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7. Place stands or blocking under front of sub-
frame to support assembly while repositioning
hoist.
8. Install a safety chain around the truck frame
and the front subframe cross member. The
safety chain will prevent the power unit from
rolling forward.
9. Place a small block behind each rear subframe
roller to prevent rolling.
10. Lower hoist to allow subframe to rest on stands
and rollers. Remove lifting device.
11. Attach hoist to front lifting eyes on subframe.
12. Remove the small blocks behind the subframe
rollers, remove safety chain, and slowly roll the
power module into position over the main frame
mounts. Lower hoist until front subframe mount
is aligned and seated on the front, main frame
mount. Reinstall safety chain.
13. Relocate hoist to the rear portion of the engine/
alternator cradle structure and raise just enough
to permit removing the subframe rollers.
14. Lower the rear portion of the subframe until the
subframe rubber bushings are seated in the
rear mounting brackets located on the main
frame of the truck.
15. After subframe is seated in frame mounts, the
safety chain may be removed from the front
subframe member.
16. Install cap screws (9, Figure 2-4) and lockwash-
ers in the front mount and tighten cap screws to
298 ±30 N·m (220 ±22 ft lbs) torque. Install
ground strap between frame and subframe.
Reinstall air dam. Install cover (10) if grille is
installed.
C02027
17. Install the rear subframe mounting caps (3) and
secure caps in place with lubricated cap screws
(4). Tighten cap screws to 551 ±21 N·m (407
±15 ft lbs) torque.
18. Install radiator support struts (12).
19. Install exhaust ducts (1 & 3, Figure 2-2) Install
cap screws (2) washers and nuts to secure
ducts to turbochargers. Install "V" band clamps
(5) and support clamps (4).
20. Connect the cab heater inlet and outlet hoses
and open both valves.
21. Connect the hydraulic pump drive shaft (1, Fig-
ure 2-4) to the companion flange on the alterna-
tor. Tighten cap screws to standard torque.
22. Connect wheel motor cooling blower air outlet
hose. Tighten all clamps securely to insure a
positive air seal.
23. Install diagonal ladder on front of truck.
24. Install transition structure (4, Figure 2-1) to
alternator.
25. Install transition structure (3) to alternator.
26. Lift main alternator blower intake duct (2) into
position and install all mounting hardware at
mounts.
27. Install control cabinet air hose (5), electrical
cables and any other hoses and wiring removed
during power module removal.
28. Connect all remaining electric, oil, and fuel
lines.
29. Attach hoist to the front center deck and lift into
position. Align the rear center deck mounting
holes with the support structure in front of the
electrical cabinet. Install cap screws and flat
washers. Do not tighten at this time.
30. Align the front center deck, front mounting holes
with both left and right fender supports. Install
cap screws and flat washers. Tighten all deck
mounting cap screws to standard torque values.
Power Module
C2-9
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