Removal and Installation

WARNING: This page is about a different car, the 2004 Ford RV Cutaway, 2004 Ford Econoline, 2004 Ford E450 Super Duty, and 2004 Ford Cutaway. However, it is still accessible from the selected car via links, so may be relevant.

Drain the cooling system. For additional information, refer to COOLING SYSTEM DRAINING, FILLING AND BLEEDING .
Remove the push pin retainers and upper air deflector.

Fig 1: Removing Push Pin Retainers & Upper Air Deflector (6.0L Diesel)
Courtesy of FORD MOTOR CO.
Remove the bolts for the power steering reservoir bracket.

Fig 2: Removing Power Steering Reservoir Bracket Bolts (6.0L Diesel)
Courtesy of FORD MOTOR CO.
Remove the bolts and power steering fluid indicator. Remove the power steering reservoir mounting bracket. Install the power steering fluid indicator and position aside.

Fig 3: Removing Power Steering Reservoir Mounting Bracket (6.0L Diesel)
Courtesy of FORD MOTOR CO.
Disconnect the coolant hoses from the air cleaner outlet tube.

Fig 4: Disconnecting Coolant Hoses From Air Cleaner Outlet Tube (6.0L Diesel)
Courtesy of FORD MOTOR CO.

NOTE: Air cleaner side shown, other side similar.

Fig 5: Removing Air Cleaner Outlet Tube (6.0L Diesel)

Courtesy of FORD MOTOR CO.

Loosen the clamps and remove the air cleaner outlet tube.

NOTE: If there is any oil residue, clean both connecting ports and the inside surface of the charge air cooler pipe to prevent the pipe from blowing off.

Fig 6: Identifying Loosening Torque Of Charge Air Pipe Clamp Bolt (6.0L Diesel)

Courtesy of FORD MOTOR CO.

Loosen the clamps and remove the charge air pipe.
Disconnect and position the upper radiator hose aside.

Fig 7: Disconnecting Upper Radiator Hose (6.0L Diesel)
Courtesy of FORD MOTOR CO.
Remove the retaining nut and position the fuel line retainer aside.

Fig 8: Removing Fuel Line Retainer Nut (6.0L Diesel)
Courtesy of FORD MOTOR CO.
Remove the stud bolts and thermostat assembly.
- Remove and discard the O-ring seal.
Fig 9: Loosening Torque Of Thermostat Assembly Stud Bolts (6.0L Diesel)
Courtesy of FORD MOTOR CO.
To install, reverse the removal procedure.
- Install a new O-ring seal on the thermostat assembly.