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Home >> Ford >> 2004 >> Explorer 4.6 W, AWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 1745 (Engine - 6.0L Diesel -- F250-F550 Super Duty 6.0L (99P F450/550)) >> In-Vehicle Servicing >> Engine Rear Cover >> Removal >> All vehicles

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WARNING: This page is about a different car, the 2007 Ford Pickup, 2007 Ford F550 Super Duty, 2007 Ford F450 Super Duty, and 2007 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.
  1. Remove the starter. For additional information, refer to STARTING SYSTEM - DIESEL ENGINE article.
  2. Remove the transmission. For additional information, refer to AUTOMATIC TRANSAXLE/TRANSMISSION - TORQSHIFT article for automatic transmission or MANUAL TRANSAXLE/TRANSMISSION - ZF 6-SPEED article for manual transmission.


Fig 1: Identifying Flexplate/Flywheel Bolts
G03887287Courtesy of FORD MOTOR CO.
  1. Remove the bolts and the flexplate or flywheel.
    • Discard the bolts.
    2. Fig 2: Identifying Flywheel Adapter
    G03887288Courtesy of FORD MOTOR CO.
    NOTE: Use extreme care when removing the flywheel front adapter to prevent damage to the alignment dowel pin.
  2. Remove the flywheel front adapter.
    3. Fig 3: View Of Holes On RH and LH Side of Seal
    G03887289Courtesy of FORD MOTOR CO.
    CAUTION: To prevent engine damage, do not remove the rear primary crankshaft flange bolts under any circumstances. If the flange is removed and reinstalled, it will result in engine vibration and premature transmission component wear.
    NOTE: The drill bit used must be the appropriate size for the body dent puller used in the following step.
  3. Using the appropriate drill bit, drill a hole on the RH side of the seal and another directly across from it on the LH side of the seal, as shown.
    4. Fig 4: Removing Crankshaft Rear Oil Seal
    GF0005722Courtesy of FORD MOTOR CO.
    NOTE: It will be necessary to alternate between the 2 holes, drilled in the previous step, to walk the seal out of the engine rear cover.
  4. Using the special tool and a commercially available body dent puller attachment, remove and discard the rear main seal.
    5. Fig 5: Removing Crankshaft Rear Seal Wear Sleeve
    GF0005723Courtesy of FORD MOTOR CO.
    NOTE: Production engines will not have a wear sleeve.
  5. If equipped with a crankshaft wear sleeve, use the special tool to remove and discard the crankshaft rear wear sleeve.
    6. Fig 6: Identifying Crankshaft Sealing Surface
    G03887292Courtesy of FORD MOTOR CO.
  6. Clean and inspect the crankshaft sealing surface.
    7. Fig 7: Locating Harness Retainer Nut And Ground Wire Nut
    G03906757Courtesy of FORD MOTOR CO.
  7. Remove the nuts from the heat shield bracket and disconnect the ground wire from the stud.
    8. Fig 8: Locating Wiring Retainer
    G03906758Courtesy of FORD MOTOR CO.
  8. Disconnect the wiring retainer from the heat shield bracket.
    9. Fig 9: Locating Heat Shield Bracket Bolts
    G03906759Courtesy of FORD MOTOR CO.
  9. Remove the bolts and heat shield bracket.
    10. Fig 10: Locating Turbocharger Heat Shield Bolts
    G03907003Courtesy of FORD MOTOR CO.
  10. Remove the 3 bolts and the turbocharger heat shield.
    11. Fig 11: Locating Rear Engine Cover Bolts
    G03887334Courtesy of FORD MOTOR CO.
    CAUTION: To prevent engine damage, replace damaged or missing dowel pins before installing the engine rear cover.
  11. Remove the 8 bolts from the engine rear cover.
    12. Fig 12: Cutting Sealant At Oil Pump Cover Joint
    GF0005724Courtesy of FORD MOTOR CO.
    NOTE: Use care when removing the engine rear cover so that the oil pump cover gasket is not pulled out on removal.
  12. Using a thin-blade scraper, cut the sealant at the oil pump cover joint.
    13. Fig 13: Cutting Sealant At Crankcase And Lower Crankcase Seam
    GF0005725Courtesy of FORD MOTOR CO.
    CAUTION: Sealant is used where the crankcase and the lower crankcase meet. Failure to cut the sealant could result in pulling the lower crankcase seal out while removing the rear cover.
    NOTE: A 139.7 mm (5.5 in) long thin-blade scraper will be needed to correctly cut the sealant.
  13. Use a thin-blade scraper to cut the sealant where the crankcase and the lower crankcase meet.
    14. Fig 14: Cutting Sealant At Crankcase And Lower Crankcase Seam
    GF0005726Courtesy of FORD MOTOR CO.
    CAUTION: Sealant is used where the crankcase and the lower crankcase meet. Failure to cut the sealant could result in pulling the lower crankcase seal out while removing the rear cover.
    NOTE: A 139.7 mm (5.5 in) long thin-blade scraper will be needed to correctly cut the sealant.
  14. Use a thin-blade scraper to cut the sealant where the crankcase and the lower crankcase meet. Remove the rear cover.
    • Remove and discard the press-in-place gasket.
    • Clean and inspect the sealing surfaces.
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