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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) >> Removal And Installation >> Body - Diesel >> Removal and Installation

Removal and Installation

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.

All vehicles 

NOTE: Use a 2-post hoist to lift the body from the chassis.
  1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to JACKING & LIFTING .
  2. Drain the engine coolant and secondary cooling system. For additional information, refer to ENGINE COOLING - DIESEL ENGINE and ENGINE COOLING - 6.7L DIESEL POWERTRAIN SECONDARY COOLING .
  3. Disconnect the battery cables from the LH and RH batteries. For additional information, refer to BATTERY, BATTERY MOUNTING SYSTEM & BATTERY CABLES .
  4. Separate the leads from the RH battery positive cable.
    • To install, tighten to 9 Nm (80 lb-in).
  5. Separate the leads from the RH battery negative cable.
    • To install, tighten to 9 Nm (80 lb-in).
  6. Remove the LH and RH batteries. For additional information, refer to BATTERY, BATTERY MOUNTING SYSTEM & BATTERY CABLES
  7. Disconnect the hose from the degas bottle.
    Fig 1: Locating Degas Bottle Hose
    G07486576Courtesy of FORD MOTOR CO.
  8. Detach the 2 pin-type retainers and position the LH battery cables aside.
    Fig 2: Locating Pin-Type Retainers
    G07486577Courtesy of FORD MOTOR CO.

    Four-Wheel Drive (4WD) vehicles 

  9. Lift up on the transfer case shift lever boot to access the shift lever bolt.
    Fig 3: Locating Transfer Case Shift Lever Boot
    G07486578Courtesy of FORD MOTOR CO.
  10. Remove the bolt and the shift lever.
    • To install, tighten to 27 Nm (20 lb-ft).
    Fig 4: Locating Shift Lever Bolt
    G07486579Courtesy of FORD MOTOR CO.
  11. Remove the 2 screws and the transfer case shift lever bezel.
    Fig 5: Locating Transfer Case Shift Lever Bezel Screws
    G07486580Courtesy of FORD MOTOR CO.

    All vehicles 

  12. Disengage the retaining clip and disconnect the upper radiator hose from the radiator.
  13. Position the LH battery tray aside.
    • Remove the 6 bolts.
    • Disconnect the vacuum hoses.
    • To install, tighten to 25 Nm (18 lb-ft).
    Fig 6: Locating LH Battery Tray With Bolts
    G07486581Courtesy of FORD MOTOR CO.
  14. Disengage the retaining clip, then disconnect the fill hose from the degas bottle and remove the LH battery tray.
  15. Disconnect the Mass Air Flow (MAF) sensor electrical connector and detach the harness from the Air Cleaner (ACL) housing.
  16. Loosen the clamp on the ACL  pipe.
  17. Remove the ACL  housing.
  18. Disengage the 3 pin-type retainers (2 shown) from the RH battery tray and position the wiring harness aside.
    Fig 7: Locating Pin-Type Retainers Of RH Battery Tray
    G07486582Courtesy of FORD MOTOR CO.
  19. Disengage the pin-type retainer from the RH battery tray and position the battery cables aside.
    Fig 8: Locating Pin-Type Retainer Of RH Battery Tray
    G07486583Courtesy of FORD MOTOR CO.
  20. Detach the battery buss assembly from the RH battery tray and position the buss assembly aside.
    Fig 9: Locating Battery Buss Assembly Of RH Battery Tray
    G07486584Courtesy of FORD MOTOR CO.
  21. Disconnect the RH battery positive cable from the battery buss.
    Fig 10: Locating RH Battery Positive Cable
    G07486585Courtesy of FORD MOTOR CO.
  22. Disengage the 5 pin-type retainers from the RH battery tray and disconnect.
    Fig 11: Locating Pin-Type Retainers Of RH Battery Tray
    G07486586Courtesy of FORD MOTOR CO.
  23. Disconnect the RH hood strut at the lower end and position the hood strut aside.
    Fig 12: Locating RH Hood Strut
    G07486587Courtesy of FORD MOTOR CO.
  24. Remove the 4 RH battery tray bolts.
    • To install, tighten to 18 Nm (159 lb-in).
    Fig 13: Locating RH Battery Tray Bolts
    G07486588Courtesy of FORD MOTOR CO.
  25. Remove the RH battery tray bolt.
    • To install, tighten to 18 Nm (159 lb-in).
    Fig 14: Locating RH Battery Tray Bolt
    G07486589Courtesy of FORD MOTOR CO.
  26. Position the RH battery tray aside.
  27. Disconnect the washer pump electrical connector.
    Fig 15: Locating Washer Pump Electrical Connector
    G07486590Courtesy of FORD MOTOR CO.
  28. Disconnect the 3 glow plug relay electrical connectors located on the bottom of the RH battery tray.
    Fig 16: Locating Glow Plug Relay Electrical Connectors
    G07486591Courtesy of FORD MOTOR CO.
  29. Disconnect the washer pump hose.
    Fig 17: Locating Washer Pump Hose
    G07486592Courtesy of FORD MOTOR CO.
  30. Remove the RH battery tray.
  31. Connect the RH hood strut.
  32. Recover the A/C system refrigerant. For additional information, refer to HVAC - CLIMATE CONTROL SYSTEM - GENERAL INFORMATION & DIAGNOSTICS .
  33. Disconnect the A/C compressor-to-condenser discharge line at the condenser and position the line aside.
    • Discard the O-rings and cap off the fittings.
    • To install, tighten to 15 Nm (133 lb-in).
    Fig 18: Locating A/C Compressor-To-Condenser Discharge Line Fitting
    G07486593Courtesy of FORD MOTOR CO.
  34. Disconnect the 2 EGR  cooler lines from cooler.
  35. Disconnect the 2 PCM electrical connectors.
    Fig 19: Locating PCM Electrical Connectors
    G07486594Courtesy of FORD MOTOR CO.
  36. Disconnect the electrical connector.
    Fig 20: Locating Electrical Connector
    G07486595Courtesy of FORD MOTOR CO.
  37. Disconnect the heater core hose to engine.
    Fig 21: Locating Heater Core Hose
    G07486596Courtesy of FORD MOTOR CO.
  38. Disconnect the turbocharger air inlet hose and the Charge Air Cooler (CAC) outlet hose at the T-fitting.
    Fig 22: Locating Turbocharger Air Inlet Hose And Charge Air Cooler (CAC) Outlet Hose
    G07486597Courtesy of FORD MOTOR CO.
  39. Disconnect the Charge Air Cooler Temperature (CACT) sensor electrical connector.
    Fig 23: Locating Charge Air Cooler Temperature (CACT) Sensor Electrical Connector
    G07486598Courtesy of FORD MOTOR CO.
  40. Disconnect the CAC  coolant inlet and outlet hoses.
    Fig 24: Locating CAC Coolant Inlet And Outlet Hoses
    G07486599Courtesy of FORD MOTOR CO.
  41. Remove the CAC  .
  42. Using a suitable suction device, remove the power steering fluid from the power steering reservoir.
  43. Disconnect the 3 hoses from the power steering fluid reservoir.
    Fig 25: Locating Power Steering Fluid Reservoir Hoses
    G07486600Courtesy of FORD MOTOR CO.
  44. Remove the bolt and the power steering fluid reservoir.
    • To install, tighten to 7 Nm (62 lb-in).
    Fig 26: Locating Power Steering Fluid Reservoir Bolt
    G07486601Courtesy of FORD MOTOR CO.
  45. If equipped, disconnect the 2 brake Hydro-Boost power steering fluid lines.
    • Discard the O-rings.
    • To install, tighten to 62 Nm (46 lb-ft).
    Fig 27: Locating Brake Hydro-Boost Power Steering Fluid Lines
    G07486602Courtesy of FORD MOTOR CO.
  46. Disconnect the brake fluid level switch electrical connector.
    Fig 28: Locating Brake Fluid Level Switch Electrical Connector
    G07486603Courtesy of FORD MOTOR CO.
  47. Remove and discard the 2 brake master cylinder nuts (1 shown) and then position the brake master cylinder aside.
    NOTE: The brake master cylinder nuts are a torque-prevailing type and cannot be reused.
    • To install:
      • For vacuum boost equipped vehicles, tighten the new nuts to 23 Nm (17 lb-ft).
      • For Hydro-Boost® equipped vehicles, tighten the new nuts to 30 Nm (22 lb-ft).
    Fig 29: Locating Brake Master Cylinder Nut
    G07486604Courtesy of FORD MOTOR CO.
  48. Disconnect the degas bottle hose from the radiator outlet, then detach the hose from the top of the radiator.
    Fig 30: Locating Degas Bottle Hose Of Radiator Outlet
    G07486605Courtesy of FORD MOTOR CO.
  49. Disconnect the degas bottle-to-coolant pump hose and coolant pump-to-radiator hose from the coolant pump, for additional information refer to Coolant Pump in ENGINE COOLING - 6.7L DIESEL POWERTRAIN SECONDARY COOLING .
  50. Remove the 2 bolts from the degas bottle.
    • To install, tighten to 7 Nm (62 lb-in).
    Fig 31: Locating Degas Bottle Bolts
    G07486606Courtesy of FORD MOTOR CO.
  51. Disconnect the 2 hoses from the bottom of the degas bottle and remove the degas bottle.
    Fig 32: Locating Degas Bottle Hoses
    G07486607Courtesy of FORD MOTOR CO.
  52. Detach the EGR  cooler hose and the wiring harness from the RH side of the upper fan shroud.
    Fig 33: Locating EGR Cooler Hose And Wiring Harness
    G07486608Courtesy of FORD MOTOR CO.
  53. Remove the upper fan shroud. For additional information, refer to the Radiator and Cooling Fan Exploded View in ENGINE COOLING - DIESEL ENGINE .
  54. Disconnect the fuel cooler hose from T-fitting at CAC  .
  55. Remove the radiator grille. For additional information, refer to EXTERIOR TRIM & ORNAMENTATION .
  56. Remove the nut and disconnect the A/C evaporator-to-compressor suction line fitting.
    • Discard the O-rings and cap off the fittings.
    • To install, tighten to 15 Nm (133 lb-in).
    Fig 34: Locating A/C Evaporator-To-Compressor Suction Line Fitting Nut
    G07486609Courtesy of FORD MOTOR CO.
  57. Remove and discard the intermediate shaft bolt, then disconnect the lower steering column shaft from the upper steering column shaft.
    NOTE: Do not allow the steering column shaft to rotate while the intermediate shaft is disconnected or damage to the clockspring can result. If there is evidence that the shaft has rotated, remove and recenter the clockspring. For additional information, refer to SUPPLEMENTAL RESTRAINT SYSTEM .
    • To install, tighten the new bolt to 48 Nm (35 lb-ft).
    Fig 35: Locating Intermediate Shaft Bolt
    G06780931Courtesy of FORD MOTOR CO.
  58. Remove the bolt and position the RH engine ground strap aside.
    • To install, tighten to 10 Nm (89 lb-in).
    Fig 36: Locating RH Engine Ground Strap Bolt
    G07486611Courtesy of FORD MOTOR CO.
  59. Remove the 4 deflector pushpins from the lower radiator.
  60. Disconnect the lower power steering cooler hose and remove from hose retainer.
    Fig 37: Locating Lower Power Steering Cooler Hose Retainer
    G07486612Courtesy of FORD MOTOR CO.
  61. Detach the radiator hose from the lower radiator support.
    Fig 38: Locating Radiator Hose Of Lower Radiator Support
    G07486613Courtesy of FORD MOTOR CO.
  62. Position a suitable drain pan under the radiator hose and release the radiator hose coupling locking clip.
    Fig 39: Locating Radiator Hose Coupling Locking Clip
    G07486614Courtesy of FORD MOTOR CO.
  63. Disconnect the radiator hose coupling and allow the coolant to drain.
    Fig 40: Locating Radiator Hose Coupling
    G07486615Courtesy of FORD MOTOR CO.
  64. Disconnect the hose from the transmission cooler.
    Fig 41: Locating Transmission Cooler Hose
    G07486616Courtesy of FORD MOTOR CO.
  65. Remove the bolt and position the body ground strap aside.
    • To install, tighten to 25 Nm (18 lb-ft).
    Fig 42: Locating Body Ground Strap Bolt
    G07486617Courtesy of FORD MOTOR CO.
  66. Separate the parking brake cable at the cable union.
    Fig 43: Locating Parking Brake Cable
    G07486618Courtesy of FORD MOTOR CO.
  67. Release the parking brake cable retainer and route the front parking brake cable out of the frame.
    Fig 44: Locating Parking Brake Cable Retainer
    G07486619Courtesy of FORD MOTOR CO.
  68. Disconnect the transmission selector linkage.
    Fig 45: Locating Transmission Selector Linkage
    G07486620Courtesy of FORD MOTOR CO.
  69. Remove the transmission selector linkage locking clip and position the linkage aside.
    Fig 46: Locating Transmission Selector Linkage Locking Clip
    G07486621Courtesy of FORD MOTOR CO.
  70. Remove and discard the 2 Front End Sheet Metal (FESM) body mount bolts, then remove the body mount lower insulators.
    NOTE: LH shown in illustration, RH similar.
    • To install, tighten to 103 Nm (76 lb-ft).
    Fig 47: Locating Front End Sheet Metal (FESM) Body Mount Bolt
    G07486622Courtesy of FORD MOTOR CO.
  71. Remove and discard the 2 No. 1 body mount bolts, then remove the No. 1 body mount lower insulators.
    NOTE: LH shown in illustration, RH similar.
    • To install, tighten to 103 Nm (76 lb-ft).
    Fig 48: Locating No. 1 Body Mount Bolt
    G07486623Courtesy of FORD MOTOR CO.
  72. If equipped, remove and discard the 2 No. 2 body mount bolts, then remove the No. 2 body mount lower insulators.
    NOTE: LH shown in illustration, RH similar.
    • To install, tighten to 103 Nm (76 lb-ft).
    Fig 49: Locating No. 2 Body Mount Bolt
    G07486624Courtesy of FORD MOTOR CO.
  73. Remove and discard the 2 No. 3 body mount bolts, then remove the No. 3 body mount lower insulators.
    NOTE: LH shown in illustration, RH similar.
    • To install, tighten to 103 Nm (76 lb-ft).
    Fig 50: Locating No. 3 Body Mount Bolt
    G07486625Courtesy of FORD MOTOR CO.
  74. Place several fender covers between the cab and the pickup bed.
  75. Mark the position of the tires on the floor.
    NOTE: Mark the position of the tires to aid in aligning the cab to the chassis.
  76. Position equally side-to-side the hoist lift pads below the pinch welds at the furthest most possible front and rear positions.
    NOTE: Use 2-post hoist to lift the body from the chassis.
  77. Using the Universal Cab Hold-Down Strap, secure the vehicle to the hoist.
    WARNING: Securely strap the cab to the lift using an appropriate tool. If the cab is not correctly secured, it could shift or fall. Failure to follow this instruction may result in serious personal injury.
    Fig 51: Securing Vehicle To Hoist Using Universal Cab Hold-Down Strap
    G06780946Courtesy of FORD MOTOR CO.
  78. With the aid of an assistant, lift the body from the chassis.
    NOTE: Use an assistant to make sure all connections are disconnected and nothing interferes with the raising of the body while it is lifted.
  79. To install, reverse the removal procedure.
    • Align the tires to the marks on the floor.
    • Top off the fluids.
    • Install new body mount bolts.
    • Connect all disconnected electrical connectors.
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