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Preformed ABS Headliner Board Installation Instructions - 4 Door Crew Cab

May 14, 2025

Applicable for most preformed ABS replacement headliner boards used in 4-door crew cab pickup trucks.

Common applications include:

  • 1999–2006 Chevrolet Silverado & GMC Sierra Crew Cab
  • 1992–1997 Ford Crew Cab Pickup Trucks
  • Similar full-size 4-door crew cab truck applications

Please read all instructions completely before beginning installation.

Before You Begin

Factory Interiors crew cab ABS headliner boards are vacuum-formed to match the original roof contours of your truck.

Because crew cab headliners are significantly larger than standard applications:

  • Installation is strongly recommended as a two-person job.
  • Extra care should be taken when maneuvering the headliner inside the vehicle.
  • Test fit all trim and accessories before final tightening.

Most replacement headliners arrive covered in OEM-style headliner fabric, though some applications may also be paintable depending on vehicle configuration.

Recommended Tools

The following tools are recommended for installation:

  • Phillips screwdriver
  • Thin flat-blade screwdriver
  • Trim removal tools
  • Upholstery tucking tools
  • Pliers
  • Razor knife or safety knife
  • Flashlight
  • Adhesive or masking tape

Professional trim tools are highly recommended for easier molding removal and installation.

Important Installation Notes

Two-Person Installation Recommended

Crew cab headliners are large and more difficult to maneuver than standard passenger vehicle applications.

A second person can help:

  • Prevent accidental bending or cracking
  • Align the headliner evenly
  • Hold the board during visor and trim installation

Pre-Cut Openings

All ABS headliner boards include pre-cut openings for factory accessories such as:

  • Dome lights
  • Sun visor brackets
  • Coat hooks
  • Overhead consoles
  • Wiring pass-throughs

The upholstery material will cover these openings.

To expose an opening:

  1. Locate the opening.
  2. Cut a small “X” in the center using a razor knife.
  3. Fold the material flaps behind the board.
  4. Secure using tape or adhesive.

This method creates a cleaner finished appearance.

Vehicle Variations

Due to production tolerances and vehicle age:

  • Some openings may require slight enlargement.
  • Minor trimming adjustments may be necessary.
  • Always test fit accessories before final tightening.

Included Hook & Loop Fastener

Some kits include adhesive-backed hook-and-loop fastener (Velcro).

This may be used:

  • In loose areas needing additional support
  • Around overhead consoles or trim sections
  • To improve overall fitment and stability

Removing the Original Headliner

1. Remove Interior Components

Remove all components attached to or surrounding the headliner, including:

  • Sun visors
  • Upper trim moldings
  • Dome lights
  • Coat hooks
  • Overhead consoles
  • Grab handles
  • Shoulder belt trim (if applicable)

Retain all hardware for reuse.

2. Disconnect Electrical Components

Disconnect all wiring and electrical harnesses attached to the headliner.

This may include:

  • Dome lights
  • Rear dome lights
  • Overhead console wiring
  • Rear climate controls
  • Rear entertainment systems

Verify nothing remains attached before lowering the original headliner.

3. Remove the Original Headliner Board

Factory crew cab headliners are often too large to remove intact.

To remove the original headliner:

  1. Use a razor knife to carefully cut the original board in half side-to-side.
  2. Remove each section from the vehicle separately.

Original factory boards are typically made from pressed fiberboard and are often brittle from age and heat exposure.

Installing the New ABS Headliner

4. Prepare the New Headliner

The replacement ABS headliner is typically shipped folded in half for transportation.

When unpacking:

  • Leave the board folded initially.
  • Carefully insert it through either front door opening.
  • Ensure the rear section of the board is oriented toward the rear of the truck.

Once inside the vehicle:

  1. Position the folded board across the seat backrests.
  2. Remove shipping tape and protective plastic.
  3. Carefully unfold the headliner inside the cab.

ABS plastic is significantly more durable than original fiberboard, but excessive twisting or sharp bending should still be avoided.

5. Prepare Cutouts

Before raising the headliner into final position:

  • Identify all required openings.
  • Cut small “X” openings through the fabric.
  • Fold material behind the board.
  • Secure material using tape or adhesive.

Avoid cutting large openings until final alignment is confirmed.

6. Position the Headliner

Raise the headliner into position carefully.

Align:

  • Visor bracket openings
  • Dome light cutouts
  • Rear accessory openings
  • Trim edges

At this stage, the headliner should rest loosely against the roof structure.

7. Install Front Visor Brackets

Loosely reinstall the front visor brackets on both sides.

These brackets will help support and position the front portion of the headliner.

Do not fully tighten hardware yet.

8. Secure Rear Section

Install the rear push-pin fasteners or factory retainers.

This will secure the rear section of the headliner and help establish final alignment.

9. Reinstall Trim and Components

Reinstall all remaining components, including:

  • Upper trim moldings
  • Dome lights
  • Coat hooks
  • Grab handles
  • Overhead consoles
  • Seat belt trim
  • Electrical accessories

Reconnect all electrical wiring before reinstalling light housings and trim.

Once all components are aligned correctly:

  • Fully tighten visor brackets and trim fasteners.

Installation is now complete.

Helpful Installation Tips

Test Fit Before Tightening

Before fully securing the headliner:

  • Verify all openings align correctly.
  • Check dome light placement.
  • Confirm visor bracket alignment.
  • Ensure trim moldings fit flush.

Warm Temperatures Improve Flexibility

Allowing the headliner to warm to room temperature or warmer can help the material relax and improve installation.

Avoid Over-Trimming

Only enlarge openings when necessary.

Small adjustments are much easier than repairing oversized cuts.

Use Care When Unfolding

Although ABS headliners are designed to flex:

  • Avoid aggressive bending.
  • Do not sharply crease the board.
  • Use two people whenever possible.

Advantages of ABS Crew Cab Headliners

Compared to original factory fiberboard headliners, ABS headliner boards offer:

  • Greater durability
  • Improved resistance to sagging
  • Better moisture resistance
  • Easier handling during installation
  • Longer service life in hot truck interiors

ABS headliners are especially beneficial in crew cab trucks that experience high interior heat and large unsupported roof spans.

Additional Notes

  • Minor adjustments may be required due to vehicle production variations.
  • Reusing original hardware and trim clips is common.
  • Additional trimming may occasionally be needed around aftermarket accessories or previous repairs.

For questions regarding fitment, materials, or installation assistance, contact Factory Interiors customer support at 1-888-269-6287 (MATS).