (2) and remove the slack
fromthewirerope.
Page 4698 of 5267
page page
GAP AND FLUSH
SPECIFICATIONS ............................ 362
OPENING DIMENSIONS
SPECIFICATIONS ............................ 367
SEALER LOCATIONS
SPECIFICATIONS ............................ 370STRUCTURAL ADHESIVE LOCATIONS
SPECIFICATIONS ............................ 387
WELD LOCATIONS
SPECIFICATIONS ............................ 395
Page 4699 of 5267
GAP AND FLUSH
SPECIFICATIONS
GAP & FLUSH DIMENSIONS INDEX
DESCRIPTION FIGURE
STANDARD CAB 1
QUAD CAB 2
PICKUP BOX 3
MEGA CAB 4
NOTE:
All measurements are in mm. O/F = Over Flush. U/F = Under Flush.
DIMENSION DESCRIPTION GAP FLUSH
*1 Bumper to grille 19.0 ± 3.0 —
*2 Hood to grille 1.5 ± 1.0
Parallel within 2.0U/F 0.75 ± 1.75
*3 Fender to hood 6.0 ± 2.0
Parallel within 1.0U/F 3.2 ± 1.5
(Under flush from front of
hood to start of hockey
stick area only)
*4 Fender to hood
(Up/Down surface only)6.0 ± 1.5
Parallel within 1.00.0 ± 1.5
*5 Front door to windshield — O/F 20.5 ± 1.5
(Base of windshield)
O/F 9.0 ± 1.5
(Top of windshield)
*6 Roof to front door — U/F 6.0 ± 1.5
Parallel within 1.5
Fig. 1 GAP & FLUSH - STANDARD CAB
Page 4700 of 5267
NOTE:
All measurements are in mm. O/F = Over Flush. U/F = Under Flush.
DIMENSION DESCRIPTION GAP FLUSH
7 Quarter to front door 5.0 ± 1.5
Parallel within 1.00.0 ± 1.5
8 Front door to quarter character line
alignment— Up/Down 0.0 ± 1.5
*9 Front door to fender character line
alignment— Up/Down 0.0 ± 1.5
*10 Front door to fender 5.0 ± 1.5
Parallel within 1.00.0 ± 1.5
*11 Bumper to fender 19.0 ± 3.0
Parallel within 3.0O/F 5.0 ± 5.0 (SLT)
O/F 14.0 ± 5.0 (SPORT)
*12 Bumper to headlamp 19.0 ± 4.0 —
*ALLMODELS
NOTE:
All measurements are in mm. O/F = Over Flush. U/F = Under Flush.
DIMENSION DESCRIPTION GAP FLUSH
1 Roof to rear door — U/F 6.0 ± 1.5
Parallel within 1.5
2 Quarter to rear door 5.0 ± 1.5
Parallel within 2.00.0 ± 1.5
3 Rear door to quarter character line
alignment— Up/Down 0.0 ± 1.5
4 Rear door to front door character line
alignment— Up/Down 0.0 ± 1.5
5 Rear door to front door 5.0 ± 1.5
Parallel within 2.00.0 ± 1.5
Fig. 2 GAP & FLUSH - QUAD CAB
Page 4701 of 5267
NOTE:
All measurements are in mm. O/F = Over Flush. U/F = Under Flush.
DIMENSION DESCRIPTION GAP FLUSH
1 Tailgate to outer box
(Up/Down surface only)— 0.0 ± 1.5
Parallel within 1.0
2 Cab Back to box front 31.0 ± 5.0
Parallel within 3.0—
3 Fuel door to outer box 5.0 ± 1.5
Parallel within 1.00.0 ± 1.5
4 Cab to box side 31.0 ± 5.0
Parallel within 3.04.0 ± 2.5 (Standard Cab)
O/F 5.0 ± 2.5 (Quad Cab)
5 Cab to box character line alignment — Up/Down 0.0 ± 3.0
6 Tailgate to outer box 5.0 ± 2.0
Parallel within 1.0U/F 1.5 ± 1.5
7 Bumper to outer box 24.75 ± 5.0 (F/A)
23.75±5.0(C/C)
Parallel within 5.0—
8 Tailgate to outer box character line
adjustment— Up/Down 0.0 ± 1.5
9 Bumper to tailgate 30.25 ± 3.0
Parallel within 4.0—
Fig. 3 GAP & FLUSH - PICKUP BOX
Page 4702 of 5267
NOTE:
All measurements are in mm. O/F = Over Flush. U/F = Under Flush.
DIMENSION DESCRIPTION GAP FLUSH
1 Bumper To Grille 19.0 ± 4.0 —
Fig. 4 MEGA CAB - GAP & FLUSH
Page 4703 of 5267

NOTE:
All measurements are in mm. O/F = Over Flush. U/F = Under Flush.
DIMENSION DESCRIPTION GAP FLUSH
2 Hood To Grille 1.5 ± 1.0 U/F 0.5 ± 1.75
3 Fender To Hood 6.0 ± 2.0
Parallel Within 1.0U/F 3.2 ± 1.5
(Under flush from front of
hood to start of hockey
stick area only.)
4 Fender To Hood
(Up/Down Surface Only)6.0 ± 2.0
Parallel Within 2.00.0 ± 1.5
5 Front Door To Windshield — O/F 20.5 ± 1.5
(Base of windshield)
O/F 9.0 ± 1.5
(Top of windshield)
6 Front Door To Roof — O/F 6.0 ± 1.5
Parallel within 1.5
7 Rear Door To Roof — O/F 0.0 ± 1.5
8 Rear Door To Quarter Panel 5.0 ± 1.5
Parallel Within 1.50.0 ± 1.5
9 Fuel Door To Outer Box 5.0 ± 1.5
Parallel Within 1.50.0 ± 1.5
10 Rear Door To Quarter Character Line
Alignment— Up/Down 0.0 ± 1.5
11 Rear Door To Front Door 5.0 ± 1.5
Parallel Within 1.50.0 ± 1.5
12 Rear Door To Front Door Character
Line Alignment— Up/Down 0.0 ± 1.5
13 Front Door To Fender 5.0 ± 1.5
Parallel Within 1.5U/F 0.5 ± 1.5
14 Front Door To Fender Character Line
Alignment— Up/Down 0.0 ± 1.5
15 Bumper To Fender 16.0 ± 4.0
Side To Side 3.0O/F 6.5 ± 5.0 (SLT)
O/F 14.5 ± 5.0 (SPORT)
16 Bumper To Headlamp 16.0 ± 4.0 —
17 Tailgate To Outer Box Character Line
Alignment— 0.0 ± 1.5
18 Cab Back To Box Front 31.0 ± 5.0
Parallel Within 1.5—
19 Cab To Box Side 30.5 ± 5.0
Parallel Within 3.0O/F 5.25 ± 3.5
20 Cab To Box Character Line Alignment — Up/Down 0.0 ± 3.0
21 Tailgate To Outer Box 5.0 ± 2.0
Parallel Within 1.5U/F 1.5 ± 1.5
Side to side within 2.0
22 Bumper To Outer Box 24.0 ± 5.0 (F/A)
25.0 ± 5.0 (C/C)
Parallel Within 5.0—
23 Tailgate To Outer Box Character Line
Alignment— Up/Down 0.0 ± 1.5
24 Bumper To Tailgate 30.0 ± 3.0
Parallel Within 4.0—
Page 4704 of 5267
OPENING DIMENSIONS
SPECIFICATIONS
BODY OPENING DIMENSIONS INDEX
DESCRIPTION FIGURE
WINDSHIELD OPENING 5
DOOR OPENING - STANDARD CAB 6
DOOR OPENINGS - QUAD CAB 7
REAR WINDOW OPENING 8
ENGINE COMPARTMENT/FRONT STRUCTURE 9
REAR DOOR OPENING - MEGA CAB 10
Fig. 5 WINDSHIELD OPENING