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Home >> Ford >> 2004 >> Excursion 6.8 S, RWD >> Repair and Diagnosis (Single Page) >> Engine Mechanical >> Mechanical >> Engine - 6.8L - Excursion & F250-F550 Super Duty >> In-Vehicle Repair >> Oil Pan - Manual Transmission >> Installation

Oil Pan - Manual Transmission: Installation

    NOTE: The oil pump screen and pickup tube must be in the oil pan when the oil pan is positioned in the vehicle.
    NOTE: To install the oil pan, position the oil pan to the left rear side of the engine and rotate slightly while sliding the front of the pan toward the right side of the engine.
    Fig 1: Installing Oil Pan Gasket And Oil Pan
    G02771431Courtesy of FORD MOTOR CO.
  1. Position the oil pan gasket and the oil pan in the vehicle from the rear of the engine.
    2. CAUTION: Make sure the O-ring is in place and not damaged. A missing or damaged O-ring can cause foam in the lubrication system, low oil pressure and severe engine damage.
    NOTE: Clean and inspect the mating surfaces and install a new O-ring. Lubricate with clean engine oil.
  2. Install the oil pump screen and pickup tube.
    1. Install and tighten the spacer.
    2. Position the oil pump screen and pickup tube on the engine.
    3. Install the bolts.
      Fig 2: Installing Oil Pump Screen And Pickup Tube
      G02771432Courtesy of FORD MOTOR CO.
    3. NOTE: If not secure within four minutes, the sealant must be removed and the sealing area cleaned. To clean the sealing area, follow the directions provided on the packaging of the silicone gasket remover and the metal surface prep. Failure to follow this procedure can cause future oil leakage.
    Fig 3: Identifying Location For Applying Silicone Gasket And Sealant
    G02771433Courtesy of FORD MOTOR CO.
  3. Apply a bead of silicone gasket and sealant at the crankshaft rear seal retainer-to-cylinder block surface, at the locations shown.
    4. NOTE: If not secure within four minutes, the sealant must be removed and the sealing area cleaned. To clean the sealing area, follow the directions provided on the packaging of the silicone gasket remover and the metal surface prep. Failure to follow this procedure can cause future oil leakage.
    Fig 4: Applying Silicone Gasket And Sealant At Engine Front Cover-To-Cylinder Block Surface
    G02771434Courtesy of FORD MOTOR CO.
  4. Apply a bead of silicone gasket and sealant at the engine front cover-to-cylinder block surface, at the locations shown.
    5. NOTE: Be sure to tighten the bolts in two stages.
  5. Tighten the bolts in the sequence shown.
    • Stage 1: Tighten to 20 Nm (15 lb-ft).
    • Stage 2: Tighten an additional 60 degrees.
      Fig 5: Identifying Tightening Sequence Of Oil Pan Bolts (Manual Transmission)
      G02771435Courtesy of FORD MOTOR CO.
  6. Position the RH engine mount on the engine and install the bolts.
    • Tighten the bolts to 80 Nm (59 lb-ft).
  7. Using the special tool, lower the engine and remove the special tool.
    Fig 6: Lowering Engine
    G02771436Courtesy of FORD MOTOR CO.
  8. Install the starter motor. Refer to STARTERS .
  9. Position the oil cooler and install the threaded insert.
    Fig 7: Identifying Tightening Torque Of Oil Cooler Threaded Insert
    G02771437Courtesy of FORD MOTOR CO.
  10. Install a new oil filter.
    Fig 8: Identifying Tightening Torque Of Oil Filter
    G02771438Courtesy of FORD MOTOR CO.
    11. NOTE: Make sure that both the engine and transmission mounts are correctly seated before installing the mounting nuts.
    Fig 9: Identifying Tightening Torque Of Engine Mount Nuts
    G02771439Courtesy of FORD MOTOR CO.
  11. Install the engine mount nuts.
  12. Install the transmission mount nuts.
    Fig 10: Identifying Tightening Torque Of Transmission Mount Nuts
    G02771440Courtesy of FORD MOTOR CO.
  13. Position the wire harness and install the bracket and nut on the engine front cover stud.
    Fig 11: Identifying Tightening Torque Of Engine Front Cover Stud
    G02771441Courtesy of FORD MOTOR CO.
  14. Install the ground strap to the engine.
    Fig 12: Identifying Tightening Torque Of Ground Strap
    G02771442Courtesy of FORD MOTOR CO.
  15. Position the exhaust Y-pipe and install the nuts on the exhaust manifold studs.
    Fig 13: Identifying Tightening Torque Of Exhaust Manifold Studs
    G02771443Courtesy of FORD MOTOR CO.
  16. Install the exhaust Y-pipe flange nuts.
    Fig 14: Installing Exhaust Y-Pipe Flange Nuts
    G02771444Courtesy of FORD MOTOR CO.
  17. Connect the heated oxygen sensor electrical connectors.
    Fig 15: Connecting Heated Oxygen Sensor Electrical Connectors
    G02771445Courtesy of FORD MOTOR CO.
  18. Remove the special tool.
    Fig 16: Removing Special Tool From Engine
    G02771446Courtesy of FORD MOTOR CO.
  19. Using the special tools, install the cooling fan and the fan clutch to the coolant pump pulley.
    Fig 17: Installing Cooling Fan And Fan Clutch To Coolant Pump Pulley
    G02771447Courtesy of FORD MOTOR CO.
  20. Install the generator. Refer to GENERATORS & REGULATORS .
  21. Install the accelerator cable bracket.
    • Position the accelerator cable through the bulkhead.
    • Install the bolts.
      Fig 18: Installing Accelerator Cable Bracket Bolt
      G02771448Courtesy of FORD MOTOR CO.
  22. Connect the accelerator cable routing clip to the dash panel stud.
    Fig 19: Connecting Accelerator Cable Routing Clip To Dash Panel Stud
    G02771449Courtesy of FORD MOTOR CO.
  23. Connect the accelerator cable to the accelerator pedal and shaft.
    Fig 20: Connecting Accelerator Cable To Accelerator Pedal And Shaft
    G02771450Courtesy of FORD MOTOR CO.
    24. NOTE: The idle air control valve (IAC) is shown removed for clarity.
  24. Position back the throttle body adapter.
    • Position a new throttle body adapter gasket.
    • Position the throttle body adapter.
    • Install four bolts and tighten in two stages.
      • Stage 1: Tighten to 9 Nm (80 lb-in).
      • Stage 2: Tighten an additional 90 degrees.
        Fig 21: Installing Throttle Body Adapter
        G02771451Courtesy of FORD MOTOR CO.
  25. Connect the TP sensor electrical connector.
    Fig 22: Connecting TP Sensor Electrical Connector
    G02771452Courtesy of FORD MOTOR CO.
  26. Connect the IAC motor bypass hose and connector.
    • Install the routing clip for the IAC hose.
      Fig 23: Connecting IAC Motor Bypass Hose And Connector
      G02771453Courtesy of FORD MOTOR CO.
  27. Connect the vacuum hose.
    Fig 24: Connecting Vacuum Hose
    G02771454Courtesy of FORD MOTOR CO.
  28. Connect the PCV tube and the vacuum hoses.
    Fig 25: Connecting PCV Tube And Vacuum Hoses
    G02771455Courtesy of FORD MOTOR CO.
  29. Position the accelerator bracket.
    • Position the bracket.
    • Install the bolts.
      Fig 26: Identifying Tightening Torque Of Accelerator Bracket
      G02771456Courtesy of FORD MOTOR CO.
  30. Connect the accelerator and speed control cables and return spring.
    Fig 27: Connecting Accelerator And Speed Control Cables And Return Spring
    G02771457Courtesy of FORD MOTOR CO.
  31. Install the accelerator cable splash shield.
    Fig 28: Installing Accelerator Cable Splash Shield
    G02771458Courtesy of FORD MOTOR CO.
  32. Install the air cleaner outlet tube. Refer to INTAKE AIR DISTRIBUTION & FILTERING .
    33. CAUTION: The oil pump must be primed prior to starting the engine.
  33. Fill the engine with clean engine oil.
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