Removal and Installation

WARNING: This page is about a different car, the 2004 Ford Pickup, 2004 Ford F550 Super Duty, 2004 Ford F450 Super Duty, 2004 Ford Excursion, and 2004 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.

Vehicles with automatic transmission

Remove the transmission fluid level indicator.

Fig 1: Removing Transmission Fluid Level Indicator
Courtesy of FORD MOTOR CO.
Remove the nut.

Fig 2: Removing Nut
Courtesy of FORD MOTOR CO.

All vehicles
Loosen the clamp and disconnect the downpipe from the turbocharger.

Fig 3: Disconnecting Downpipe From Turbocharger
Courtesy of FORD MOTOR CO.
Remove the nuts and the RH intake heat shield.

Fig 4: Removing Nuts And RH Intake Heat Shield
Courtesy of FORD MOTOR CO.
With the vehicle in NEUTRAL, position on a hoist. Refer to JACKING & LIFTING .
Disconnect the wire loom from the crossmember.

Fig 5: Disconnecting Wire Loom From Crossmember
Courtesy of FORD MOTOR CO.
Using a suitable high-lift transmission jack, support the transmission.
Remove the nuts.

Fig 6: Removing Nuts
Courtesy of FORD MOTOR CO.
Remove the nuts, bolts and the RH crossmember bracket.

Fig 7: Removing Nuts, Bolts And RH Crossmember Bracket
Courtesy of FORD MOTOR CO.
Remove the RH crossmember nuts and bolts.

Fig 8: Removing RH Crossmember Nuts And Bolts
Courtesy of FORD MOTOR CO.
Remove the LH crossmember bolts.
- Remove the crossmember.
  
  Fig 9: Removing LH Crossmember
  Courtesy of FORD MOTOR CO.
  
  Vehicles with automatic transmission
Separate the transmission fluid filler tube and position aside.

Fig 10: Separating Transmission Fluid Filler Tube
Courtesy of FORD MOTOR CO.

4x4 vehicles
Remove the nut, washer and bolt.

Fig 11: Removing Nut, Washer And Bolt (1 Of 2)
Courtesy of FORD MOTOR CO.
Remove the nut, washer, bolt and the right front stabilizer bar link.

Fig 12: Removing Nut, Washer And Bolt (2 Of 2)
Courtesy of FORD MOTOR CO.

All vehicles

NOTE: Lower the transmission jack approximately 25 mm (1 in) to ease the removal of the downpipe.

Fig 13: Removing Downpipe

Courtesy of FORD MOTOR CO.

Remove the nuts, bolts and the downpipe.
To install, reverse the removal procedure.