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Removal and Installation

WARNING: This page is about a different car, the 2013 Ford F-550 Super Duty, 2013 Ford F-450 Super Duty, 2013 Ford F-350 Super Duty, and 2013 Ford F-250 Super Duty. 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. Lift up on the transfer case shift lever boot and bezel to access the shift lever bolt.
    Fig 1: Locating Transfer Case Shift Lever Boot
    G07486578Courtesy of FORD MOTOR CO.
  3. Remove the bolt and the shift lever.
    • To install, tighten to 27 Nm (20 lb-ft).
      Fig 2: Locating Shift Lever Bolt
      G07486579Courtesy of FORD MOTOR CO.

    All vehicles 

  4. Recover the A/C system refrigerant. For additional information, refer to CLIMATE CONTROL SYSTEM - GENERAL INFORMATION & DIAGNOSTICS .
  5. Drain the engine coolant and secondary cooling system. For additional information, refer to ENGINE COOLING - DIESEL ENGINES and ENGINE COOLING - 6.7L DIESEL POWERTRAIN SECONDARY COOLING .
  6. Disconnect the battery cables from the LH and RH batteries. For additional information, refer to BATTERY, MOUNTING AND CABLES .
  7. Separate the leads from the RH battery positive cable.
    • To install, tighten to 9 Nm (80 lb-in).
  8. Separate the leads from the RH battery negative cable.
    • To install, tighten to 9 Nm (80 lb-in).
  9. Remove the battery hold-down clamp nut.
    • To install, tighten to 4 Nm (35 lb-in).
      G07975990
  10. Remove the LH battery. For additional information, refer to BATTERY, MOUNTING AND CABLES .

    All vehicles 

  11. Remove the 4 LH battery tray bolts.
    • To install, tighten to 18 Nm (159 lb-in).
      G07975991
  12. Release the clip and disconnect the upper radiator hose at the radiator.
    G07975992
  13. Disconnect the hose at the degas bottle.
    • Release the spring clamp.
    • Disconnect the hose.
      G07975993
  14. Remove the 2 pin-type retainers at the degas bottle and position the battery cable aside.
    G07975994
  15. Disconnect the Charge Air Cooler (CAC) inlet tube.
    • Release the CAC inlet tube-to-CAC clamp.
      • To install, tighten to 9 Nm (80 lb-in).
    • Disconnect the CAC inlet tube.
      G07975995
  16. Disconnect the CAC coolant outlet hose at the CAC.
    G07975996
  17. Disconnect the CAC coolant outlet hose at the spring clip and position the tube aside.
    G07975997
  18. Disconnect the Charge Air Cooler Temperature (CACT) sensor electrical connector and disconnect the wiring harness retainer.
    Fig 3: Locating Charge Air Cooler Temperature Sensor Electrical Connector
    G07486598Courtesy of FORD MOTOR CO.
  19. Disconnect the CAC tube outlet tube at the engine.
    G07975999
  20. Disconnect the degas bottle-to-engine hose.
    G07976000
  21. If equipped, disconnect the 4X4 vacuum hose.
    G07976001
  22. If equipped, disconnect the Constant Vacuum Hublock (CVH) solenoid electrical connector and regulator vacuum hose.
    G07976002
  23. If equipped, disconnect the vacuum line at the brake booster.
    G07976003
  24. Remove the LH battery tray, degas bottle and CAC as an assembly.
  25. Disconnect the 3 electrical connectors at the LH side.
    G07976004
  26. Using a suitable suction device, remove the power steering fluid from the power steering reservoir.
  27. Disconnect the hose from the power steering fluid reservoir.
    Fig 4: Locating Power Steering Fluid Reservoir Hose Clamp
    G07976005Courtesy of FORD MOTOR CO.
  28. 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 5: Locating Brake Hydro-Boost Power Steering Fluid Lines
      G07486602Courtesy of FORD MOTOR CO.
  29. Disconnect the brake fluid level switch electrical connector and release wiring harness retainers.
    Fig 6: Locating Brake Fluid Level Switch Electrical Connector And Wiring Harness Retainers
    G07486603Courtesy of FORD MOTOR CO.
  30. NOTE: The brake master cylinder nuts are a torque-prevailing type and cannot be reused.

    Remove and discard the 2 brake master cylinder nuts (1 shown below) and then position the brake master cylinder aside.

    • 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 7: Locating Brake Master Cylinder Nuts
        G07486604Courtesy of FORD MOTOR CO.
  31. Disconnect the 2 fuel cooler hoses from T-fittings.
    G07976009
  32. 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 .

    Remove and discard the intermediate shaft bolt, then disconnect the lower steering column shaft from the upper steering column shaft.

    • To install, tighten the new bolt to 48 Nm (35 lb-ft).
      Fig 8: Locating Intermediate Shaft Bolt
      G06780931Courtesy of FORD MOTOR CO.
  33. Remove the bolt, release the wiring harness retainer and position the LH engine ground strap aside.
    • To install, tighten to 10 Nm (89 lb-in).
      G07976011
  34. Remove the Air Cleaner (ACL) housing box.
    1. Disconnect the Mass Air Flow (MAF) sensor electrical connector.
    2. Remove the ACL housing bolt.
      • To install tighten to 6 Nm (53 lb-in).
    3. Loosen the ACL outlet pipe clamp.
      • To install tighten to 4 Nm (35 lb-in).
    4. Remove the ACL assembly.
      G07976012
  35. Detach the RH battery buss cover.
  36. Remove the nut and disconnect the RH battery positive cable from the RH battery buss.
    Fig 9: Locating RH Battery Positive Cable Nut
    G07976013Courtesy of FORD MOTOR CO.
  37. Disconnect the 5 electrical connectors.
    Fig 10: Locating Electrical Connectors
    G07486586Courtesy of FORD MOTOR CO.
  38. Disconnect the 2 PCM electrical connectors and wiring harness retainers.
    Fig 11: Locating PCM Electrical Connectors
    G07486594Courtesy of FORD MOTOR CO.
  39. Disconnect the electrical connector.
    Fig 12: Locating Electrical Connector
    G07486595Courtesy of FORD MOTOR CO.
  40. Release the RH battery cable retainer.
    G07976017
  41. 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 13: Locating A/C Compressor-To-Condenser Discharge Line At Condenser
      G07486593Courtesy of FORD MOTOR CO.
  42. Disconnect the heater core hose-to-engine.
    • Release the clamp and disconnect the upper hose.
    • Release the quick disconnect and disconnect the heater core hose-to-engine.
      G07976019
  43. Disconnect the 2 EGR cooler lines from cooler.
    • Release retainers and position aside the hoses.
      G07976020
  44. Disconnect the EGR valve coolant vent hose.
    G07976021
  45. Position a suitable drain pan under the coolant hoses at the water pump.
  46. Disconnect the upper and lower coolant hoses at the water pump and allow to drain.
    • Release the spring clips on each coolant hose.
    • Disconnect the coolant hoses.
      G07976022
  47. Disconnect the transmission secondary coolant outlet hose at the reservoir.
    G07976023
  48. 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 14: Locating A/C Evaporator-To-Compressor Suction Line Fitting Nut
      G07486609Courtesy of FORD MOTOR CO.
  49. Remove the 3 deflector pushpins from the front bumper.
  50. If equipped, disconnect the fog lamps.
  51. Disconnect the lower power steering cooler hose and remove from hose retainer.
    G07976025
  52. Detach the radiator hose from the lower radiator support.
    Fig 15: Locating Radiator Hose And Lower Radiator Support Clamps
    G07486613Courtesy of FORD MOTOR CO.
  53. Position a suitable drain pan under the radiator hose and release the radiator hose coupling locking clip.
    Fig 16: Locating Radiator Hose Coupling Locking Clip
    G07486614Courtesy of FORD MOTOR CO.
  54. Disconnect the radiator hose coupling and allow the coolant to drain.
    Fig 17: Locating Radiator Hose Coupling
    G07486615Courtesy of FORD MOTOR CO.
  55. Disconnect the hose from the transmission cooler.
    Fig 18: Locating Transmission Cooler Hose Clamp
    G07486616Courtesy of FORD MOTOR CO.
  56. Remove the bolt and position the body ground strap aside.
    • To install, tighten to 25 Nm (18 lb-ft).
      Fig 19: Locating Body Ground Strap Bolt
      G07486617Courtesy of FORD MOTOR CO.
  57. Separate the parking brake cable at the cable union.
    Fig 20: Locating Parking Brake Cable At Cable Union
    G07486618Courtesy of FORD MOTOR CO.
  58. Release the parking brake cable retainer and route the front parking brake cable out of the frame.
    Fig 21: Locating Parking Brake Cable Retainer
    G07486619Courtesy of FORD MOTOR CO.
  59. Disconnect the transmission selector linkage.
    Fig 22: Locating Transmission Selector Linkage
    G07486620Courtesy of FORD MOTOR CO.
  60. Remove the transmission selector linkage locking clip and position the linkage aside.
    Fig 23: Locating Transmission Selector Linkage Locking Clip
    G07486621Courtesy of FORD MOTOR CO.
  61. NOTE: LH shown, RH similar.
    NOTE: Make sure the insulator is removed with the body bolt.
    NOTE: If the captured cage nut spins, refer to SPUN CAB RETAINER CAGE NUT - 6.7L DIESEL .

    Remove the Front End Sheet Metal (FESM) body mount bolts.

    • Position a floor jack on the FESM core support and apply pressure to cage nuts to prevent spinning during removal.
    • Remove the FESM bolts using an impact wrench.
    • To install, tighten to 103 Nm (76 lb-ft).
      Fig 24: Locating Front End Sheet Metal Body Mount Bolt
      G07976035Courtesy of FORD MOTOR CO.
  62. NOTE: LH shown, RH similar.
    NOTE: Make sure the insulator is removed with the bolt.
    NOTE: If the captured cage nut spins, refer to SPUN CAB RETAINER CAGE NUT - 6.7L DIESEL .

    Remove the remaining body mounting bolts with an impact wrench starting with the rear bolts.

    • To install, tighten to 103 Nm (76 lb-ft).
      Fig 25: Locating Body Mounting Bolts
      G06780945Courtesy of FORD MOTOR CO.
  63. If equipped, disconnect the running boards electrical connectors.
  64. Place several fender covers between the cab and the pickup bed.
  65. NOTE: Mark the position of the tires to aid in aligning the cab to the chassis.

    Mark the position of the tires on the floor.

  66. NOTE: Use 2-post hoist to lift the body from the chassis.

    Position equally side-to-side the hoist lift pads below the pinch welds at the furthest most possible front and rear positions.

  67. Using the Universal Cab Hold-Down Strap, secure the vehicle to the hoist.
    Fig 26: Securing Vehicle To Hoist Using Universal Cab Hold-Down Strap
    G06780946Courtesy of FORD MOTOR CO.
  68. NOTE: Prior to raising cab on lift, verify that the steering shaft is clear of obstruction and has been positioned aside to prevent damage to shaft assembly.

    Lift the body from the chassis.

  69. NOTE: Prior to lowering cab on lift, verify that the steering shaft is clear of obstruction and has been positioned aside to prevent damage to shaft assembly.

    To install, reverse the removal procedure.

    • Align the tires to the marks on the floor.
    • With the aide of an assistant in alignment, lower the body on the chassis.
    • Install new bolts for all discarded.
    • Prior to reusing the body support mounting bolts, use a wire wheel to clean all threadlock material from the threads.
    • Apply threadlock and sealer to the threads of all body support mounting bolts prior to installation.
    • Install new o-ring seals for all discarded.
    • If installing a new engine or short block, fill both cooling systems with new coolant. In these circumstances, flushing the engine and cooling system is not necessary. For additional information, refer to ENGINE COOLING - DIESEL ENGINES and ENGINE COOLING - 6.7L DIESEL POWERTRAIN SECONDARY COOLING .
    • Top off the fluids.
    • Evacuate and recharge the A/C system. For additional information, HVAC - CLIMATE CONTROL SYSTEM (GENERAL INFORMATION & ELECTRICAL DIAGNOSTICS) .
    • Connect all disconnected electrical connectors.
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