Oil Pan: Installation

4x2/4x4 

1. Install a new oil pan gasket.

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2. Clean and prepare the RTV sealing surface. Refer to: RTV Sealing Surface Cleaning and Preparation .

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3. NOTE: If the oil pan is not installed and the fasteners tightened within 5 minutes, the sealant must be removed and the sealing area cleaned. Failure to follow this procedure can cause future oil leakage. If this timing cannot be met, tighten fasteners 7, 8, 9 and 10 to 8 Nm (71 lb-in) within 5 minutes of applying the sealer and final torque all of the fasteners within 1 hour of applying the sealer.
   NOTE: If the engine front cover has been removed, it is only necessary to apply sealant to the crankshaft rear seal retainer plate-to-cylinder block sealing surfaces.

   Apply 15 mm (0.59 in) diameter drops of silicone gasket and sealant to the crankshaft rear seal retainer plate-to-cylinder block sealing surfaces and the engine front cover-to-cylinder block sealing surfaces.

   Material

   : Motorcraft® High Performance Engine RTV Silicone / TA-357 (WSE-M4G323-A6)

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4. Install the oil pan and the bolts.

   Torque:Stage 1: 18 lb.in (2 Nm)

   Stage 2: 89 lb.in (10 Nm)

   Stage 3: 45 deg.

   Fig 1: Oil Pan Bolts Tightening Sequence

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5. Install the crossmember, bolts and the nuts.

   Torque: 66 lb.ft (90 Nm)

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6. 1. Position an adjustable stand and wood block under transmission bellhousing. Use the General Equipment: Vehicle/Axle StandsUse the General Equipment: Wooden Block
   2. Raise the adjustable stand 63.5 mm (2.5 in).

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7. Remove the wood block.

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8. 1. Using the adjustable stand, lower the engine to the installed position. Use the General Equipment: Vehicle/Axle Stands
   2. Remove the stand.

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9. Position the stabilizer bar and install the new nuts.

   Torque: 41 lb.ft (55 Nm)

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10. NOTE: Only use hand tools when installing the engine mount studs or damage to the engine mount can occur.
    NOTE: Apply threadlock to the stud threads prior to installation.

    Install the engine mount studs.

    Material

    : Motorcraft® Threadlock 262 / TA-26 (WSK-M2G351-A6)

    Torque: 22 lb.ft (30 Nm)

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11. NOTE: Only use hand tools when installing the engine mount nuts or damage to the engine mount can occur.

    Install the new RH engine mount nuts.

    Torque: 111 lb.ft (150 Nm)

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12. NOTE: Only use hand tools when tightening the engine mount through bolts or damage to the engine mount-to-cylinder block bracket can occur.

    Install the new LH engine mount through bolt.

    Torque: 258 lb.ft (350 Nm)

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13. NOTE: Only use hand tools when installing the transmission mount-to-crossmember nuts or damage to the transmission mount can occur.

    Tighten the transmission mount-to-crossmember nuts.

    Torque: 85 lb.ft (115 Nm)

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14. • Position the exhaust Y-pipe dual catalytic converter-to-exhaust intermediate pipe and install the bolts.
    • Tighten the inner exhaust Y-pipe dual catalytic converter-to-exhaust intermediate pipe bolt.

      Torque: 30 lb.ft (40 Nm)

    • Tighten the outer exhaust Y-pipe dual catalytic converter-to-exhaust intermediate pipe bolt.

      Torque: 30 lb.ft (40 Nm)

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    4x4 

15. Using an adjustable stand, raise the front axle carrier into position. Use the General Equipment: Vehicle/Axle Stands

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16. NOTE: It may be necessary to reposition the axle assembly to prevent interference with the steering components when installing the bolt.

    Install the new upper front axle carrier mounting bushing nut and the bolt finger tight.

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17. Install the new axle shaft housing carrier mounting bushing nut and the bolt finger tight.

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18. Install the new lower front axle carrier mounting bushing bolt.

    Torque: 129 lb.ft (175 Nm)

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19. Tighten the axle shaft housing carrier bushing bolt.

    Torque: 129 lb.ft (175 Nm)

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20. Tighten the upper front axle carrier mounting bushing bolt.

    Torque: 129 lb.ft (175 Nm)

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21. Remove the adjustable stand. Use the General Equipment: Vehicle/Axle Stands

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22. Install the steering gear boot.

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23. 1. Position back the steering column shaft U-joint to the steering gear.
    2. WARNING: Install a new steering column shaft bolt. Reuse could result in bolt failure and loss of vehicle control. Failure to follow this instruction may result in serious injury to vehicle occupant(s).

       Install a new steering column shaft bolt.

       Torque: 22 lb.ft (30 Nm)

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24. Install the front drive shaft. Refer to: Front Driveshaft .
25. Remove the holding device from the steering wheel.

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    4x2/4x4 

26. Install the engine cooler. Refer to: Oil Cooler .
27. Install the LH heat shield and the bolts.

    Torque: 177 lb.in (20 Nm)

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28. 1. Position the wiring harness and attach the wiring harness retainer.
    2. Position the coolant tubes and install the nut.

       Torque: 106 lb.in (12 Nm)

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29. 1. Connect the oil level sensor electrical connector.
    2. Attach the wiring harness retainers.

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30. Position the wiring harness and install the nut.

    Torque: 106 lb.in (12 Nm)

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31. 1. Connect the A/C compressor electrical connectors.
    2. Attach the wiring harness retainer.
    3. Install the pin-type retainer.

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32. 1. Position the coolant tubes and bracket and install the nut.

       Torque: 119 lb.in (13.5 Nm)

    2. Attach the coolant tube retainer.

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33. Connect the coolant hose quick release couplings.

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34. NOTE: If equipped.

    Install the skid plate and bolts.

    Torque: 30 lb.ft (40 Nm)

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35. NOTE: If equipped.

    Install the underbody shield and the bolts.

    Torque: 71 lb.in (8 Nm)

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36. If equipped, install the underbody shield and fasteners.

    Torque: 30 lb.ft (40 Nm)

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37. If equipped, install the skid plate and bolts.

    Torque: 30 lb.ft (40 Nm)

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38. Install the oil level indicator.

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39. Install the following items:
    1. Air cleaner. Refer to: Air Cleaner .
    2. Air cleaner outlet pipe. Refer to: Air Cleaner Outlet Pipe .

40. Fill the engine with clean engine oil. Refer to: Engine Oil Draining and Filling .
41. Connect the battery ground cable. Refer to: Battery Disconnect and Connect .
42. Fill and bleed the engine cooling system. Refer to: Engine Cooling System Draining, Vacuum Filling and Bleeding .
43. Start engine and check exhaust system for leaks.