Roof Side Rail Inflatable Restraint Module Replacement (Extended Cab)

Preliminary Procedures

1. Disable the SIR system. Refer to SIR Disabling and Enabling .
2. Remove the rear door sill plate. Refer to Rear Side Door Sill Trim Plate Replacement (Crew Cab) or Rear Side Door Sill Trim Plate Replacement (Extended Cab) .
3. Remove the rear window lower trim panel. Refer to Rear Window Lower Garnish Molding Replacement (Ext Cab/Crew Cab w/A48) , Rear Window Lower Garnish Molding Replacement (Ext Cab/Crew Cab w/o A48) , Rear Window Lower Garnish Molding Replacement (Regular Cab) .
4. Remove body lock pillar garnish molding. Refer to Body Lock Pillar Trim Replacement (Crew Cab) , Body Lock Pillar Trim Replacement (Extended Cab) or Body Lock Pillar Trim Replacement (Regular Cab) .
5. Remove the rear assist handle. Refer to Roof Rail Rear Assist Handle Replacement .
6. Remove the front assist handle (passenger side only). Refer to Front Assist Handle Replacement .
7. Remove the windshield garnish molding. Refer to Windshield Pillar Garnish Molding Replacement .
8. Lower the side of headliner. Refer to Headlining Trim Panel Replacement (Crew Cab) , Headlining Trim Panel Replacement (Extended Cab) or Headlining Trim Panel Replacement (Regular Cab) .

Procedure

1. The following repair procedure should be used if an inflatable restraint roof rail module M-6 nut is stripped:
   1. Remove the current M-6 bolt.
   2. Retain the module out of the way if necessary. Ensure that the module does not get damaged. Remove any other module bolts if installed, to help retain the module out of the way if necessary.
2. If location is at second row roof rail assist handle bracket attachments:
   • Remove the roof rail assist handle bracket if installed.
   • Drill out the slot at the location on roof rail assist handle bracket at the stripped weld-nut location to 8 mm (0.31 in) diameter.
   • Hand tap (thread) stripped weld-nut to M7 X 1.00 thread for M-7 replacement bolt.
3. If location is at second row roof rail assist handle bracket attachments, reinstall the roof rail assist handle bracket.
4. If present, remove the M-6 bolt and plastic pre-fixation bracket from the module assembly.
5. Reinstall the module. Ensure the module does not get damaged.
6. Hand start the replacement M-7 bolt P/N 11609538. For cushion attachments, ensure the bolt goes through both layers of the attachment webbing.
7. Hand start any other bolts that were removed.
8. Tighten the bolts to original specification.

Tighten:  9 N.m (80 lb ft)

Procedure

1. Release the connector position assurance (CPA) retainer.
2. Disconnect the electrical connectors.
3. Ensure roof rail inflator has been fully deployed before disposal. Refer to Inflatable Restraint Module Handling and Scrapping .