Fenders

REMOVAL & INSTALLATION

1994–97 B Series Pick-up Models

1. Clean out all dirt from the fender attaching hardware and lubricate them to ease removal.
2. Remove the grille.
3. With the door open, remove the bolt attaching the rear end of the fender to the cowl.
4. Remove the screws around the wheel opening attaching the fender apron (splash shield).
5. Remove the bolt attaching the lower rear of the fender to the rocker.
6. Remove the bolts along the top of the fender.
7. Remove the bolt attaching the brace to radiator support assembly.
8. Remove the fender and remove the brace from the fender.

   To install:

9. Position the nuts, retainers and brace on the fender. Tighten the brace-to-fender bolt to 8–10 ft. lbs. (11–14 Nm).
10. Position the fender on the apron and loosely install the apron retaining bolts.
11. Loosely install the bolt from inside the cab attaching the rear end of the fender to the cowl.
12. Loosely install the bolt attaching the rear lower end of the fender to the lower corner of the cab.
13. Loosely install the bolt attaching the brace to the radiator support assembly.
14. Loosely install the 4 bolts along the fender inner body attaching the fender.
15. Adjust the position of the fender and tighten all mounting bolts. Tighten all of the fender mounting bolts to 8–10 ft. lbs. (11–14 Nm).
16. Install the grille.
17. Install the apron screws around the wheel opening.

    Fig. 1: Exploded view of the B Series Pick-up front fender assembly

1998 B Series Pick-up Models

1. Clean out all dirt from the fender attaching hardware and lubricate them to ease removal.
2. Remove the front bumper.
3. Remove the parking lamp assembly.
4. Remove the radiator opening cover pushpins, then remove the radiator opening cover..
5. Remove the pushpin, then remove the stone deflector.
6. If equipped, remove the mud flap.
7. Remove the mounting screws, bolts and pushpin, then remove the inner fender splash shield. If removing the right side front inner splash shield, disconnect the vacuum lines from the vacuum storage reservoir.
8. With the door open, remove the bolt attaching the rear end of the fender to the cowl.
9. Remove the bolt attaching the lower rear of the fender to the rocker. If equipped, remove and retain the front fender spacers.
10. Remove the bolts along the top of the fender.
11. Remove the bolt attaching the brace to radiator support assembly.
12. Remove the fender and remove the brace from the fender.

    To install:

13. Position the nuts, retainers and brace on the fender.
14. Position the fender onto the vehicle.
15. Loosely install the bolt from inside the cab attaching the rear end of the fender to the cowl.
16. Loosely install the bolt attaching the rear lower end of the fender to the lower corner of the cab.
17. Loosely install the bolt attaching the brace to the radiator support assembly.
18. Loosely install the 4 bolts along the fender inner body attaching the fender.
19. Adjust the position of the fender and tighten all mounting bolts. Tighten all of the fender mounting bolts to 8–10 ft. lbs. (11–14 Nm).
20. Install the inner fender splash shield. Install the pushpin and tighten the mounting screws and bolts. If installing the right side inner fender splash shield, connect the vacuum lines to the vacuum storage reservoir.
21. If equipped, install mud flaps.
22. Install the stone deflector and secure with pushpin.
23. Install the radiator opening cover and secure with the pushpins.
24. Install the parking lamp assembly.
25. Install the front bumper.

Navajo Models

1. Clean out all dirt from the fender attaching hardware and lubricate them to ease removal.
2. Remove the headlight door and side marker lamp.
3. Remove both bolts attaching the headlight assembly to the fender.
4. From inside the door opening, remove the bolt attaching the rear end of the fender to the cowl.
5. Remove the 4 bolts along the top of the fender inner body attaching the fender.
6. Raise the truck to a convenient height.
7. Remove the bolt attaching the brace to the radiator support assembly.
8. Remove the 2 bolts attaching the fender to the bumper stone deflector.
9. Remove the 4 screws attaching the fender apron to the fender.
10. Remove the 2 bolts attaching the fender to the rocker panel.
11. Lower the vehicle and remove the fender. Remove the brace from the fender.

    Fig. 2: Exploded view of the Navajo front fender assembly

    To install:

12. Install the fender and raise the truck.
13. Position the nuts, retainers and brace on the fender.
14. Install the 2 bolts attaching the fender to the rocker panel.
15. Install the 4 screws attaching the fender apron to the fender.
16. Install the 2 bolts attaching the fender to the bumper stone deflector.
17. Install the bolt attaching the brace to the radiator support. Lower the truck.
18. Install the 4 bolts along the top of the fender inner body attaching the fender.
19. Install the bolt attaching the rear end of the fender to the cowl. Tighten all fender mounting screws, bolts and washer assemblies to 7–10 ft. lbs. (9–14 Nm).
20. Install both bolts attaching the headlight assembly to the fender.
21. Install the headlight door and side marker lamp.

MPV

1. Clean all of the dirt from the fender mounting screws, bolts and nuts.
2. Remove the radiator grille.
3. Remove the front combination light assembly.
4. Remove the front bumper.
5. Remove the windshield molding.

   Fig. 3: MPV front fender assembly

6. Remove the mud guard.
7. Remove the top bolt attaching the rear of the front fender to the windshield cowl.
8. Remove the top bolts that mount the fender to the inter-body.
9. Loosen the wheel lugs slightly. Raise and safely support the vehicle. Remove the wheel and tire assembly.
10. Remove the retaining nuts that secure the back of the fender to the hinge pillar.
11. Remove the bolts attaching the fender to the radiator support, and remove the bolts attaching the fender to the fender apron (inner splash shield).
12. Remove the bolt mounting the fender to the lower rocker sill. Check for any other mounting bolts, remove them. Remove the fender.
13. Place the fender in position and install the mounting bolts loosely. Align the lower edge of the fender to the rocker sill and secure the bolts. Align the upper edge of the fender to the cowl and tighten the bolts.
14. Tighten the remaining mounting bolts. Install the lighting equipment.