Headliner

Complete removal and replacement of the headliner fabric and backing board, requiring removal of interior trim, visors, grab handles, and dome lights.

Warnings

Tools required

Parts

• Headliner fabric material × 1 — Cut to fit Crew Cab or Regular Cab application
• Trim panel clips (assorted) × 10 — Use OEM specification
• Sunvisor mounting screws (if corroded) × 4 — Use OEM specification
• Dome light lens clips (if broken) × 2 — Use OEM specification

Preparation

1. Park vehicle on level surface in a clean, enclosed area with adequate lighting and space
2. Disconnect negative battery cable and wait 10 minutes for airbag system capacitors to discharge
3. Remove both front seats to provide working space and access (save seat mounting bolts)
4. Place drop cloths over seats if not removed to protect upholstery
5. Take detailed photos of all trim mounting locations and wire routing before removal
6. Determine cab configuration (Regular Cab, Quad Cab, or Crew Cab) as headliner size varies

Procedure

1. 1

   Remove A-pillar trim panels
   Starting at the top near the windshield header, carefully pry the A-pillar trim covers away from the pillar. These are held by clips along the length. Pull firmly but steadily to release clips without breaking them. Disconnect any wire harnesses for tweeter speakers if equipped. Remove trim from both driver and passenger sides.
   Torque spec

   Trim Panel Clips2 Nm (1.5 lb-ft)
2. 2

   Remove sun visors and mounting brackets
   Flip down each sun visor. Remove the Phillips screws securing the visor to the mounting bracket (typically 2 screws per visor). Remove the visor. Then remove the mounting bracket screws from the roof structure. Save all hardware. Disconnect any wiring for lighted vanity mirrors if equipped.
   Torque spec

   Seat Mounting Bolts45 Nm (33 lb-ft)
3. 3

   Remove dome lights and overhead console
   Carefully pry the dome light lens down using a trim tool or flat screwdriver. Remove the bulbs. Remove screws securing the dome light base to the headliner/roof structure. Disconnect electrical connector. If equipped with overhead console, remove mounting screws and disconnect any additional connectors (compass, garage door opener, etc.).
4. 4

   Remove grab handles
   Pry off the decorative covers on each grab handle to expose mounting screws. Remove the mounting screws securing each grab handle to the roof structure. There are typically 2-3 grab handles depending on cab configuration. Keep hardware organized by location.
   Torque spec

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

   Remove B-pillar and C-pillar trim panels
   For Club Cab / Quad Cab models, remove B-pillar upper trim by releasing clips. Remove rear seat belt anchor cover and upper mounting bolt cover. Remove the rear pillar trim panels by pulling away from clips. On regular cab models, remove only the B-pillar trim. Disconnect any wire harnesses.
   Torque spec

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

   Remove windshield header trim
   Remove the center rearview mirror by loosening the set screw or sliding retention clip depending on model year. Remove any covers at the ends of the windshield header trim. Carefully pull down the header trim panel, starting from one end and working across. This panel typically has clips every 6-8 inches along its length.
   Torque spec

   Trim Panel Clips2 Nm (1.5 lb-ft)
7. 7

   Remove rear window trim (if applicable)
   On models with rear sliding window or fixed rear glass, remove the upper trim piece above the rear window. This is typically held by clips similar to the windshield header. For Club/Quad cabs, remove the upper rear window trim carefully as it may be brittle on older vehicles.
   Torque spec

   Trim Panel Clips2 Nm (1.5 lb-ft)
8. 8

   Remove coat hooks and remaining fasteners
   Remove any remaining coat hooks, sunroof trim (if equipped), or other accessories attached to the headliner. Check all edges of the headliner for any remaining screws or clips holding it to the roof structure. The headliner should now be free from all attachment points.
9. 9

   Extract headliner board from vehicle
   With a helper, carefully tilt and maneuver the headliner board out through the passenger side door opening. For Club Cab / Quad Cab models, tilt the front edge down and angle it out the rear door opening. Be extremely careful not to bend or crease the board. This step requires patience and may need to angle the board at various positions to clear the door opening. Remove rear seats if necessary for clearance.
   ⚠The headliner board is very fragile and will crack if bent too sharply. Work slowly and use a helper to support the board at all times.
10. 10

    Remove old headliner fabric
    Place the headliner board on a clean, flat surface with the fabric side up. Peel away the old sagging headliner fabric from the foam backing board. Use a wire brush or scraper to remove all remaining foam and old adhesive from the board surface. The board must be clean and smooth for the new fabric to adhere properly. Be gentle to avoid gouging the backing board.
    ℹ️Wear a dust mask during this step as old foam deteriorates into fine particles.
11. 11

    Apply new headliner fabric
    Lay the new headliner fabric face-down on a clean surface. Center the cleaned backing board foam-side down on the fabric. Starting from the center, spray headliner adhesive on a small section of the board (approximately 12 inches square). Immediately smooth the fabric onto the adhesive, working from center outward to eliminate wrinkles. Continue this process, working outward from the center in all directions. Allow 15-20 minutes between sections for adhesive to tack up.
    ⚠Work in a well-ventilated area when using headliner adhesive spray. Vapors are flammable and harmful if inhaled.
    ℹ️Do not spray too much adhesive at once as it will soak through the fabric. Light, even coats work best.
12. 12

    Trim excess fabric and cut openings
    Once adhesive has fully cured (typically 1 hour), trim excess fabric around the edges of the board leaving approximately 1-2 inches. Fold this excess over the edge and glue to the back side. Cut openings for dome lights, visors, grab handles, and any other mounting points using a sharp utility knife. Make cuts slightly smaller than needed and enlarge as necessary for a tight fit.
    ℹ️Use the old headliner fabric as a template for opening locations if possible.
13. 13

    Reinstall headliner board into vehicle
    With a helper, carefully insert the recovered headliner board back into the vehicle through the door opening, reversing the removal process. Tilt and angle as needed to clear the door frame without bending the board. Position the board against the roof structure, ensuring all mounting holes align properly with roof attachment points.
    ⚠Take your time during insertion. Rushing can crack the freshly recovered headliner board.
14. 14

    Reinstall all trim and accessories
    Reinstall all components in reverse order of removal: windshield header trim, rear window trim, grab handles, dome lights/overhead console, sun visors with mounting brackets, A-pillar trim, B-pillar and C-pillar trim (if applicable), and coat hooks. Reconnect all electrical connectors. Ensure all clips seat fully and trim pieces are flush against mounting surfaces. Torque all fasteners to specification.
    Torque spec

    Trim Panel Clips2 Nm (1.5 lb-ft)

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

    Reinstall seats and reconnect battery
    If front seats were removed, reinstall them and torque mounting bolts to specification. Seat mounting bolts are safety critical. Torque them to the factory specification for this vehicle (verify in service manual) and verify seats are locked down securely before driving. Ensure all seat belt connections are secure. Reconnect the negative battery cable. Test all electrical components including dome lights, vanity mirror lights, and overhead console functions.
    ⚠️Seat mounting bolts are safety critical. Ensure they are torqued to exactly 45 Nm (33 lb-ft) and verify seats are locked down securely before driving.
    Torque spec

    Seat Mounting Bolts45 Nm (33 lb-ft)

Reassembly

1. Ensure all trim panel clips are fully seated and panels are flush with no gaps
2. Verify all electrical connectors are fully engaged with positive locks seated
3. Check that all grab handles and sun visors operate smoothly and are securely mounted
4. Confirm rearview mirror is properly tightened and adjusted
5. Inspect headliner fabric for any wrinkles, sags, or areas not properly adhered

Verification

• Test all dome lights and overhead console functions to confirm proper electrical connections
• Check that headliner fabric is taut and smooth with no sagging or loose areas
• Verify all trim panels are secure with no rattles when closing doors firmly
• Ensure sun visors pivot smoothly and stay in position when flipped up or to the side
• Confirm grab handles are solidly mounted and can support normal pulling force
• Check that all openings for lights and accessories are properly aligned and trimmed
• Verify front seats are locked down securely and seat belts function normally if seats were removed

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