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Home >> Ford >> 2003 >> Cutaway 7.3 F >> Repair and Diagnosis >> External Pages >> Different car >> Section 2671 (Full Frame & Body Mounting -- F250-F550 Super Duty) >> General Procedures >> Body Retainer Cage Nuts >> Front End Sheet Metal (FESM)

Front End Sheet Metal (FESM)

WARNING: This page is about a different car, the 2011 Ford Pickup, 2011 Ford F550 Super Duty, 2011 Ford F450 Super Duty, and 2011 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.
NOTE: The Front End Sheet Metal (FESM) body cage nut has an additional access point if needed, by removing the radiator. For additional information, refer to ENGINE COOLING - GASOLINE ENGINES , ENGINE COOLING - DIESEL ENGINE or ENGINE COOLING - 6.7L DIESEL POWERTRAIN SECONDARY COOLING .
  1. Remove the headlamp assembly. For additional information, refer to EXTERIOR LIGHTING SYSTEM .
  2. Remove the pushpins and position the splash shield aside, if equipped.
    Fig 1: Locating Splash Shield Pushpins
    G06780883Courtesy of FORD MOTOR CO.
  3. Bend the tabs of the damaged cage nut retainer upward to access the cage nut.
    Fig 2: Locating Tabs Of Damaged Cage Nut Retainer
    G06174307Courtesy of FORD MOTOR CO.
  4. Using a suitable tool, hold the cage nut and remove the FESM  mounting bolt.
    NOTE: Upper is 5.4L, lower is 6.4L and 6.8L.
    • Discard the FESM  bolt.
    Fig 3: Locating FESM Mounting Bolt
    G06780885Courtesy of FORD MOTOR CO.
  5. Install the new cage nut into the location that the damaged nut was removed from.
    NOTE: Do not use a standard nut as a replacement for the nut being removed. Failure to use the correct part number for the nut may result in damage to the vehicle.
    NOTE: If the cage nut is not damaged, it is not necessary to replace it with a new cage nut. The old cage nut may be used if the threads of the nut are not damaged.
    NOTE: Make sure that the surface of the cage nut retainer is flat prior to installing the cage nut.
    NOTE: Remove the new cage nut from the cage and install the cage nut into the pre-existing cage.
  6. Bend the tabs of the cage nut retainer back into position to secure the cage nut.
  7. Install a new FESM  bolt.
    • To install, tighten the new bolt to 103 Nm (76 lb-ft).
  8. Install the splash shield and pushpins.
  9. Install the headlamp assembly. For additional information, refer to EXTERIOR LIGHTING SYSTEM .

    Body Mount No. 1 

    NOTE: The No. 1 body mount has an additional access point if needed, located under the carpet.
  10. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to JACKING & LIFTING .
  11. Remove the tire and wheel. For additional information, refer to TIRES & WHEELS .
  12. Remove the fender splash shield. For additional information, refer to BODY PANEL SYSTEM - FRONT END BODY PANELS .
  13. Bend the tabs of the damaged cage nut retainer upward to access the cage nut.
    Fig 4: Locating Tabs Of Damaged Cage Nut Retainer
    G06174307Courtesy of FORD MOTOR CO.
  14. Using a suitable tool, hold the cage nut and remove the body mounting bolt.
    • Discard the bolt.
    Fig 5: Locating Body Mounting Bolt
    G06780887Courtesy of FORD MOTOR CO.
  15. Install the new cage nut into the location that the damaged nut was removed from.
    NOTE: Do not use a standard nut as a replacement for the nut being removed. Failure to use the correct part number for the nut may result in damage to the vehicle.
    NOTE: If the cage nut is not damaged, it is not necessary to replace it with a new cage nut. The old cage nut may be used if the threads of the nut are not damaged.
    NOTE: Make sure that the surface of the cage nut retainer is flat prior to installing the cage nut.
    NOTE: Remove the new cage nut from the cage and install the cage nut into the pre-existing cage.
  16. Bend the tabs of the cage nut retainer back into position to secure the cage nut.
  17. Install a new body bolt.
    • To install, tighten the new bolt to 103 Nm (76 lb-ft).
  18. Install the fender splash shield. For additional information, refer to BODY PANEL SYSTEM - FRONT END BODY PANELS .
  19. Install the tire and wheel. For additional information, refer to TIRES & WHEELS .

    Body Mount No. 2 (Crew Cab Only) 

  20. Remove the rear seat. For additional information, refer to SEAT SYSTEM .
  21. Position the carpet aside to gain access to the plug.
  22. Bend the tabs of the damaged cage nut retainer upward to access the cage nut.
    Fig 6: Locating Tabs Of Damaged Cage Nut Retainer
    G06174307Courtesy of FORD MOTOR CO.
  23. Using a suitable tool, hold the cage nut and remove the body mounting bolt.
    • Discard the bolt.
    Fig 7: Locating Body Mounting Bolt
    G06780889Courtesy of FORD MOTOR CO.
  24. Install the new cage nut into the location that the damaged nut was removed from.
    NOTE: Do not use a standard nut as a replacement for the nut being removed. Failure to use the correct part number for the nut may result in damage to the vehicle.
    NOTE: If the cage nut is not damaged, it is not necessary to replace it with a new cage nut. The old cage nut may be used if the threads of the nut are not damaged.
    NOTE: Make sure that the surface of the cage nut retainer is flat prior to installing the cage nut.
    NOTE: Remove the new cage nut from the cage and install the cage nut into the pre-existing cage.
  25. Bend the tabs of the cage nut retainer back into position to secure the cage nut.
  26. Install a new body bolt.
    • To install, tighten the new bolt to 103 Nm (76 lb-ft).

    Body Mount No. 3 

  27. Remove the rear seat, if equipped. For additional information, refer to SEAT SYSTEM .
  28. Position the carpet aside to gain access to the plug.
    Fig 8: Locating Carpet Plug
    G06780890Courtesy of FORD MOTOR CO.
  29. Using a suitable socket trace a 50 mm (1.968 in) outline around the access hole.
    Fig 9: Locating Access Hole With Tracing Socket
    G06780891Courtesy of FORD MOTOR CO.
  30. Using a suitable tool, grind the access hole to 50 mm (1.968 in).
    NOTE: The finished access hole must not be larger than 50 mm (1.968 in) or the service plug (7C3Z-2500155-B) will not fit properly.
    Fig 10: Locating Access Hole
    G06780892Courtesy of FORD MOTOR CO.
  31. Bend the tabs of the damaged cage nut retainer upward to access the cage nut.
    Fig 11: Locating Tabs Of Damaged Cage Nut Retainer
    G06174307Courtesy of FORD MOTOR CO.
  32. Using a suitable tool, hold the cage nut and remove the body mounting bolt.
    • Discard the bolt.
  33. Install the new cage nut into the location that the damaged nut was removed from.
    NOTE: Do not use a standard nut as a replacement for the nut being removed. Failure to use the correct part number for the nut may result in damage to the vehicle.
    NOTE: If the cage nut is not damaged, it is not necessary to replace it with a new cage nut. The old cage nut may be used if the threads of the nut are not damaged.
    NOTE: Make sure that the surface of the cage nut retainer is flat prior to installing the cage nut.
    NOTE: Remove the new cage nut from the cage and install the cage nut into the pre-existing cage.
  34. Bend the tabs of the cage nut retainer back into position to secure the cage nut.
  35. Install a new body bolt.
    • To install, tighten the new bolt to 103 Nm (76 lb-ft).
  36. Install the new service plug (7C3Z-2500155-B).
  37. Install the rear seat, if equipped. For additional information, refer to SEAT SYSTEM .
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