Carpet

Complete removal and replacement of interior carpet, requiring removal of seats, center console, door sill trim, and various interior panels.

Warnings

Tools required

Parts

• Replacement carpet kit × 1 — Aftermarket molded carpet or OEM equivalent
• Trim panel clips × 10 — Various sizes - inspect during removal
• Carpet retaining clips × 5 — Replace broken clips

Preparation

1. Park vehicle on level surface and engage parking brake
2. Disconnect negative battery terminal and wait 10 minutes for airbag system capacitor discharge
3. Remove any aftermarket floor mats or loose items from interior
4. Move front seats to full forward position for rear bolt access
5. Open all doors for easier access during removal

Procedure

1. 1

   Remove front seats
   Remove the four seat mounting bolts per seat (two front, two rear). On seats with electrical connections, disconnect the wiring harnesses underneath before fully removing the seat. Carefully remove seats from vehicle and place in protected area. Note the position of any shims or spacers under seat mounts.
   Torque spec

   Seat Mounting Bolts45 Nm (33 lb-ft)
2. 2

   Remove center console and shifter trim
   Remove screws securing center console (typically two at front under rubber mat, two at rear near cupholders). Lift up console slightly and disconnect any electrical connections for power outlets or switches. For manual transmission, remove shifter boot retaining ring. For automatic, carefully pry shifter bezel upward. Remove entire console assembly.
3. 3

   Remove door sill plates and kick panels
   Remove screws from door sill plates on both sides (driver, passenger, and rear if crew cab). Carefully pry up sill plates to release any remaining clips. Remove kick panel screws on both front footwells and pull panels away from firewall. Disconnect any electrical connectors for courtesy lights if equipped.
   Torque spec

   Trim Panel Clips2 Nm (1.5 lb-ft)
4. 4

   Disconnect pedal assemblies
   Remove the accelerator pedal assembly mounting bolts (typically two bolts at top bracket). For early 12-valve models (1994-1998) with mechanical linkage, disconnect the throttle cable at the pedal. For later 24-valve models (1998.5-2007) with electronic controls, disconnect the accelerator pedal position sensor (APPS) connector. Disconnect the brake light switch or brake pedal position sensor connector if equipped and accessible. Parking brake pedal assembly typically remains in place but may need bracket bolts loosened for carpet clearance.
   Torque spec

   Seat Mounting Bolts45 Nm (33 lb-ft)
5. 5

   Remove lower dashboard trim and panels
   Remove lower steering column cover by removing screws at bottom edge. Remove lower dashboard end caps on both driver and passenger sides by pulling straight back. Remove any additional lower trim panels below the glove box and on driver side that overlap carpet edges. These typically use a combination of screws and push clips.
   Torque spec

   Dashboard Screws3 Nm (2 lb-ft)

   Trim Panel Clips2 Nm (1.5 lb-ft)
6. 6

   Disconnect electrical sensors and components
   Locate and disconnect any floor-mounted electrical connections including ground straps bolted to the floor pan and any interior wiring harness connectors that cross the floor. Note the Cummins engine control module is engine-mounted and does not need disconnecting for this job. Label all connections for reinstallation.
   Torque spec

   Connector Bolts7 Nm (5 lb-ft)
7. 7

   Remove rear seat (crew cab models)
   For crew cab models, remove rear seat cushion by lifting front edge sharply upward to release clips, then pull forward. Remove rear seat back by locating and removing mounting bolts at bottom hinge points (typically two or three bolts per side). Disconnect any seatbelt buckle sensors before fully removing seat back.
   Torque spec

   Seat Mounting Bolts45 Nm (33 lb-ft)
8. 8

   Disconnect parking brake cable
   From underneath vehicle or through access point in floor, disconnect parking brake cable at equalizer or front cable connection point where it enters cabin. This prevents damage to cable during carpet removal. May require loosening bracket bolts to provide slack.
9. 9

   Remove old carpet
   Starting from rear of cab, carefully pull carpet forward and upward. Work around any remaining obstacles including steering column, brake pedal bracket, and wiring harnesses. The carpet is typically one piece and may require folding or rolling to extract through door opening. Cut away severely degraded sections if necessary to facilitate removal. Remove all old padding or insulation adhered to floor pan.
   ⚠Use caution around sharp metal edges on floor pan and seat mount holes during carpet removal.
10. 10

    Clean and inspect floor pan
    Thoroughly vacuum and clean floor pan surface. Inspect for rust, corrosion, or damage. Wire brush any surface rust and treat with rust converter if needed. Check all drain plugs and ensure they are properly sealed. Inspect sound deadening material and replace if deteriorated. Check condition of all wiring harnesses and ensure proper routing clips are intact.
    ℹ️Address any rust or floor pan damage before installing new carpet to prevent further deterioration.
11. 11

    Install new carpet and padding
    Position new carpet padding or insulation on floor pan if included with kit. Starting from firewall area, carefully position new molded carpet into cab, working it around steering column and pedal areas. Ensure carpet fits properly in all corners and contours. Pull carpet tight to eliminate wrinkles, working from center outward. Align all mounting holes for seats, console, and trim pieces.
    ℹ️New molded carpet may be stiff initially. Allow to warm in sun or use heat gun carefully to improve flexibility during installation.
12. 12

    Reinstall electrical components and sensors
    Reconnect all electrical sensors, ground straps, and control modules removed during disassembly. Route all wiring harnesses in original locations using existing clips and brackets. Ensure no wires are pinched under carpet edges or near seat mounting points. Torque all sensor mounting bolts and electrical connector bolts to specification.
    Torque spec

    Connector Bolts7 Nm (5 lb-ft)
13. 13

    Reinstall door sills, kick panels, and lower trim
    Install kick panels first, ensuring proper fit over carpet edges. Replace any broken clips. Install door sill plates, aligning screw holes carefully. Torque sill plate screws and install trim panel clips properly. Reinstall lower dashboard panels and end caps, ensuring carpet is tucked neatly under all edges.
    Torque spec

    Trim Panel Clips2 Nm (1.5 lb-ft)
14. 14

    Reinstall pedal assemblies and center console
    Reconnect parking brake cable through floor. Reinstall accelerator pedal assembly and torque mounting bolts to specification. Reconnect throttle cable if applicable and verify smooth operation. Position center console and reconnect all electrical connections. Secure console with screws, ensuring proper engagement with carpet and no interference with shifter operation.
    Torque spec

    Seat Mounting Bolts45 Nm (33 lb-ft)
15. 15

    Reinstall seats
    Position front seats over mounting holes, ensuring carpet is not trapped under seat bases. Install any shims or spacers noted during removal. Reconnect all seat electrical harnesses. Install seat mounting bolts and torque to specification, tightening in a cross pattern for even seating. Verify seats are secure with no movement. Reinstall rear seats on crew cab models following reverse of removal procedure.
    ⚠️Seat mounting bolts are safety-critical. Verify all four bolts per seat are properly torqued and fully engaged in mounting threads.
    Torque spec

    Seat Mounting Bolts45 Nm (33 lb-ft)

Reassembly

1. Reconnect negative battery terminal and verify no airbag warning lights remain illuminated
2. Test all seat adjustments and verify electrical seat functions operate correctly
3. Verify all door sill plates and trim pieces are secure with no rattles
4. Check parking brake operation and pedal feel
5. Confirm accelerator pedal returns smoothly and throttle operates correctly

Verification

• Inspect all carpet edges to ensure proper fit with no gaps or wrinkles
• Verify all seat mounting bolts are torqued to 45 Nm (33 lb-ft) and seats are rock-solid
• Confirm no airbag warning lights on instrument cluster after battery reconnection
• Test all electrical components that were disconnected (sensors, switches, power outlets)
• Check that all trim panels, console, and door sills are properly secured
• Verify parking brake engages and releases properly
• Ensure no wiring harnesses are pinched or interfering with pedal operation
• Test drive vehicle to verify no unusual noises or seat movement

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