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Home >> Ford >> 2022 >> Transit Connect Titanium, Gas/Ethanol >> Repair and Diagnosis >> External Pages >> Different car >> Section 645 (Full Frame And Body Mounting) >> Removal And Installation >> Body - 3.0L Power Stroke Diesel >> Removal

Body - 3.0L Power Stroke Diesel: Removal

WARNING: This page is about a different car, the 2021 Ford F-150. However, it is still accessible from the selected car via links, so may be relevant.
NOTE: Before performing this procedure, align the vehicle to the hoist and make sure the hoist arms/pads can be positioned to lift the body by the pinch welds while clearing the frame and all other vehicle components. Pay particular attention to the body mount extensions of the frame. Failure to properly align the vehicle and position the hoist arms may cause damage to the vehicle frame, body, components, or cause misalignment of the body during installation which may result in Noise, Vibration and Harshness (NVH) concerns.
NOTE: SuperCrew Cab shown in illustration, 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.
    GFD563534Courtesy 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 .
    • Disconnect the TCM electrical connector.

    • Disconnect the electrical connector.

    • Detach the wire retainer and position aside the wiring.

    GFD563536Courtesy of FORD MOTOR COMPANY
    • Disconnect the PCM electrical connector.

    • Disconnect the electrical connector.

    • Detach the wire retainers and position aside the wiring.

    GFD563537Courtesy of FORD MOTOR COMPANY
  7. Disconnect the electrical connectors.
    GFD563539Courtesy of FORD MOTOR COMPANY
  8. Release and position aside the wiring bracket.
    GFD563540Courtesy of FORD MOTOR COMPANY
  9. Remove the power distribution cover.
    GFD563541Courtesy of FORD MOTOR COMPANY
    • Remove the nuts and position out the battery wire harness.

      Torque

      : 97 lb.in (11 Nm)

    • Disconnect the wire harness retainers and position aside.

    GFD563542Courtesy of FORD MOTOR COMPANY
  11. Remove the degas bottle. Refer to: Degas Bottle .
  12. Remove the cooling fan. Refer to: Cooling Fan .
  13. Remove the cooling fan lower shroud. Refer to: Cooling Fan Lower Shroud .
  14. Remove the CAC intake pipe. Refer to: Charge Air Cooler (CAC) Intake Pipe .
  15. Remove the engine appearance cover.
    GFD563566Courtesy of FORD MOTOR COMPANY
  16. Remove the retainers and the engine appearance cover bracket.

    Torque

    : 44 lb.in (5 Nm)

    GFD563567Courtesy of FORD MOTOR COMPANY
    • Detach the retainers and position aside the wiring harness.

    • Loosen the clamp

      Torque

      : 44 lb.in (5 Nm)

    • Remove the fasteners and position aside the air cleaner outlet pipe.

      Torque

      : 53 lb.in (6 Nm)

    GFD563568Courtesy of FORD MOTOR COMPANY
    • Disconnect the electrical connector and detach the retainer.

    • Loosen the clamp to remove the air cleaner outlet pipe and crankcase vent oil seperator as an assembly.

      Torque

      : 44 lb.in (5 Nm)

    GFD563569Courtesy of FORD MOTOR COMPANY
  19. Disconnect the A/C pressure transducer electrical connector.
    GFD563570Courtesy 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

    : 159 lb.in (18 Nm)

    GFD563571Courtesy 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

    : 159 lb.in (18 Nm)

    GFD563572Courtesy of FORD MOTOR COMPANY
  22. Remove the nut, the wiring ground terminal and detach the wiring harness retainer.

    Torque

    : 106 lb.in (12 Nm)

    GFD563546Courtesy of FORD MOTOR COMPANY
    • Disconnect the LH body wiring harness connectors.

    • Detach the wiring retainer and position aside.

    GFD563547Courtesy of FORD MOTOR COMPANY
  24. Remove the front bumper. Refer to: Front Bumper .
  25. Remove running boards. Refer to: Running Board . Refer to: Power Running Board (PRB) .
  26. NOTE: If equipped.

    Remove the bolts and the underbody shield.

    Torque

    : 1: 30 lb.ft (40 Nm)

    2: 71 lb.in (8 Nm)

    GFD563573Courtesy of FORD MOTOR COMPANY
  27. NOTE: If equipped.

    Remove the bolts and the underbody skid plate.

    Torque

    : 30 lb.ft (40 Nm)

    GFD563549Courtesy of FORD MOTOR COMPANY
  28. NOTE: If equipped.

    Remove the underbody shield.

    Torque

    : 1: 30 lb.ft (40 Nm)

    2: 71 lb.in (8 Nm)

    GFD563550Courtesy of FORD MOTOR COMPANY
  29. NOTE: If equipped.

    Remove the fasteners and the underbody shield.

    Torque

    : 71 lb.in (8 Nm)

    GFD563574Courtesy of FORD MOTOR COMPANY
  30. NOTE: Place the transmission selector lever in Neutral after removing cable.

    • Remove the bolt and the nut.

      Torque

      : Nut: 80 lb.in (9 Nm)

      Bolt: 177 lb.in (20 Nm)

    • Pull out and position aside the selector lever cable.

    GFD563575Courtesy of FORD MOTOR COMPANY
  31. NOTE: Place the transmission selector lever in Neutral after removing cable.

    Install the shift bracket bolt.

    GFD563576Courtesy of FORD MOTOR COMPANY
  32. Remove the body-to-frame ground strap bolt RH frame bracket and position aside.

    Torque

    : 106 lb.in (12 Nm)

    GFD563555Courtesy of FORD MOTOR COMPANY
  33. WARNING: Do not reuse steering column shaft bolts. This may result in fastener failure and steering column shaft detachment or loss of steering control. Failure to follow this instruction may result in serious injury to vehicle occupant(s).

    Separate the steering column lower shaft.

    • Remove and discard the steering column shaft bolt.

      Torque

      : 41 lb.ft (55 Nm)

    • Separate the steering column lower shaft coupler from the steering column upper shaft.

    GFD563557Courtesy of FORD MOTOR COMPANY
  34. Disconnect the heater hose retainers. Disconnect and position aside the heater hoses.
    GFD563577Courtesy of FORD MOTOR COMPANY
  35. Remove the clamp and disconnect the upper radiator hose at the radiator.
    GFD563560Courtesy of FORD MOTOR COMPANY
  36. NOTE: Place a drain pan under the radiator to capture excess fluid.

    Disconnect the lower radiator hose at the radiator.

    GFD563578Courtesy of FORD MOTOR COMPANY
  37. NOTE: Do not allow the master cylinder tubes and hoses to bend or kink. Failure to follow this instruction may compromise brake performance.
    NOTE: Make sure to cover any open ports to prevent debris from entering the system.

    Disconnect the brake lines and position aside.

    Torque

    : 159 lb.in (18 Nm)

    GFD563562Courtesy of FORD MOTOR COMPANY
  38. 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.

    GFD563563Courtesy of FORD MOTOR COMPANY
  39. 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)

    GFD563564Courtesy of FORD MOTOR COMPANY
  40. If the body mount fastener captured nut spins. Refer to: Body Mount Fastener .
  41. 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 in illustration, others similar.

    Remove and discard the body mount bolts.

    Torque

    : Body mount bolts: 76 lb.ft (103 Nm)

    GFD563523Courtesy of FORD MOTOR COMPANY
  42. Position equally side-to-side, the hoist lifting pads below the pinch welds on the body at the furthest most front and rear positions.
    GFD563565Courtesy of FORD MOTOR COMPANY
  43. Using Universal Cab Hold-Down straps or equivalent, secure the body to the hoist.
  44. Place several cloth fender covers between the cab and the pickup bed.
  45. 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.

  46. 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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