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Section 59 (Engine - 6.8L (3V) -- F250-F550 Super Duty): Removal: Engine: Removal

WARNING: This page is about a different car, the 2005 Ford Pickup, 2005 Ford F550 Super Duty, 2005 Ford F450 Super Duty, and 2005 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.

    All vehicles 

  1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to JACKING AND LIFTING .
  2. Remove the hood.
  3. Remove the intake manifold. For additional information, refer to INTAKE MANIFOLD .
  4. Remove the radiator grille support. For additional information, refer to FRONT END BODY PANELS .
  5. Remove the A/C condenser core. For additional information, refer to AIR CONDITIONING .
  6. Remove the cowl vent grille. For additional information, refer to FRONT END BODY PANELS .
  7. Remove the radiator, fan shroud and engine cooling fan. For additional information, refer to ENGINE COOLING .
  8. Remove the degas bottle. For additional information, refer to ENGINE COOLING .
  9. Remove the powertrain control module (PCM). For additional information, refer to ELECTRONIC ENGINE CONTROLS - GASOLINE ENGINES .
  10. Remove the accessory drive belt from the engine.
  11. Disconnect the degas bottle coolant hose.
    Fig 1: Disconnecting Degas Bottle Coolant Hose
    G03920175Courtesy of FORD MOTOR CO.
  12. Disconnect the 2 electrical connectors on the LH fender splash shield.
    Fig 2: Disconnecting Electrical Connectors On LH Fender Splash Shield
    G03920176Courtesy of FORD MOTOR CO.
  13. If equipped, disconnect the block heater electrical connector.
    Fig 3: Locating Block Heater Electrical Connector
    G03920195Courtesy of FORD MOTOR CO.
  14. Remove the 3 bolts and position the power steering pump aside.
    Fig 4: Identifying Power Steering Pump Bolts
    G03886436Courtesy of FORD MOTOR CO.
  15. Disconnect the generator wiring harness retainer from the RH cylinder head.
    Fig 5: Disconnecting Generator Wiring Harness Retainer From RH Cylinder Head
    G03920178Courtesy of FORD MOTOR CO.
  16. Disconnect the A/C compressor and the A/C high pressure cut-off switch electrical connectors.
    Fig 6: Disconnecting A/C Compressor And A/C High Pressure Cut-Off Switch Electrical Connectors
    G03920179Courtesy of FORD MOTOR CO.
  17. Disconnect the generator wiring harness retainer from the RH cylinder head and position the harness aside.
    Fig 7: Disconnecting Generator Wiring Harness Retainer From RH Cylinder Head
    G03920180Courtesy of FORD MOTOR CO.
  18. Disconnect the crankshaft position (CKP) sensor wiring harness retainer from the starter motor wiring harness.
    Fig 8: Disconnecting Crankshaft Position (CKP) Sensor Wiring Harness Retainer From Starter Motor Wiring Harness
    G03920181Courtesy of FORD MOTOR CO.
  19. Disconnect the engine wiring harness retainer from the evaporative emissions (EVAP) canister purge valve bracket.
    Fig 9: Disconnecting Engine Wiring Harness Retainer From Evaporative Emissions (EVAP) Canister Purge Valve Bracket
    G03919860Courtesy of FORD MOTOR CO.
  20. Disconnect EVAP tube quick connect couplings and the electrical connector from EVAP canister purge valve. For additional information, refer to FUEL SYSTEM-GENERAL INFORMATION - GASOLINE AND DIESEL .
    Fig 10: Disconnecting EVAP Tube Quick Connect Couplings And Electrical Connector From EVAP Canister Purge Valve
    G03919866Courtesy of FORD MOTOR CO.
  21. Remove the 3 nuts and remove EVAP canister purge valve and bracket assembly.
    Fig 11: Removing Nuts And EVAP Canister Purge Valve And Bracket Assembly
    G03919862Courtesy of FORD MOTOR CO.
  22. Disconnect the heater hose at the rear of the engine.
    Fig 12: Disconnecting Heater Hose At Rear Of Engine
    G03905677Courtesy of FORD MOTOR CO.
  23. Disconnect the body wiring harness retainer from the degas bottle support bracket.
    Fig 13: Disconnecting Body Wiring Harness Retainer From Degas Bottle Support Bracket
    G03920185Courtesy of FORD MOTOR CO.
  24. Remove the 3 nuts and the degas bottle support bracket.
    Fig 14: Removing Nuts And Degas Bottle Support Bracket
    G03920186Courtesy of FORD MOTOR CO.
  25. Drain the engine oil.
  26. Remove the 4 exhaust manifold-to-catalytic converter nuts.
    Fig 15: Locating Exhaust Manifold-To-Catalytic Converter Nuts
    G03920889Courtesy of FORD MOTOR CO.
  27. Disconnect the 2 heated exhaust gas oxygen sensor (HO2S) electrical connectors.
    Fig 16: Disconnecting Heated Exhaust Gas Oxygen Sensor (HO2S) Electrical Connectors
    G03920201Courtesy of FORD MOTOR CO.
  28. Remove the nut and the ground cable and disconnect the wiring harness and retainer from the bracket.
    Fig 17: Removing Nut And Ground Cable
    G03920908Courtesy of FORD MOTOR CO.

    29. Manual transmission vehicles 

  29. Remove the clutch disc and pressure plate. For additional information, refer to CLUTCH .

    30. All vehicles 

  30. Remove and discard the oil filter.
    Fig 18: Locating Oil Filter
    G03920097Courtesy of FORD MOTOR CO.
  31. Disconnect the coolant hoses from the oil cooler.
    Fig 19: Disconnecting Coolant Hoses From Oil Cooler
    G03920297Courtesy of FORD MOTOR CO.
  32. Loosen the threaded shaft and remove the oil cooler.
    • Discard the oil cooler.
      Fig 20: Identifying Threaded Shaft
      G03920099Courtesy of FORD MOTOR CO.

    33. Automatic transmission vehicles 

  33. Remove the starter motor. For additional information, refer to STARTING SYSTEM - GASOLINE ENGINES .
  34. Remove the transmission filler tube. For additional information, refer to AUTOMATIC TRANSAXLE/TRANSMISSION - TORQSHIFT .
  35. Remove the bolts and position the transmission oil cooler lines and bracket aside.
    Fig 21: Identifying Transmission Cooler Tube Support Bracket And Nut
    G03905682Courtesy of FORD MOTOR CO.

    36. All vehicles 

  36. Remove the stud bolt and position the ground strap aside.
    Fig 22: Removing Stud Bolt
    G03905683Courtesy of FORD MOTOR CO.
  37. Remove the nut and position the starter electrical harness support bracket aside.
    Fig 23: Locating Starter Wiring Harness Support Bracket Bolt
    G03919905Courtesy of FORD MOTOR CO.
  38. Remove the 3 bolts and position the A/C compressor aside.
    Fig 24: Locating Bolt Access Holes For A/C Compressor
    G03919912Courtesy of FORD MOTOR CO.

    39. Automatic transmission vehicles 

  39. Remove the 2 bolts and the flexplate inspection cover.
    Fig 25: Locating Flexplate Inspection Cover Bolts
    G03885458Courtesy of FORD MOTOR CO.
  40. Remove the access plug.
    Fig 26: Removing Access Plug
    G03905685Courtesy of FORD MOTOR CO.
  41. Remove the 6 torque converter-to-flexplate nuts.
    • Discard the nuts.
      Fig 27: Locating Torque Converter-To-Flexplate Nuts
      G03885557Courtesy of FORD MOTOR CO.
  42. Remove the 5 lower transmission-to-engine bolts.
    Fig 28: Removing Lower Transmission-To-Engine Bolts
    G03905687Courtesy of FORD MOTOR CO.

    43. Automatic transmission vehicles 

  43. Remove the upper 2 transmission-to-engine bolts.
    Fig 29: Removing Upper Transmission-To-Engine Bolts
    G03920204Courtesy of FORD MOTOR CO.

    44. All vehicles 

  44. Install the special tool and support the engine with a suitable floor crane.
    Fig 30: Identifying Special Tool
    G03920205Courtesy of FORD MOTOR CO.
    45. CAUTION: Only use hand tools when removing the engine mount nut or damage to the engine mount can occur.
    NOTE: RH shown, LH similar.
    Fig 31: Identifying Engine Mount Nuts
    G03920590Courtesy of FORD MOTOR CO.
  45. Remove the 4 engine mount nuts.

    46. Automatic transmission vehicles 

  46. Support the transmission with a jack.

    47. All vehicles 

  47. Using a suitable floor crane, remove the engine assembly from the vehicle.
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