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Body - 3.0L Power Stroke Diesel: Removal

WARNING: This page is about a different car, the 2020 Ford F-150. However, it is still accessible from the selected car via links, so may be relevant.
NOTE: SuperCrew Cab shown, all other cab styles similar.
NOTE: Use a 2-post hoist to lift the body from the chassis.
NOTE: Removal steps in this procedure may contain installation details.
  1. Using a holding device, hold the steering wheel in the straight ahead position.
    GFD468149Courtesy of FORD MOTOR COMPANY
  2. Drain the cooling system. Refer to: Engine Cooling System Draining, Vacuum Filling and Bleeding .
  3. Recover the A/C refrigerant. Refer to: Air Conditioning (A/C) System Recovery, Evacuation and Charging - Vehicles With: R1234YF Refrigerant . Refer to: Air Conditioning (A/C) System Recovery, Evacuation and Charging - Vehicles With: R134A Refrigerant .
  4. Remove the battery tray. Refer to: Battery Tray .
  5. Disconnect the battery cable ground cable, retainer and position aside the battery cable harness.

    Torque

    : : 80 lb.in (9 Nm)

    GFD468192Courtesy of FORD MOTOR COMPANY
  6. Disconnect the retainer. Position aside the power distribution box cover.
    GFD468193Courtesy of FORD MOTOR COMPANY
  7. Remove the Power Distribution Box terminal fasteners and position aside the wiring.

    Torque

    : 93 lb.in (10.5 Nm)

    GFD468152Courtesy of FORD MOTOR COMPANY
  8. Disconnect the PCM electrical connectors, release the harness retainers to position aside wire harness.
    GFD468194Courtesy of FORD MOTOR COMPANY
  9. NOTE: Shown with retainer clips detached

    Disconnect the RH wiring harness connectors, below the PCM and position aside.

    GFD468154Courtesy of FORD MOTOR COMPANY
  10. Remove the degas bottle. Refer to: Degas Bottle .
  11. Remove the cooling fan. Refer to: Cooling Fan .
  12. Remove the cooling fan lower shroud. Refer to: Cooling Fan Lower Shroud .
  13. Loosen the cooling fan shroud lower mounting bracket bolts to provide clearance for removal of the cooling fan shroud.

    Torque

    : 30 lb.ft (40 Nm)

    GFD468195Courtesy of FORD MOTOR COMPANY
  14. Remove the CAC shroud.

    Torque

    : 62 lb.in (7 Nm)

    GFD468196Courtesy of FORD MOTOR COMPANY
  15. Remove the CAC intake pipe. Refer to: Charge Air Cooler (CAC) Intake Pipe .
  16. Remove the engine appearance cover.
    GFD468197Courtesy of FORD MOTOR COMPANY
  17. Remove the retainers and the engine appearance cover bracket.

    Torque

    : 44 lb.in (5 Nm)

    GFD468198Courtesy of FORD MOTOR COMPANY
  18. Disconnect the electrical connector and remove the air cleaner outlet pipe and crankcase vent oil separator as an assembly.
    GFD468199Courtesy of FORD MOTOR COMPANY
  19. Disconnect A/C pressure transducer electrical connector.
    GFD468200Courtesy of FORD MOTOR COMPANY
  20. NOTE: Make sure to cover any open ports to prevent debris from entering the system.

    Remove the nut and disconnect the A/C coupling.

    Torque

    : 133 lb.in (15 Nm)

    GFD468155Courtesy of FORD MOTOR COMPANY
  21. NOTE: Make sure to cover any open ports to prevent debris from entering the system.

    Remove the A/C compressor outlet line nut and disconnect the fitting.

    Torque

    : 133 lb.in (15 Nm)

    GFD468157Courtesy of FORD MOTOR COMPANY
  22. Remove the nut, the wiring ground terminal and detach the wiring harness retainer.

    Torque

    : 106 lb.in (12 Nm)

    GFD468159Courtesy of FORD MOTOR COMPANY
  23. Disconnect the LH body wiring harness connectors and position aside.
    GFD468160Courtesy of FORD MOTOR COMPANY
  24. NOTE: If equipped.

    Disconnect the electrical connector and vacuum hose(s) from 4WD solenoid.

    GFD468161Courtesy of FORD MOTOR COMPANY
  25. If equipped, disconnect the front drive axle vent retainer.
    GFD468201Courtesy of FORD MOTOR COMPANY
  26. Disconnect the brake fluid level sensor electrical connector.
    GFD468202Courtesy of FORD MOTOR COMPANY
  27. NOTE: Do not allow the master cylinder tubes and hoses to bend or kink. Carefully position the master cylinder and secure using tie straps, wire or similar retainers. Failure to follow this instruction may compromise brake performance.

    Disconnect the electrical connector, remove the nuts and position aside the master cylinder. Carefully position and secure the master cylinder to a suitable area in the engine compartment to avoid bending or kinking of the brake tubes and hoses.

    Torque

    : 18 lb.ft (25 Nm)

    GFD468162Courtesy of FORD MOTOR COMPANY
  28. Disconnect the brake booster vacuum hose and position aside.
    GFD468163Courtesy of FORD MOTOR COMPANY
  29. NOTE: If equipped.

    On both sides. Disconnect the 4WD wheel speed sensor electrical connector and position aside the wiring.

    GFD468164Courtesy of FORD MOTOR COMPANY
  30. Disconnect the ABS module electrical connector and position aside the wiring harness.
    GFD468165Courtesy of FORD MOTOR COMPANY
  31. NOTE: If equipped.

    Remove the front bumper trim panel.

    GFD468203Courtesy of FORD MOTOR COMPANY
  32. Remove the CCM nuts.

    Torque

    : 9 lb.in (1 Nm)

    GFD468204Courtesy of FORD MOTOR COMPANY
    • Release the CCM grommets from the ball studs.

    • Disconnect the CCM electrical connector.

    GFD468205Courtesy of FORD MOTOR COMPANY
  34. Position aside the engine block heater wire harness.
    GFD468206Courtesy of FORD MOTOR COMPANY
  35. Remove the front bumper. Refer to: Front Bumper .
  36. NOTE: If equipped.

    Disconnect the fog lamp electrical harness connector and position the wiring harness aside.

    GFD468166Courtesy of FORD MOTOR COMPANY
  37. NOTE: If equipped.

    Remove the power running boards. Refer to: Power Running Board (PRB) .

  38. NOTE: If equipped.

    Remove the underbody shield.

    Torque

    : 71 lb.in (8 Nm)

    GFD468168Courtesy of FORD MOTOR COMPANY
  39. NOTE: If equipped.

    Remove the underbody shield.

    GFD468169Courtesy of FORD MOTOR COMPANY
  40. NOTE: If equipped.

    Remove the underbody shield.

    Torque

    : 1: 30 lb.ft (40 Nm) 2: 71 lb.in (8 Nm)

    GFD468170Courtesy of FORD MOTOR COMPANY
  41. Disconnect the transmission selector lever cable.
    GFD468179Courtesy of FORD MOTOR COMPANY
  42. NOTE: Place the transmission selector lever in Neutral after removing cable.

    Use a screwdriver to release the selector lever cable retainer, detach the selector lever cable retainer from the bracket, and position aside the selector lever cable.

    GFD468180Courtesy of FORD MOTOR COMPANY
  43. Remove the body-to-frame ground strap bolt RH frame bracket and position aside.

    Torque

    : 106 lb.in (12 Nm)

    GFD468181Courtesy of FORD MOTOR COMPANY
  44. NOTE: If equipped.

    Detach the front parking brake cable from the cable union.

    GFD468182Courtesy of FORD MOTOR COMPANY
  45. Remove and discard the bolt and disconnect the upper steering shaft.

    Torque

    : 35 lb.ft (48 Nm)

    GFD468184Courtesy of FORD MOTOR COMPANY
  46. Disconnect the heater core inlet and outlet hoses.
    GFD468186Courtesy of FORD MOTOR COMPANY
  47. Remove the clamp and disconnect the upper radiator hose at the radiator.
    GFD468187Courtesy of FORD MOTOR COMPANY
  48. NOTE: Place a drain pan under the radiator to capture excess fluid.

    Disconnect the lower radiator hose at the radiator.

    GFD468188Courtesy of FORD MOTOR COMPANY
  49. NOTE: NOTICE:

    Do not apply open flame to Front End Sheet Metal (FESM) or body mount bolts, use an inductive heat type tool to loosen the body mount bolts.

    NOTE: Cycle the inductive heat tool in 20-30 second increments to avoid damage the body mount insulators and surrounding area.
    NOTE: Adhesive is applied to threads on body mount bolts during manufacture.

    Using an inductive heat tool, apply heat to the body mount bolt to soften adhesive, following the tool manufacturer's instructions.

    GFD468189Courtesy of FORD MOTOR COMPANY
  50. NOTE: Use hand tools only to remove the Front End Sheet Metal (FESM) bolts, power tools may damage the body mount retainer nuts.

    Remove and discard the Front End Sheet Metal (FESM) bolts.

    Torque

    : Front End Sheet Metal (FESM) body mount bolt: 59 lb.ft (80 Nm)

    GFD468190Courtesy of FORD MOTOR COMPANY
  51. If the body mount fastener captured nut spins. Refer to: Body Mount Fastener .
  52. NOTE: Use hand tools only to remove the body mount bolts, power tools may damage the body mount retainer nuts.
    NOTE: Number 1 body mount shown, others similar.

    Remove and discard the body mount bolts.

    Torque

    : Body mount bolts: 85 lb.ft (115 Nm)

    GFD468137Courtesy of FORD MOTOR COMPANY
  53. Position equally side-to-side, the hoist lifting pads below the pinch welds on the body at the furthest most front and rear positions.
    GFD468191Courtesy of FORD MOTOR COMPANY
  54. Using Universal Cab Hold-Down straps or equivalent, secure the body to the hoist.
  55. Place several cloth fender covers between the cab and the pickup bed.
  56. 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.

  57. NOTE: Prior to raising the body on the lift, verify that the steering shaft, hoses and wire harnesses are clear of obstruction and have been positioned aside to prevent damage.

    Raise the body slightly to gain clearance and position the chassis rearward slightly, to allow enough clearance between the body and pickup bed, and lift the body from the chassis.

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