Section 11 - Chassis Sheet Metal

1.   Remove front bumper at frame. Unhook both hood hinge springs at lower ends, and remove hood by unbolting each hinge arm at the side panels. Drain radiator. Disconnect radiator in­let and outlet hose connections.
2.   Disconnect hood latch control cable at swivel and clamp on latch plate just back from swivel. Pull cable back through grommet in top baffle, then disconnect from clip on left fender at radiator support, and pull cable out of bracket at left side baffle.
3.    (On both sides.) Remove 1 hex head bolt hold­ing rear lower flange of side baffle to frame side rail; 2 hex head bolts at hood hinge spring bracket to fender ledge; 1 hex head bolt at top rear section of fender to bracket on cowl.
4.   (On both sides.) Remove fender skirt to frame brace bolt at fender. Under fender remove 3 sheet metal bolts connecting fender rear baffle to fender. Remove bolt at front end of body sill molding, and loosen molding back about half­way along rocker panel. At outer front end of step plate remove 1 bolt holding step to fender.
5.   Remove 2 radiator support bolts at frame front cross member. Disconnect all wires at junction blocks on side baffles just to rear of radiator support. Disconnect wiring harness from 3 clips on left fender near top, from 5 clips across top and side of radiator core and support, and from 1 clip on right fender near junction block. Pull wiring harness back out of the way on left side toward cowl.
6.   The complete sheet metal unit may now be re­moved from the chassis. During removal it will be necessary to spring the rear end of each fender outward slightly, to allow the brackets inside the fender skirts to clear the fender rear baffles.
The additional disassembly necessary for actual engine removal from the chassis, consisting of re­moving the generator wires, coil, primary wire, bat­tery, etc., is outlined in Section 6 of this Manual.
The rear gravel deflector is mounted on the rear bumper, and completely fills the space between the rear end of the body and the rear bumper bar. The body rear lower panel is designed to permit the deflector to lap under the rear end of the body. Rubber bumpers in the gravel deflector insulate it from the body. The ends of the deflector are flanged down and extend forward between the inside flanges of the rear fenders, being sealed to the fend­ers with a sponge rubber seal. The rear edge of the deflector is sealed against the bumper bar with an extruded rubber seal.
Adjustment of the rear gravel deflector is pro­vided in the supporting brackets attached to the bumper bar support bolts so the deflector can always be brought into proper alignment with the body.
The front end sheet metal assembly on conven­tional trucks is attached to the radiator support at the front and to the running boards and cowl at the rear.
The radiator support is attached to the frame front cross member by two bolts through a rubber mounting. This method of mounting prevents frame distortions being transmitted to the front end sheet metal assembly when passing over rough or uneven roads.
Front Fender Removal
1.    Raise the hood.
2.   Disconnect electrical wiring at the junction block.
3.   Remove bolts attaching fender to running board.
4.   Remove bolts attaching fender and fender skirt to cowl.
5.   Remove bolts attaching fender to radiator grille. The fender may now be removed from the truck.
Replacement of the fender is the reverse of the foregoing operations.
To remove all front end sheet metal, including both fenders, radiator core, support, etc., to facili­tate engine removal or major repair work on the front end of the truck, proceed as follows:
1.   Remove the hood and radiator brace rods.
2.   Drain the radiator and disconnect all hose con­nections.
3.   Disconnect electrical wiring at the junction block on each side.
4.   Remove fender to running board bolts, and the fender to cowl bolts on each side.
5.   Remove front bumper.
6.   Remove the radiator support to frame front cross member bolts.
7.   Slide the front end sheet metal assembly for­ward until the fan shroud (on 1-1/2-ton models only) clears the fan blades, then lift the as­sembly off the chassis.





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