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Removal And Installation: Body

Special Tools

Illustration Tool Name Tool Number
GF0002311Courtesy of FORD MOTOR CO.
 Disconnect Tool, Transmission Cooler Lines 307-441
GF0005897Courtesy of FORD MOTOR CO.
 Disconnect Tool, Transmission Cooler Lines 307-459
Fig 1: Exploded View Of Body Off Mounting Locations
GF0021950Courtesy of FORD MOTOR CO.
Item Part Number Description
1 - Front end sheet metal (FESM) mounting bolt (2 required)
2 - Body mount No. 1 mounting bolt (2 required)
3 - Body mount No. 2 mounting bolt (2 required)
4 - Body mount No. 3 mounting bolt (2 required)
5 - Body mount No. 4 mounting bolt (2 required)
    NOTE: A 2-post hoist must be used to lift the body from the chassis.
  1. Open the tailgate.
  2. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to JACKING AND LIFTING article.
  3. Disconnect the battery cables. For additional information, refer to BATTERY, MOUNTING AND CABLES article.
  4. Remove the nut and separate the leads from the battery positive cable and position aside.
    • To install, tighten to 9 N.m (80 lb-in).
    5. Fig 2: Battery Positive Cable Leads Nut
    GF0021951Courtesy of FORD MOTOR CO.
  5. Remove the nut and the ground wire from the right fender.
    • To install, tighten to 12 N.m (9 lb-ft).
    6. Fig 3: Ground Wire & Nut
    GF0021952Courtesy of FORD MOTOR CO.
  6. Remove the ground wire from the clip on the battery tray.
  7. Recover the refrigerant. For additional information, refer to CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS article.
  8. Drain the engine coolant. For additional information, refer to ENGINE COOLING article.
  9. Remove the front bumper cover. For additional information, refer to BUMPERS article.
  10. Remove the rear bumper cover. For additional information, refer to BUMPERS article.
  11. Raise the vehicle.
  12. Remove the running boards, if equipped. For additional information, refer to EXTERIOR TRIM AND ORNAMENTATION article.
  13. Release the parking brake tension and disconnect the parking brake cable at the intermediate connection.
    14. Fig 4: Parking Brake Cable Intermediate Connection
    GF0021953Courtesy of FORD MOTOR CO.
  14. Remove the parking brake cable-to-frame bolt.
    • To install, tighten to 15 N.m (11 lb-ft).
    15. Fig 5: Parking Brake Cable-To-Frame Bolt
    GF0021954Courtesy of FORD MOTOR CO.
  15. Disconnect the automatic transmission cable from the manual valve and retainer clip.
    16. Fig 6: Identifying Auto Transmission Cable & Retainer Clip
    GF0002320Courtesy of FORD MOTOR CO.
  16. Disconnect the steering gear electrical connector and remove the connector from the frame.
    17. Fig 7: Steering Gear Electrical Connector
    GF0021955Courtesy of FORD MOTOR CO.
  17. Remove the retaining ring and disconnect the lower radiator hose from the radiator.
    18. Fig 8: Lower Radiator Hose & Retaining Ring At Radiator
    GF0021956Courtesy of FORD MOTOR CO.
  18. Remove the 4 pushpins (2 each side) from the frame-to-radiator air deflector.
    19. Fig 9: Frame-To-Radiator Air Deflector Push Pin
    GF0021957Courtesy of FORD MOTOR CO.
  19. Remove the safety clips from the transmission cooler lines.
    20. Fig 10: Transmission Cooler Line & Safety Clip
    GF0021958Courtesy of FORD MOTOR CO.
  20. Using the special tool, disconnect the transmission cooler lines from the auxiliary cooler.
    21. Fig 11: Disconnecting Transmission Cooler Lines From Auxiliary Cooler
    GF0021959Courtesy of FORD MOTOR CO.
  21. Remove the retainer from the splash shield on the front LH frame.
    22. Fig 12: Splash Shield Retainer At Left Front Frame
    GF0021960Courtesy of FORD MOTOR CO.
  22. Remove the retainer from the splash shield on the front RH frame.
    23. Fig 13: Splash Shield Retainer At Right Front Frame
    GF0021961Courtesy of FORD MOTOR CO.
  23. Remove the 3 retainers from the splash shield on the lower condenser.
    24. Fig 14: Splash Shield Retainer At Lower Condenser
    GF0021962Courtesy of FORD MOTOR CO.
  24. Release the fan shroud from the retainers and open the fan shroud.
    25. Fig 15: Fan Shroud Retainers
    GF0021963Courtesy of FORD MOTOR CO.
  25. If equipped, disconnect the air hose from the air suspension compressor.
    26. Fig 16: Air Suspension Compressor & Hose
    GF0021964Courtesy of FORD MOTOR CO.
  26. Remove the bolt and the ground wire from the body.
    27. Fig 17: Ground Wire & Bolt
    GF0021965Courtesy of FORD MOTOR CO.
    NOTE: Right front body bolt shown, all other bolts similar.
    NOTE: Front end sheet metal body support bolt shown, all other bolts similar.
  27. Remove the 6 body mount bolts and 2 front end sheet metal body support bolts.
    • Discard the body bolts.
    • To install, tighten the front end sheet metal body mount No. 2 and No. 3 to 80 N.m (59 lb-ft).
    • To install, tighten No. 1 body mount to 103 Nm (76 lb-ft).
    28. Fig 18: Body Support Bolt
    GF0021966Courtesy of FORD MOTOR CO.
  28. Lower the vehicle and chock the wheels to prevent the chassis from moving.
  29. Remove the 2 bolt covers from the rear storage compartment.
    30. Fig 19: Bolt Cover
    GF0021967Courtesy of FORD MOTOR CO.
  30. Remove the 2 rear body mount nuts from the rear storage compartment.
    • Discard the nuts.
    • To install, tighten to 80 N.m (59 lb-ft).
    31. Fig 20: Rear Body Mount Nut
    GF0021968Courtesy of FORD MOTOR CO.
    CAUTION: The fuel tank filler pipe may become caught on the inside of the fender when lifting the vehicle. Make sure the fuel tank filler pipe is not binding when lifting the vehicle, or damage may occur.
  31. Remove the 3 screws from the fuel tank filler pipe.
    32. Fig 21: Fuel Tank Filler Pipe Screws
    GF0021969Courtesy of FORD MOTOR CO.
  32. Remove the engine cover, if equipped.
  33. Remove the air cleaner intake pipe. For additional information, refer to INTAKE AIR DISTRIBUTION AND FILTERING article.
  34. Disconnect the fuel bundle wiring harness connector and remove from the splash shield.
    35. Fig 22: Fuel Bundle Wiring Harness Connector
    GF0021970Courtesy of FORD MOTOR CO.
  35. Disconnect the left ABS wheel speed sensor (WSS) connector.
    36. Fig 23: Left ABS Wheel Speed Sensor (WSS) Connector
    GF0021971Courtesy of FORD MOTOR CO.
  36. Disconnect the master cylinder electrical connector.
    37. Fig 24: Master Cylinder Electrical Connector
    GF0021972Courtesy of FORD MOTOR CO.
  37. Disconnect the brake booster electrical connector.
    38. Fig 25: Brake Booster Electrical Connector
    GF0021973Courtesy of FORD MOTOR CO.
  38. Disconnect the canister purge valve electrical connector and remove it from the bracket, position the canister aside.
    39. Fig 26: Canister Purge Valve Electrical Connector
    GF0021974Courtesy of FORD MOTOR CO.
  39. Disconnect the electrical connector and the 2 hoses from the degas bottle/air cleaner module.
    • Unclip the RH hose from the retainers on the side of the degas bottle/air cleaner module.
    40. Fig 27: Degas Bottle/Air Cleaner Module Electrical Connector & 2 Hoses
    GF0021975Courtesy of FORD MOTOR CO.
  40. Remove the 2 bolts from the degas bottle/air cleaner module and remove the module.
    41. Fig 28: Degas Bottle/Air Cleaner Module Bolts
    GF0021976Courtesy of FORD MOTOR CO.
  41. Remove the 2 master cylinder nuts (1 each side) from the brake booster and secure the master cylinder to the engine.
    42. Fig 29: Master Cylinder Nuts
    GF0021977Courtesy of FORD MOTOR CO.
  42. Disconnect the brake booster vacuum supply hose and secure the hose to the engine.
    43. Fig 30: Brake Booster Vacuum Supply Hose
    GF0021978Courtesy of FORD MOTOR CO.
    NOTE: Make sure that the vehicle wheels are straight.
  43. Place the vehicle in PARK and remove the key.
    44. CAUTION: Do not allow the steering column shaft to rotate while the intermediate shaft is disconnected or damage to the clockspring may result. If there is evidence that the shaft has rotated, the clockspring must be removed and recentered. For additional information, refer to SUPPLEMENTAL RESTRAINT SYSTEM article.
  44. Remove the steering shaft bolt at the joint between the intermediate and lower shafts and separate the shafts.
    • To install, refer to 25 N.m (18 lb-ft).
    45. Fig 31: Steering Shaft Joint Bolt
    GF0021979Courtesy of FORD MOTOR CO.
  45. Disconnect the power steering reservoir-to-power steering pump hose.
    46. Fig 32: Power Steering Reservoir-To-Power Steering Pump Hose
    GF0021980Courtesy of FORD MOTOR CO.
  46. Disconnect the power steering pump-to-power steering cooler line quick connect.
    • Disconnect the hose from the retainer on the fan shroud.
    47. Fig 33: Power Steering Pump-To-Power Steering Cooler Line & Retainer
    GF0021981Courtesy of FORD MOTOR CO.
  47. Disconnect the ABS module connector.
    48. Fig 34: ABS Module Connector
    GF0021982Courtesy of FORD MOTOR CO.
  48. Disconnect the upper radiator hose from the engine.
    49. Fig 35: Upper Radiator Hose At Engine
    GF0021983Courtesy of FORD MOTOR CO.
  49. Remove the nut from the condenser-to-manifold and tube assembly and position aside.
    • Install new O-rings before installing the manifold and tube assembly.
      • To install, tighten to 25 N.m (18 lb-ft).
    50. Fig 36: Condenser-To-Manifold And Tube Assembly Nut
    GF0021984Courtesy of FORD MOTOR CO.
  50. Remove the nut from the accumulator-to-manifold and tube assembly and position aside.
    • Install new O-rings before installing the manifold and tube assembly.
      • To install, tighten to 25 N.m (18 lb-ft).
    51. Fig 37: Accumulator-To-Manifold And Tube Assembly Nut
    GF0021985Courtesy of FORD MOTOR CO.
  51. Remove the nut and disconnect the electrical connector from the generator wiring harness and remove from the retainer.
    52. Fig 38: Generator Wiring Harness & Electrical Connector
    GF0021986Courtesy of FORD MOTOR CO.
  52. Disconnect the electrical connector from the electrical thermal connector on the front of the engine.
    53. Fig 39: Electrical Thermal Connector
    GF0021987Courtesy of FORD MOTOR CO.
    NOTE: RH shown, LH similar.
  53. Remove the bolts and the camshaft position (CMP) sensors (1 each side). Discard the O-ring seals.
    • To install, tighten to 10 N.m (89 lb-in).
    • Lubricate the O-ring seal with clean engine oil prior to installation.
    54. Fig 40: Camshaft Position (CMP) Sensor & Electrical Connector
    GF0021988Courtesy of FORD MOTOR CO.
  54. If equipped, disconnect the right vacuum lines for the four wheel drive (4WD) hub actuators.
    55. Fig 41: Four Wheel Drive (4WD) Hub Actuator Right Vacuum Lines
    GF0021989Courtesy of FORD MOTOR CO.
  55. Disconnect the heater hose from the engine.
    56. Fig 42: Heater Hose At Engine
    GF0021990Courtesy of FORD MOTOR CO.
  56. Disconnect the 3 heater hose quick disconnect fittings.
    57. Fig 43: Heater Hose Quick Disconnect Fittings
    GF0021991Courtesy of FORD MOTOR CO.
  57. Disconnect the engine electrical connector from the powertrain control module (PCM) and remove the retainer from the bulkhead.
    58. Fig 44: Powertrain Control Module (PCM) Engine Electrical Connector & Bulkhead Retainer
    GF0021992Courtesy of FORD MOTOR CO.
  58. Disconnect the engine electrical connector from the wiring harness and position aside.
    59. Fig 45: Engine Electrical Connector
    GF0021993Courtesy of FORD MOTOR CO.
  59. Disconnect the transmission electrical connector from the harness and the clip on the A/C line.
    60. Fig 46: Transmission Electrical Connector
    GF0021994Courtesy of FORD MOTOR CO.
  60. Disconnect the right side ABS WSS connector.
    61. Fig 47: Right ABS WSS Connector
    GF0021995Courtesy of FORD MOTOR CO.
  61. Remove the bolt and the ground wire from the front of the bulkhead.
    62. Fig 48: Ground Wire & Bolt
    GF0021996Courtesy of FORD MOTOR CO.
    NOTE: Marking the position of the tires will aid in aligning the cab to the chassis.
  62. Mark the position of the tires on the floor.
    63. NOTE: A 2-post hoist must be used to lift the body from the chassis.
  63. Position the hoist lift pads, equally side-to-side, below the pinch welds at the furthest most possible front and rear positions.
    64. WARNING: Securely strap the cab to the lift using an appropriate tool. If the cab is not correctly secured, it could shift or fall. Failure to follow this instruction may result in serious personal injury.
    CAUTION: An assistant will be necessary to make sure all the connections are disconnected and nothing interferes with the raising of the body while it is lifted.
  64. With the aid of an assistant lift the body from the chassis.
  65. To install, reverse the removal procedure.
    • Align the tires to the marks on the floor.
    • Top off the fluids.
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