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ICU (Integrated Control Unit): Installation

  1. Install ICU onto its mounting bracket.
  2. Install three bolts attaching ICU to mounting bracket. See Figure. Tighten mounting bolts to 10 N.m (85 in. lbs.) torque.
  3. Install primary and secondary brake tubes from the master cylinder at ICU hydraulic control unit. See Figure. Tighten primary and secondary brake tube nuts to 17 N.m (145 in. lbs.) torque.
  4. Install three chassis brake tubes into their respective outlet ports in ICU hydraulic control unit. See Figure. Tighten three brake tube nuts to 17 N.m (145 in. lbs.) torque.
    CAUTION: Before installing the 24-way connector in the CAB, be sure the seal is properly installed in the connector.
  5. Install 24-way connector into socket of CAB as follows:
    • Position 24-way connector in socket of CAB and carefully push it down as far as possible.
    • Once connector is fully seated into CAB socket, push connector lock inward. This pulls connector into socket of CAB and locks it in place.
  6. Install belly pan front extension. (Refer to BODY/EXTERIOR/BELLY PAN - INSTALLATION)
  7. Install access panel in forward portion of left front wheel well.
  8. Install tire and wheel assembly (Refer to TIRES/WHEELS - INSTALLATION) . Progressively tighten the wheel mounting nuts in the proper sequence to 122 N.m (90 ft. lbs.) torque.
  9. Lower vehicle.
  10. Connect battery negative (-) terminal to battery post.
    NOTE: The ICU may need to be initialized using the
  11. Remove brake pedal prop.
  12. Connect DRBIII(R) to data link connector below steering column to initialize new CAB. Check for any faults. Refer to Appropriate Diagnostic Information.
  13. Bleed base brakes and ABS, then repeat bleeding base brake hydraulic system. Refer to STANDARD PROCEDURE - BASE BRAKE BLEEDING or STANDARD PROCEDURE - ANTILOCK BRAKE SYSTEM BLEEDING 
  14. Fill master cylinder to proper fill level.
  15. Road test vehicle to ensure proper operation of base and antilock brake systems.
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