Removal and Installation

All vehicles 

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to JACKING & LIFTING .

   Four-Wheel Drive (4WD) vehicles 

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

   Courtesy 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

     Courtesy of FORD MOTOR CO.

   All vehicles 

4. Recover the A/C system refrigerant. For additional information, refer to CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS .
5. 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 .
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).
     Fig 3: Locating Battery Hold-Down Clamp Nut

     Courtesy of FORD MOTOR CO.
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).
      Fig 4: Locating LH Battery Tray Bolts

      Courtesy of FORD MOTOR CO.
12. Release the clip and disconnect the upper radiator hose at the radiator.
    Fig 5: Locating Upper Radiator Hose Clip

    Courtesy of FORD MOTOR CO.
13. Disconnect the hose at the degas bottle.
    • Release the spring clamp.
    • Disconnect the hose.
      Fig 6: Locating Hose Spring Clamp At Degas Bottle

      Courtesy of FORD MOTOR CO.
14. Remove the 2 pin-type retainers at the degas bottle and position the battery cable aside.
    Fig 7: Locating Pin-Type Retainers At Degas Bottle

    Courtesy of FORD MOTOR CO.
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.
      Fig 8: Locating CAC Inlet Tube Clamp

      Courtesy of FORD MOTOR CO.
16. Disconnect the CAC coolant outlet hose at the CAC.
    Fig 9: Locating CAC Coolant Outlet Hose At CAC

    Courtesy of FORD MOTOR CO.
17. Disconnect the CAC coolant outlet hose at the spring clip and position the tube aside.
    Fig 10: Locating CAC Coolant Outlet Hose At Spring Clip

    Courtesy of FORD MOTOR CO.
18. Disconnect the Charge Air Cooler Temperature (CACT) sensor electrical connector and disconnect the wiring harness retainer.
    Fig 11: Locating Charge Air Cooler Temperature Sensor Electrical Connector

    Courtesy of FORD MOTOR CO.
19. Disconnect the CAC tube outlet tube at the engine.
    Fig 12: Locating CAC Tube Outlet Tube At Engine

    Courtesy of FORD MOTOR CO.
20. Disconnect the degas bottle-to-engine hose.
    Fig 13: Locating Degas Bottle-To-Engine Hose

    Courtesy of FORD MOTOR CO.
21. If equipped, disconnect the 4X4 vacuum hose.
    Fig 14: Locating 4X4 Vacuum Hose

    Courtesy of FORD MOTOR CO.
22. If equipped, disconnect the Constant Vacuum Hublock (CVH) solenoid electrical connector and regulator vacuum hose.
    Fig 15: Locating Constant Vacuum Hublock (CVH) Solenoid Electrical Connector And Regulator Vacuum Hose

    Courtesy of FORD MOTOR CO.
23. If equipped, disconnect the vacuum line at the brake booster.
    Fig 16: Locating Vacuum Line At Brake Booster

    Courtesy of FORD MOTOR CO.
24. Remove the LH battery tray, degas bottle and CAC as an assembly.
25. Disconnect the 3 electrical connectors at the LH side.
    Fig 17: Locating Electrical Connectors At LH Side

    Courtesy of FORD MOTOR CO.
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 18: Locating Hose Clamp At Power Steering Fluid Reservoir

    Courtesy 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 19: Locating Brake Hydro-Boost Power Steering Fluid Lines

      Courtesy of FORD MOTOR CO.
29. Disconnect the brake fluid level switch electrical connector and release wiring harness retainers.
    Fig 20: Locating Brake Fluid Level Switch Electrical Connector And Wiring Harness Retainers

    Courtesy of FORD MOTOR CO.
NOTE: The brake master cylinder nuts are a torque-prevailing type and cannot be reused.
30. Remove and discard the 2 brake master cylinder nuts (1 shown in illustration) 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 21: Locating Brake Master Cylinder Nuts

        Courtesy of FORD MOTOR CO.
31. Disconnect the 2 fuel cooler hoses from T-fittings.
    Fig 22: Locating Fuel Cooler Hoses At T-Fittings

    Courtesy of FORD MOTOR CO.
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 .
32. 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 23: Locating Intermediate Shaft Bolt

      Courtesy 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).
      Fig 24: Locating Wiring Harness Retainer Bolt And LH Engine Ground Strap

      Courtesy of FORD MOTOR CO.
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.
       Fig 25: Locating MAF Sensor Electrical Connector, ACL Housing Bolt And ACL Outlet Pipe Clamp

       Courtesy of FORD MOTOR CO.
35. Detach the RH battery buss cover.
36. Remove the nut and disconnect the RH battery positive cable from the RH battery buss.
    Fig 26: Locating RH Battery Positive Cable Nut

    Courtesy of FORD MOTOR CO.
37. Disconnect the 5 electrical connectors.
    Fig 27: Locating Electrical Connectors

    Courtesy of FORD MOTOR CO.
38. Disconnect the 2 PCM electrical connectors and wiring harness retainers.
    Fig 28: Locating PCM Electrical Connectors And Wiring Harness Retainers

    Courtesy of FORD MOTOR CO.
39. Disconnect the electrical connector.
    Fig 29: Locating Electrical Connector

    Courtesy of FORD MOTOR CO.
40. Release the RH battery cable retainer.
    Fig 30: Locating RH Battery Cable Retainer

    Courtesy of FORD MOTOR CO.
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 31: Locating A/C Compressor-To-Condenser Discharge Line At Condenser

      Courtesy 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.
      Fig 32: Locating Clamp And Heater Core Hose-To-Engine

      Courtesy of FORD MOTOR CO.
43. Disconnect the 2EGR cooler lines from cooler.
    • Release retainers and position aside the hoses.
      Fig 33: Locating EGR Cooler Lines Clamps

      Courtesy of FORD MOTOR CO.
44. Disconnect the EGR valve coolant vent hose.
    Fig 34: Locating EGR Valve Coolant Vent Hose

    Courtesy of FORD MOTOR CO.
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.
      Fig 35: Locating Coolant Hose Clamp

      Courtesy of FORD MOTOR CO.
47. Disconnect the transmission secondary coolant outlet hose at the reservoir.
    Fig 36: Locating Transmission Secondary Coolant Outlet Hose At Reservoir

    Courtesy of FORD MOTOR CO.
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 37: Locating A/C Evaporator-To-Compressor Suction Line Fitting Nut

      Courtesy 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.
    Fig 38: Locating Lower Power Steering Cooler Hose Retainer

    Courtesy of FORD MOTOR CO.
52. Detach the radiator hose from the lower radiator support.
    Fig 39: Locating Radiator Hose And Lower Radiator Support

    Courtesy of FORD MOTOR CO.
53. Position a suitable drain pan under the radiator hose and release the radiator hose coupling locking clip.
    Fig 40: Locating Radiator Hose Coupling Locking Clip

    Courtesy of FORD MOTOR CO.
54. Disconnect the radiator hose coupling and allow the coolant to drain.
    Fig 41: Locating Radiator Hose Coupling

    Courtesy of FORD MOTOR CO.
55. Disconnect the hose from the transmission cooler.
    Fig 42: Locating Hose At Transmission Cooler

    Courtesy 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 43: Locating Body Ground Strap Bolt

      Courtesy of FORD MOTOR CO.
57. Separate the parking brake cable at the cable union.
    Fig 44: Locating Parking Brake Cable At Cable Union

    Courtesy of FORD MOTOR CO.
58. Release the parking brake cable retainer and route the front parking brake cable out of the frame.
    Fig 45: Locating Parking Brake Cable Retainer

    Courtesy of FORD MOTOR CO.
59. Disconnect the transmission selector linkage.
    Fig 46: Locating Transmission Selector Linkage

    Courtesy of FORD MOTOR CO.
60. Remove the transmission selector linkage locking clip and position the linkage aside.
    Fig 47: Locating Transmission Selector Linkage Locking Clip

    Courtesy of FORD MOTOR CO.
NOTE: LH shown in illustration, 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 .
61. 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 48: Locating Front End Sheet Metal Body Mount Bolt

      Courtesy of FORD MOTOR CO.
NOTE: LH shown in illustration, 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 .
62. 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 49: Locating Body Mounting Bolts

      Courtesy 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.
NOTE: Mark the position of the tires to aid in aligning the cab to the chassis.
65. Mark the position of the tires on the floor.
NOTE: Use 2-post hoist to lift the body from the chassis.
66. 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 50: Securing Vehicle To Hoist Using Universal Cab Hold-Down Strap

    Courtesy of FORD MOTOR CO.
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.
68. Lift the body from the chassis.
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.
69. 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 ENGINE and ENGINE COOLING - 6.7L DIESEL POWERTRAIN SECONDARY COOLING .
    • Top off the fluids.
    • Evacuate and recharge the A/C system. For additional information, CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS .
    • Connect all disconnected electrical connectors.