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    2006 Ford Truck Expedition 2WD 5.4L EFI SOHC 8cyl

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    1720 S RIDGEWOOD A
    (386) 427-1210

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    Ford Excursion, Expedition, Lincoln Navigator 2000-2005

    Oil Pan

    Print

    Removal & Installation



    1. Before servicing the vehicle, refer to the precautions section.
    2.  
    3. Drain the engine oil.
    4.  
    5. Remove the bolts and the frame crossmember.
    6.  
    7. Remove the bolt and detach the wire harness bracket.
    8.  
    9. On 4WD models:
      1. Support the front axle housing with a jack stand.
        NOTE
        Mark the bolt and bracket so that alignment can be maintained on installation.

      2.  
      3. Remove the front axle housing right hand mounting bolt.
        NOTE
        Mark the bolt and bracket so that alignment can be maintained on installation.

      4.  
      5. Remove the front axle housing left hand front mounting bolt.
        NOTE
        Mark the bolt and bracket so that alignment can be maintained on installation

      6.  
      7. Remove the front axle housing left hand rear mounting bolt.
        CAUTION
        Use care when lowering the front axle housing, or the vacuum lines to the axle solenoid may become disconnected or damaged.

      8.  
      9. Lower the axle to allow clearance for the oil pan to be removed.
        NOTE
        Be careful when removing the oil pan gasket. It is reusable.

      10.  

    10.  
    11. Remove the 16 bolts, the oil pan and the gaskets. Inspect the oil pan gasket for damage.
    12.  
    13. If damaged, discard the oil pan gasket and the oil pan-to-oil pump gaskets.
    14.  

    To install:


    CAUTION
    Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges, which make leak paths. Use a plastic scraping tool to remove all traces of old sealant.

    1. Inspect the oil pan. Clean the mating surface for the oil pan with silicone gasket remover and metal surface prep.
      NOTE
      If not secured within four minutes, the sealant must be removed and the sealing area cleaned. To clean the sealing area, use silicone gasket remover and metal surface prep. Follow the directions on the packaging. Failure to follow this procedure can cause future oil leakage.

    2.  
    3. Apply silicone gasket and sealant at the crankshaft rear seal retainer plate-to-cylinder block sealing surface.
    4.  
    5. Apply silicone gasket and sealant at the engine front cover-to-cylinder block sealing surface.
    6.  
    7. Install the oil pan gasket and the oil pan and loosely install the 16 bolts.
    8.  
    9. Tighten the bolts in 3 steps, in the sequence illustrated.
      1. Step 1: Tighten to 2 Nm (18 lb-in).
      2.  
      3. Step 2: Tighten to 15 ft. lbs. (20 Nm).
      4.  
      5. Step 3: Tighten an additional 60 degrees.
      6.  

    10.  
    11. On 4WD models:
      CAUTION
      Use care when positioning the front axle housing, or the vacuum lines to the axle solenoid may become disconnected or damaged.

      1. Position the front axle housing and loosely install the three bolts, aligning the bolt location marks made during removal.
      2.  
      3. Install the front axle housing right hand mounting bolt. Tighten to 89 Nm (66 ft. lbs.).
      4.  
      5. Install the front axle housing left hand front mounting bolt. Tighten to 89 Nm (66 ft. lbs.).
      6.  
      7. Install the front axle housing left hand rear mounting bolt. Tighten to 89 Nm (66 ft. lbs.).
      8.  

    12.  
    13. Position the frame crossmember and the 4 bolts. Tighten to 75 ft. lbs. (102 Nm).
    14.  
    15. Install the wire harness bracket and the bolt. Tighten to 89 inch lbs. (10 Nm).
    16.  
    17. Fill the crankcase with clean engine oil.
    18.  

    1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
    2.  
    3. Remove the engine.
    4.  
    5. Remove the oil pan bolts.
    6.  
    7. Lower the oil pan.
      NOTE
      The oil pan is sealed to the crankcase with RTV silicone sealant in place of a gasket. It may be necessary to separate the pan from the crankcase with a utility knife. Also, the crankshaft may have to be turned to allow the pan to clear the crankshaft throws.

    8.  
    9. Clean the pan and crankcase mating surfaces thoroughly.
    10.  

    To install:

    1. Apply a 1 / 8 in. (3mm) bead of RTV silicone sealant to the pan mating surfaces, and a 1 / 4 in. (6mm) bead on the front and rear covers and in the corners; you have 15 minutes within which to install the pan!
    2.  
    3. Install the locating dowels into position.
    4.  
    5. Position the pan on the engine and install the pan bolts loosely.
    6.  
    7. Remove the dowels.
    8.  
    9. Tighten the pan bolts to:

      1 / 4 in.-20 bolts: 84 inch lbs. (10 Nm)
       
      5 / 16 in.-18 bolts: 14 ft. lbs. (19 Nm)
       
      3 / 8 in.-16 bolts: 24 ft. lbs. (33 Nm)
       

    10.  
    11. Install the engine.
    12.  

    4.6L & 5.4L Engines


    Click image to see an enlarged view

    Fig. Tighten the oil pan-to-engine block bolts in 3 steps following the sequence shown-4.6L and 5.4L engines

    1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
    2.  
    3. Raise and safely support the vehicle.
    4.  
    5. Remove the front axle housing from the vehicle.
    6.  
    7. Drain the engine oil into a suitable container.
    8.  
    9. Remove the 16 oil pan-to-engine block bolts.
    10.  
    11. Remove the oil pan and old oil pan gasket.
    12.  

    To install:

    1. Clean the oil pan and engine block mating surfaces of oil and old gasket material.
    2.  
    3. Install the new oil pan gasket and the oil pan, then install the 16 oil pan-to-engine block bolts loosely.
      NOTE
      Be sure to tighten the oil pan bolts in 3 steps.

    4.  
    5. Tighten the oil pan-to-engine bolts in the sequence shown, in the following 3 steps:
      1. Step 1: 18 inch lbs. (2 Nm).
      2.  
      3. Step 2: 15 ft. lbs. (20 Nm).
      4.  
      5. Step 3: plus an additional 60 degrees.
      6.  

    6.  
    7. Install the oil drain plug.
    8.  
    9. Install the front axle housing.
    10.  
    11. Lower the vehicle.
    12.  
    13. Fill the engine with the correct amount and type of engine oil.
    14.  

    5.4L Engine
    1. Before servicing the vehicle, refer to the precautions section.
    2.  
    3. Disconnect the negative battery cable.
    4.  
    5. Remove the air cleaner outlet pipe.
    6.  
    7. Remove the accelerator cable snow shield.
    8.  
    9. Disconnect the throttle body cam.
    10.  
    11. Disconnect the accelerator cable.
    12.  
    13. If equipped, disconnect the speed control cable.
    14.  
    15. Remove the throttle return spring.
    16.  
    17. Position the accelerator cable bracket aside.
    18.  
    19. Release the Idle Air Control (IAC) fresh air tube from the routing clip and remove it from the vehicle.
    20.  
    21. Disconnect the IAC electrical connector.
    22.  
    23. If equipped, disconnect the differential pressure feedback Exhaust Gas Recirculation (EGR) system electrical connector.
    24.  
    25. Disconnect the Throttle Position (TP) sensor electrical connector.
    26.  
    27. If equipped, disconnect the differential pressure feedback EGR system vacuum hoses.
    28.  
    29. If equipped, disconnect the exhaust manifold to EGR valve tube fittings and remove the tube.
    30.  
    31. If equipped, remove the differential pressure feedback EGR system bracket.
    32.  
    33. If equipped, disconnect the EGR valve vacuum hose.
    34.  
    35. If equipped, disconnect the EGR vacuum regulator solenoid electrical and vacuum connections.
    36.  
    37. Position aside the throttle body adapter. Discard the throttle body adapter gasket.
    38.  
    39. Remove the alternator.
      CAUTION
      The large clutch assembly nut has a right-handed thread and must be rotated counterclockwise to remove it.

    40.  
    41. Using tools shown, remove the fan and fan clutch from the coolant pump pulley.

      Click image to see an enlarged view

      Fig. Using tools shown, remove the fan and fan clutch from the coolant pump pulley-2005 Excursion models with the 5.4L engine

    42.  
    43. Install the modular engine support bracket on the engine using the alternator mounting holes.
    44.  
    45. Remove the engine mount nuts.
      CAUTION
      Damage to the Turbine Shaft Speed/Output Shaft Speed (TSS/OSS) sensors may occur and cause the transmission or torque converter operational concerns if the transmission is raised prior to removing TSS/OSS.


      CAUTION
      Sensor bosses must be cleaned prior to removal and then plugged to prevent contamination from damaging internal components.

    46.  
    47. Remove the TSS or the OSS sensor and install plugs in the transmission.
    48.  
    49. Loosely install the transmission mount nuts and the crossmember.
    50.  
    51. Loosely install the crossmember bolts.
    52.  
    53. Loosely install the crossmember bolts.
    54.  
    55. Remove the jack from under the transmission and lower the vehicle.
    56.  
    57. Raise the engine using the a heavy duty engine support.
    58.  
    59. Drain the engine oil and remove the oil bypass filter.
    60.  
    61. Disconnect the Heated Oxygen (HO 2 S) sensor connectors.
    62.  
    63. Remove the nuts and the exhaust Y-pipe.
    64.  
    65. Remove the flywheel inspection plate.
      CAUTION
      Support the transmission on the oil pan rails only or internal transmission damage can occur.

    66.  
    67. Support the transmission with a transmission jack.
    68.  
    69. Remove the transmission mount nuts.
    70.  
    71. Raise the transmission.
    72.  
    73. Remove the bolts and partially lower the oil pan.
    74.  
    75. Remove the bolts from the oil pump screen and pickup tube and let them drop into the oil pan.
    76.  
    77. Remove the rear bolt and the oil pump screen and pickup tube and let them drop into the oil pan.
    78.  
    79. Remove the oil pan and the oil pan gasket from the rear of the engine.
    80.  
    81. Clean the oil pan thoroughly and inspect the oil pan gasket.
      CAUTION
      Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surface. These tools cause scratches and gouges, which make leak paths. Use a plastic scraping tool to remove all traces of sealant.

    82.  
    83. Clean the mating surfaces for the oil pan with silicone gasket remover and metal surface prep.
    84.  

    To install:


    NOTE
    The oil pump screen and pickup tube must be in the oil pan when the oil pan is positioned in the vehicle.

    1. Position the oil pan gasket and the oil pan in the vehicle from the rear of the engine.
      CAUTION
      Make sure the O-ring is in place and not damaged. A missing or damaged O-ring can cause foam in the lubrication system, low oil pressure and severe engine damage.


      NOTE
      Clean and inspect the mating surfaces and install a new O-ring. Lubricate with clean engine oil.

    2.  
    3. Install the oil pump screen and pickup tube.
      NOTE
      If not secure within four minutes, the sealant must be removed and the sealing area cleaned.

    4.  
    5. Apply a bead of silicone gasket and sealant at the crankshaft rear seal retainer-to-cylinder block surface, at the locations shown.
      NOTE
      If not secure within four minutes, the sealant must be removed and the sealing area cleaned.



      Click image to see an enlarged view

      Fig. Apply a bead of silicone gasket and sealant at the crankshaft rear seal retainer-to-cylinder block surface-2005 Excursion models with the 5.4L engine

    6.  
    7. Apply a bead of silicone gasket and sealant at the engine front cover-to-cylinder block surface, at the locations shown.
      NOTE
      Be sure to tighten the bolts in two stages.



      Click image to see an enlarged view

      Fig. Apply a bead of silicone gasket and sealant at the engine front cover-to-cylinder block surface-2005 Excursion models with the 5.4L engine

    8.  
    9. Tighten the bolts in the sequence shown:
      1. Step 1: Tighten to 15 ft. lbs. (20 Nm).
      2.  
      3. Step 2: Tighten an additional 90 degrees.

        Click image to see an enlarged view

        Fig. Oil pan torque sequence-2005 Excursion models with the 5.4L engine

      4.  

    10.  
    11. Lower the transmission.
    12.  
    13. Remove the transmission jack.
    14.  
    15. Install the flywheel inspection plate. Tighten to 25 ft. lbs. (34 Nm).
    16.  
    17. Install the oil bypass filter.
    18.  
    19. Align the engine mount studs and lower the engine, using the engine support.
    20.  
    21. Remove the engine support.
    22.  
    23. Install the engine mount nuts. Tighten to 66 ft. lbs. (99 Nm).
    24.  
    25. Install a suitable transmission jack and support the transmission.
    26.  
    27. Remove the crossmember bolts.
    28.  
    29. Remove the transmission mount nuts and the crossmember.
    30.  
    31. Install the TSS or the OSS sensor in the transmission.
    32.  
    33. Position the exhaust Y-pipe and install the nuts on the exhaust manifold studs. Tighten to 30 ft. lbs. (40 Nm).
    34.  
    35. Install the exhaust Y-pipe flange nuts.
    36.  
    37. Connect the oxygen sensor electrical connectors.
    38.  
    39. Remove the modular engine support bracket from the engine.
      CAUTION
      The large clutch assembly nut has a right-handed thread and must be rotated counterclockwise to remove it.

    40.  
    41. Using the tools used for removal, install the fan and fan clutch to the coolant pump pulley. Tighten to 41 ft. lbs. (55 Nm).
    42.  
    43. Install the alternator.
    44.  
    45. Install the throttle body adapter using a new throttle body adapter gasket.
    46.  
    47. If equipped, connect the EGR vacuum regulator solenoid electrical and vacuum connections.
    48.  
    49. If equipped, connect the EGR valve vacuum hose.
    50.  
    51. If equipped, install the differential pressure feedback EGR system bracket.
    52.  
    53. If equipped, install the exhaust manifold to EGR valve tube as follows:
      1. Step 1: Hand-tighten the fittings.
      2.  
      3. Step 2: Tighten the upper fitting to 37 ft. lbs. (50 Nm).
      4.  
      5. Step 3: Tighten the lower fitting to 37 ft. lbs. (50 Nm).
      6.  

    54.  
    55. If equipped, connect the differential pressure feedback EGR system vacuum lines.
    56.  
    57. If equipped, connect the differential pressure feedback EGR system electrical connector.
    58.  
    59. Connect the TP sensor electrical connector.
    60.  
    61. Connect the IAC electrical connector.
    62.  
    63. Install the IAC fresh air tube and insert it in the routing clip.
    64.  
    65. Install the accelerator cable bracket.
    66.  
    67. Position the bracket and cables.
    68.  
    69. Connect the throttle body cam.
    70.  
    71. Connect the accelerator cable.
    72.  
    73. If equipped, connect the speed control cable.
    74.  
    75. Install the throttle return spring.
    76.  
    77. Install the accelerator cable snow shield.
    78.  
    79. Install the air cleaner outlet pipe.
    80.  
    81. Connect the negative battery cable.
      CAUTION
      The oil pump must be primed prior to starting the engine.

    82.  
    83. Fill the engine with clean engine oil.
    84.  

    6.0L Engine
    1. Before servicing the vehicle, refer to the precautions section.
    2.  
    3. With the vehicle in NEUTRAL, position it on a hoist.
    4.  
    5. Disconnect the negative battery cable.
      WARNING
      Never remove the pressure relief cap while the engine is operating or when the cooling system is hot. Failure to follow these instructions can result in damage to the cooling system or engine or result in personal injury. To avoid having scalding hot coolant or steam blow out of the degas bottle when removing the pressure relief cap, wait until the engine has cooled then wrap a thick cloth around the pressure relief cap and turn it slowly. Step back while the pressure is released from the cooling system. When certain all the pressure has been released, (still with a cloth) turn and remove the pressure relief cap. Failure to follow these instructions can result in personal injury.


      CAUTION
      The coolant must be removed in a suitable, clean container for reuse. If the coolant is contaminated, it must be recycled or disposed of correctly and the system filled with new coolant.


      NOTE
      Less than 80% of coolant capacity can be recovered with the engine in the vehicle. Dirty, rusty, or contaminated coolant requires replacement.

    6.  
    7. Place a suitable container below the radiator draincock. If equipped, disconnect the coolant return hose at the fluid cooler.
    8.  
    9. Remove the fill cap from the degas bottle.
    10.  
    11. Remove the oil pan drain plug and drain the engine oil.
    12.  
    13. Loosen the exhaust pipe retaining nuts.
    14.  
    15. Remove the motor mount retaining nuts.
    16.  
    17. Open the radiator draincock.
    18.  
    19. Disconnect the lower radiator hose.
    20.  
    21. Disconnect the transmission cooler tubes.
    22.  
    23. Remove the air cleaner assembly.
    24.  
    25. On vehicles with metal ducts, remove the charge air cooler duct.
      NOTE
      Charge air cooler side shown, engine side similar.

    26.  
    27. On vehicles with blow molded ducts, loosen the clamps and remove the charge air cooler duct.
    28.  
    29. Remove the radiator support brackets.
    30.  
    31. Remove the 4 pin-type retainers and pull back the sight shield.
    32.  
    33. With the sight shield pulled back, remove the 3 pin-type retainers and the 2 wiring retainers and position the harness rearward out of the way.
    34.  
    35. Disconnect the upper radiator hose and the radiator overflow hose.
    36.  
    37. Remove the radiator and shroud as an assembly.
    38.  
    39. Disconnect the cooling fan electrical connector. Unclip and position the fan and wiring aside.
      NOTE
      Use a hole in the fan hub to prevent the fan from turning.

    40.  
    41. Using the special tool 303-591, loosen the fan clutch. Remove the cooling fan.
    42.  
    43. Remove the bolts from the stator, remove the stator.
    44.  
    45. On vehicles with dual alternator perform the following:
      1. Remove the secondary accessory drive belt.
      2.  
      3. Remove the bolt and the secondary accessory drive belt tensioner.
      4.  
      5. Remove the primary accessory drive belt.
      6.  
      7. Remove the bolts, bracket and secondary accessory drive belt idler pulley.
      8.  
      9. Remove the bolts and the primary accessory drive belt tensioner.
      10.  
      11. Disconnect the wire retainer, secondary generator electrical connector and B+ wire.
      12.  
      13. Remove the bolts and the secondary generator with mounting bracket.
      14.  

    46.  
    47. On vehicles with single alternator, remove the primary accessory drive belt.
    48.  
    49. Remove the bolts and position the alternator back.
    50.  
    51. Support the hood and disconnect the hood lift assemblies.
    52.  
    53. Install two lifting eyes 303-D030 on the right hand cylinder head.
    54.  
    55. Remove the retaining bolt for the fuel lines.
    56.  
    57. Disconnect the heater hose at the coolant pump.
    58.  
    59. Remove the fan shroud mounting stud.
    60.  
    61. Install one lifting eye 303-D030 on the left hand cylinder head.
      CAUTION
      Do not use the special tool to raise the engine. Damage to the special tool or vehicle may occur.


      NOTE
      The ball studs may have to be removed.


      NOTE
      This procedure requires a second bolt hook assembly. The tools are available through Rotunda tools with the following numbers: bolt hook 303-F070-6, handle 303-F070-8, bracket 303-F070-7 and washer 303-F070-12004.

    62.  
    63. Install the special tool.
      NOTE
      The engine must be raised evenly.

    64.  
    65. Using a lifting crane, raise the engine until the turbo charger is about to touch the cowl. Secure the engine with the special tool.
    66.  
    67. Remove the transmission cooler line bracket.
    68.  
    69. Remove the bolts and position back the oil pan until the oil pick-up tube bolts are accessible.
    70.  
    71. Remove the bolts and let the oil pick-up tube go into the oil pan. Remove the oil pan.
    72.  
    73. Remove the press-in-place gasket and discard.
    74.  
    75. Clean and inspect the sealing surfaces.
    76.  
    77. Remove and discard the oil pick-up tube O-ring.
    78.  

    To install:

    1. Install a new O-ring on the oil pick-up tube and position the oil pick-up tube in the oil pan.
    2.  
    3. Install a new press-in-place gasket into the upper oil pan.
    4.  
    5. Position the oil pan in the vehicle.
    6.  
    7. Install the oil pick-up tube and bolts. Tighten to 10 ft. lbs. (13 Nm).
    8.  
    9. Position the oil pan and install the bolts. Tighten to 10 ft. lbs. (13 Nm).
    10.  
    11. Install the transmission cooler tube bracket and nut. Tighten to 18 inch lbs. (10 Nm).
    12.  
    13. Using the special tool 303-F070, lower the engine.
    14.  
    15. Remove the lifting eyes 303-D030 and the special tool.
    16.  
    17. Install the fan shroud mounting stud. Tighten to 30 ft. lbs. (40 Nm).
    18.  
    19. Connect the heater hose at the coolant pump.
    20.  
    21. Install the retaining bolt for the fuel lines. Tighten to 10 ft. lbs. (10 Nm).
    22.  
    23. If removed, install the ball studs.
    24.  
    25. Connect the hood lifts and remove the hood support.
    26.  
    27. Position the primary alternator and install the bolts.
    28.  
    29. On a vehicle with a single alternator, install the primary accessory drive belt.
    30.  
    31. On vehicles with dual alternators, perform the following:
      1. Install the secondary alternator with mounting bracket and bolts. Tighten to 35 ft. lbs. (47 Nm).
      2.  
      3. Connect the B+ wire, secondary generator electrical connector and wire retainer.
      4.  
      5. Install the primary accessory drive belt tensioner and bolts. Tighten to 18 ft. lbs. (25 Nm).
      6.  
      7. Position the secondary accessory drive belt idler pulley. Install the bracket and bolts. Tighten to 18 ft. lbs. (25 Nm).
      8.  
      9. Install the primary accessory drive belt.
      10.  
      11. Install the secondary accessory drive belt tensioner and bolt. Tighten to 18 ft. lbs. (25 Nm).
      12.  
      13. Install the secondary accessory drive belt.
      14.  

    32.  
    33. Install the stator and stator bolts. Tighten to 30 ft. lbs. (40 Nm).
    34.  
    35. Install the cooling fan clutch. Use the special tool 303-591 to tighten the cooling fan clutch. Tighten to 98 ft. lbs. (133 Nm).
    36.  
    37. Position and clip the cooling fan wiring. Connect the cooling fan electrical connector.
    38.  
    39. Install the radiator and shroud as an assembly.
    40.  
    41. Connect the upper radiator hose and the radiator overflow hose.
    42.  
    43. Position the harness wiring, install the 2 wiring retainers and 3 pin-type retainers.
    44.  
    45. Position the sight shield and install the 4 pin-type retainers.
    46.  
    47. Install the radiator support brackets. Tighten to 22 ft. lbs. (30 Nm).
    48.  
    49. On vehicles with metal ducts, install the charge air cooler duct and tighten the clamps.
    50.  
    51. On vehicles with blow molded ducts, install the charge air cooler duct and tighten the clamps.
    52.  
    53. Install the air cleaner assembly.
    54.  
    55. Connect the transmission cooler tubes. Tighten to the specifications illustrated.

      Click image to see an enlarged view

      Fig. Connect the transmission cooler tubes. Tighten to the specifications illustrated-6.0L engine

    56.  
    57. Close the radiator draincock. Connect the lower radiator hose.
    58.  
    59. Install the motor mount retaining nuts. Tighten to 76 ft. lbs. (103 Nm).
    60.  
    61. Tighten the exhaust pipe retaining nuts to 35 ft. lbs. (47 Nm).
    62.  
    63. Clean and inspect the oil pan drain plug and gasket, install new if necessary.
    64.  
    65. Install the oil pan drain plug and tighten to 18 ft. lbs. (25 Nm).
    66.  
    67. Connect the negative battery cables.
    68.  
    69. Fill the engine with clean engine oil.
    70.  
    71. Fill the coolant system.
    72.  
    73. Run the engine and check for leaks
    74.  

    6.8L Engine

    CAUTION
    Fuel injection systems remain under pressure, even after the engine has been turned OFF. The fuel system pressure must be relieved before disconnecting any fuel lines. Failure to do so may result in fire and/or personal injury.

    1. Before servicing the vehicle, refer to the precautions section.
    2.  
    3. Remove or disconnect the following:

      Negative battery cable
       
      Fuel system pressure
       
      Coolant
       
      Upper radiator hose from the intake manifold
       
      Air cleaner outlet tube
       
      Accelerator cable from the bracket and the throttle body cam
       
      Speed control actuator cable from the throttle body
       
      All vacuum hoses, fuel lines and electrical wires from the throttle body and intake manifold
       
      Brake booster vacuum hose bracket
       
      EGR valve-to-exhaust manifold tube and disconnect the vacuum line
       
      Connector and vacuum line from the Engine Vacuum Regulator (EVR) solenoid
       
      The 4 bolts and the throttle body adapter
       
      Upper fan shroud mounting screws and position the shroud toward the engine.
       
      The alternator and install the Modular Engine Support Bracket on the engine using the mounting holes.
       
      Lower engine mount-to-frame nuts
       
      Turbine Shaft Speed (TSS) and Output Shaft Speed (OSS) sensors from the transmission. Plug the openings.
       

    4.  
    5. Lower the vehicle to the floor and raise the engine using a hoist attached to the support bracket.
    6.  
    7. Install an engine support fixture with a J hook to keep the engine raised, then remove the hoist.
    8.  
    9. Remove or disconnect the following:

      Engine oil and filter
       
      Dual converter Y-pipe and the flywheel inspection cover
       
      Driveshaft and the 2 transmission mounting nuts
       
      Transmission. Be sure to support the transmission along the rails of the pan to avoid damage.
       
      Oil pan mounting bolts and partially lower the pan
       
      Oil pump pick-up tube and screen assembly and allow it to drop into the pan
       
      Oil pan towards the rear of the vehicle

      Click image to see an enlarged view

      Fig. Oil pump pick-up tube and screen assembly-6.8L engine

       

    10.  

    To install:


    WARNING
    To prevent possible oil leaks, use only a plastic scraper to clean the oil pan mounting surface.

    1. Clean the oil pan-to-engine mounting surface.
    2.  
    3. Place the oil pump pick-up tube and screen assembly in the oil pan, then position the pan and gasket near the engine.
    4.  
    5. Install the oil pump pick-up tube and screen assembly.
      1. Tighten the nut to 15-22 ft. lbs. (20-30 Nm).
      2.  
      3. Tighten the 2 bolts to 71-106 inch lbs. (8-12 Nm).
      4.  

    6.  
    7. Apply a bead of silicone sealant to the areas where the front cover and rear bearing cap meet the engine block.

      Click image to see an enlarged view

      Fig. To prevent leaks, tighten the oil pan bolts in the order shown-2001-02 6.8L engine

    8.  
    9. Install the oil pan. Tighten the bolts in sequence using 3 steps as follows:

      18 inch lbs. (2 Nm)
       
      15 ft. lbs. (20 Nm)
       
      Plus an additional 90°
       

    10.  
    11. Lower the transmission and install the 2 mounting nuts. Tighten the nuts to 60-80 ft. lbs. (81-108 Nm).
    12.  
    13. Install the driveshaft and the TSS and OSS sensors.
    14.  
    15. Install the flywheel cover and dual converter Y-pipe.
    16.  
    17. Install the oil bypass filter.
    18.  
    19. Lower the vehicle and remove the engine support fixture.
    20.  
    21. Install the engine mounting nuts. Tighten the nuts to 66 ft. lbs. (90 Nm).
    22.  
    23. Remove the modular engine support bracket and install the alternator.
    24.  
    25. Install the fan shroud.
    26.  
    27. Use a new gasket and install the throttle body adapter.
    28.  
    29. Tighten the bolts in 2 steps:

      71-88 inch lbs. (8-10 Nm)
       
      85-95 degrees
       

    30.  
    31. Connect the EVR solenoid harness and vacuum line.
    32.  
    33. Attach the vacuum line to the EGR valve.
    34.  
    35. Install the EGR valve-to-exhaust manifold tube. Tighten the fittings to 41 ft. lbs. (55 Nm).
    36.  
    37. Install the EGR transducer.
    38.  
    39. Install all remaining components in the reverse of the removal.
      WARNING
      Operating the engine without the proper amount and type of engine oil will result in severe engine damage.

    40.  
    41. Fill the engine with SAE 5W30 oil.
    42.  
    43. Fill and bleed the cooling system.
    44.  

    1. Before servicing the vehicle, refer to the precautions section.
    2.  
    3. Disconnect the negative battery cable.
    4.  
    5. Remove the air cleaner outlet tube.
    6.  
    7. Remove the accelerator cable splash shield.
    8.  
    9. Disconnect the accelerator and speed control cables and return spring.
    10.  
    11. Position the accelerator cable bracket aside.
    12.  
    13. Disconnect the Positive Crankcase Ventilation (PCV) tube and the vacuum hoses.
    14.  
    15. Disconnect the vacuum hose.
    16.  
    17. Disconnect the Throttle Position (TP) sensor electrical connector.
    18.  
    19. Disconnect the Idle Air Control (IAC) motor electrical connector and the bypass hose.
    20.  
    21. Remove the bypass hose routing clip.
    22.  
    23. Position aside the throttle body adapter. Discard the throttle body adapter gasket.
      CAUTION
      The large clutch assembly nut has a right-hand thread and must be rotated counterclockwise to remove it.

    24.  
    25. Using the tools shown, remove the fan and fan clutch from the coolant pump pulley.

      Click image to see an enlarged view

      Fig. Using tools shown, remove the fan and fan clutch from the coolant pump pulley-2005 Excursion models with the 6.8L engine

    26.  
    27. Remove the alternator.
    28.  
    29. Install the tool 303-639 on the engine, using the alternator mounting holes.
    30.  
    31. Remove the engine mount nuts.
      CAUTION
      Damage to the TSS/OSS may occur and cause the transmission or torque converter operational concerns if the transmission is raised prior to removing TSS/OSS.


      CAUTION
      Sensor bosses must be cleaned prior to removal and then plugged to prevent contamination from damaging internal components.

    32.  
    33. Remove the Turbine Shaft Speed (TSS) or Output Shaft Sensors (OSS), and install plugs in the transmission.
    34.  
    35. Loosely install the transmission mount nuts and the crossmember.
    36.  
    37. Loosely install the crossmember bolts.
    38.  
    39. Loosely install the crossmember bolts.
    40.  
    41. Remove the jack assembly supporting the transmission.
    42.  
    43. Raise the engine, using support tool 303-F070.
    44.  
    45. Drain the engine oil and remove the oil bypass filter.
    46.  
    47. Remove the threaded insert and position the oil cooler aside.
    48.  
    49. Disconnect the Heated Oxygen (HO 2 S) sensor electrical connectors.
    50.  
    51. Remove the exhaust Y-pipe flange nuts.
    52.  
    53. Remove the nuts and the exhaust Y-pipe.
    54.  
    55. Remove the flywheel inspection plate.
      CAUTION
      Support the transmission on the oil pan rails only or internal transmission damage can occur.

    56.  
    57. Support the transmission with a transmission jack.
    58.  
    59. Remove the transmission mount nuts.
    60.  
    61. Using the transmission jack, raise the transmission.
    62.  
    63. Remove the nut and detach the transmission cooling tube bracket.
    64.  
    65. Remove the bolts and partially lower the oil pan.
    66.  
    67. Remove the bolts retaining the oil pump screen cover and pickup tube.
    68.  
    69. Remove the pickup tube and spacer and let them drop into the oil pan
    70.  
    71. Remove the oil pan and the oil pan gasket from the rear of the engine.
      CAUTION
      Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surface. These tools cause scratches and gouges, which make leak paths. Use a plastic scraping tool to remove all traces of sealant.

    72.  
    73. Clean the mating surfaces and thoroughly clean the oil pan.
    74.  

    To install:

    1. Clean and inspect the oil pump screen cover and tube mating surfaces and install a new O-ring. Lubricate the O-ring with clean engine oil.
      NOTE
      The oil pump screen and pickup tube must be in the oil pan when the oil pan is positioned in the vehicle.

    2.  
    3. Position the oil pan gasket and the oil pan in the vehicle from the rear of the engine.
    4.  
    5. Install the oil pump screen and pickup tube.
      NOTE
      If not secure within four minutes, the sealant must be removed and the sealing area cleaned.

    6.  
    7. Apply a bead of silicone gasket and sealant where the front cover and rear crankshaft seal retainer fit to the engine block.
      NOTE
      Be sure to tighten the bolts in two stages.

    8.  
    9. Tighten the oil pan bolts in the sequence shown:
      1. Step 1: Tighten to 15 ft. lbs. (20 Nm).
      2.  
      3. Step 2: Tighten an additional 90 degrees.

        Click image to see an enlarged view

        Fig. Oil pan bolt torque sequence-2005 Excursion models with the 6.8L engine

      4.  

    10.  
    11. Attach the transmission cooling tube bracket and install the nut. Tighten to 18 ft. lbs. (25 Nm).
    12.  
    13. Lower the transmission.
    14.  
    15. Loosely install the transmission mount nuts.
    16.  
    17. Install the flywheel inspection plate. Tighten to 25 ft. lbs. (34 Nm).
    18.  
    19. Position the engine oil cooler adapter and install the threaded insert. Tighten to 43 ft. lbs. (58 Nm).
    20.  
    21. Install the oil bypass filter.
    22.  
    23. Align the engine mount studs and lower the engine.
    24.  
    25. Remove the engine support.
    26.  
    27. Install the engine mount nuts. Tighten to 66 ft. lbs. (90 Nm).
    28.  
    29. Install a suitable transmission jack and support the transmission.
    30.  
    31. Remove the crossmember bolts.
    32.  
    33. Remove the crossmember bolts.
    34.  
    35. Remove the transmission mount nuts and the crossmember.
    36.  
    37. Install the TSS or turbine/OSS sensors in the transmission.
    38.  
    39. Position the exhaust Y-pipe and install the nuts on the exhaust manifold studs. Tighten to 30 ft. lbs. (40 Nm).
    40.  
    41. Install the exhaust Y-pipe flange nuts.
    42.  
    43. Connect the oxygen sensor electrical connectors.
      CAUTION
      The large clutch assembly nut has a right-hand thread and must be rotated clockwise to install it.

    44.  
    45. Using the tools used during removal, install the fan and fan clutch to the coolant pump pulley. Tighten to 98 ft. lbs. (133 Nm).
    46.  
    47. Install the alternator.
    48.  
    49. Position the throttle body adapter with a new gasket.
    50.  
    51. Install the four bolts and tighten in two steps.:
      1. Step 1: Tighten to 80 inch lbs. (9 Nm).
      2.  
      3. Step 2: Tighten an additional 90 degrees.
      4.  

    52.  
    53. Connect the IAC electrical connector and the bypass hose.
    54.  
    55. Install the bypass hose routing clip.
    56.  
    57. Connect the vacuum hose.
    58.  
    59. Connect the PCV tube and the vacuum hoses.
    60.  
    61. Connect the TP sensor electrical connector.
    62.  
    63. Install the accelerator cable bracket.
    64.  
    65. Position the bracket and cables.
    66.  
    67. Connect the accelerator and speed control cables and return spring.
    68.  
    69. Install the accelerator cable splash shield.
    70.  
    71. Install the air cleaner outlet tube.
    72.  
    73. Connect the negative battery cable.
      CAUTION
      The oil pump must be primed prior to starting the engine.

    74.  
    75. Fill the engine with clean engine oil.
    76.  


    CAUTION
    Fuel injection systems remain under pressure, even after the engine has been turned OFF . The fuel system pressure must be relieved before disconnecting any fuel lines. Failure to do so may result in fire and/or personal injury.

    1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
    2.  
    3. Remove or disconnect the following:

      Negative battery cable
       
      Fuel system pressure
       
      Coolant
       
      Upper radiator hose from the intake manifold
       
      Air cleaner outlet tube
       
      Accelerator cable from the bracket and the throttle body cam
       
      Speed control actuator cable from the throttle body
       
      All vacuum hoses, fuel lines and electrical wires from the throttle body and intake manifold
       
      Brake booster vacuum hose bracket
       
      Exhaust Gas Recirculation (EGR) valve-to-exhaust manifold tube and disconnect the vacuum line
       
      Connector and vacuum line from the Engine Vacuum Regulator (EVR) solenoid
       
      The 4 bolts and the throttle body adapter
       
      Upper fan shroud mounting screws and position the shroud toward the engine
       
      The alternator and install the Modular Engine Support Bracket on the engine using the mounting holes
       
      Lower engine mount-to-frame nuts
       
      Turbine Shaft Speed (TSS) and Output Shaft Speed (OSS) sensors from the transmission. Plug the openings.
       

    4.  
    5. Lower the vehicle to the floor and raise the engine using a hoist attached to the support bracket.
    6.  
    7. Install an engine support fixture with a J hook to keep the engine raised, then remove the hoist.
    8.  
    9. Remove or disconnect the following:

      Engine oil and filter
       
      Dual converter Y-pipe and the flywheel inspection cover
       
      Driveshaft and the 2 transmission mounting nuts
       
      Transmission. Be sure to support the transmission along the rails of the pan to avoid damage.
       
      Oil pan mounting bolts and partially lower the pan
       
      Oil pump pick-up tube and screen assembly and allow it to drop into the pan.
       
      Oil pan towards the rear of the vehicle

      Click image to see an enlarged view

      Fig. Oil pump pick-up tube and screen assembly-6.8L engine

       

    10.  

    To install:


    WARNING
    To prevent possible oil leaks, use only a plastic scraper to clean the oil pan mounting surface.

    1. Clean the oil pan-to-engine mounting surface.
    2.  
    3. Place the oil pump pick-up tube and screen assembly in the oil pan, then position the pan and gasket near the engine.
    4.  
    5. Install the oil pump pick-up tube and screen assembly.
    6.  
    7. Tighten the nut to 15-22 ft. lbs. (20-30 Nm).
    8.  
    9. Tighten the 2 bolts to 71-106 inch lbs. (8-12 Nm).
    10.  
    11. Apply a bead of silicone sealant to the areas where the front cover and rear bearing cap meet the engine block.

      Click image to see an enlarged view

      Fig. To prevent leaks, tighten the oil pan bolts in the order shown-6.8L engine

    12.  
    13. Install the oil pan. Tighten the bolts in sequence using 3 steps as follows:
      1. Step 1: 18 inch lbs. (2 Nm).
      2.  
      3. Step 2: 15 ft. lbs. (20 Nm).
      4.  
      5. Step 3: plus an additional 60 degrees.
      6.  

    14.  
    15. Lower the transmission and install the 2 mounting nuts. Tighten the nuts to 60-80 ft. lbs. (81-108 Nm).
    16.  
    17. Install or connect the following:

      Driveshaft and the TSS and OSS sensors
       
      Flywheel cover and dual converter Y-pipe
       
      Oil bypass filter
       

    18.  
    19. Lower the vehicle and remove the engine support fixture.

      Engine mounting nuts. Tighten the nuts to 66 ft. lbs. (90 Nm).
       

    20.  
    21. Remove the modular engine support bracket and install the alternator.

      Fan shroud.
       
      Throttle body adapter using a new gasket
       

    22.  
    23. Tighten the bolts in 2 steps:
      1. Step 1: 71-88 inch lbs. (8-10 Nm).
      2.  
      3. Step 2: 85-95 degrees.
      4.  

    24.  
    25. Install or connect the following:
      WARNING
      Operating the engine without the proper amount and type of engine oil will result in severe engine damage.



      EVR solenoid harness and vacuum line
       
      Vacuum line to the EGR valve
       
      EGR valve-to-exhaust manifold tube. Tighten the fittings to 55 ft. lbs. (41 Nm).
       
      EGR transducer
       
      All remaining components in the reverse of the removal
       

    26.  
    27. Fill the engine with SAE 5W30 oil.
    28.  
    29. Fill and bleed the cooling system.
    30.  

    7.3L Diesel Engines
    1. Before servicing the vehicle, refer to the precautions section.
    2.  
    3. Remove the engine.
    4.  
    5. Remove the oil pan bolts.
    6.  
    7. Lower the oil pan.
      NOTE
      The oil pan is sealed to the crankcase with RTV silicone sealant in place of a gasket. It may be necessary to separate the pan from the crankcase with a utility knife. Also, the crankshaft may have to be turned to allow the pan to clear the crankshaft throws.

    8.  
    9. Clean the pan and crankcase mating surfaces thoroughly.
    10.  

    To install:

    1. Apply a 1 / 8 in. (3mm) bead of RTV silicone sealant to the pan mating surfaces, and a 1 / 4 in. (6mm) bead on the front and rear covers and in the corners; you have 15 minutes within which to install the pan!
    2.  
    3. Install the locating dowels into position.
    4.  
    5. Position the pan on the engine and install the pan bolts loosely.
    6.  
    7. Remove the dowels.
    8.  
    9. Tighten the pan bolts to:

      1 / 4 in.-20 bolts: 84 inch lbs. (10 Nm)
       
      5 / 16 in.-18 bolts: 14 ft. lbs. (19 Nm)
       
      3 / 8 in.-16 bolts: 24 ft. lbs. (33 Nm)
       

    10.  
    11. Install the engine.
    12.  

    Except 6.8L Engine
    4x2 Models With DOHC Engines
    1. Before servicing the vehicle, refer to the precautions section.
    2.  
    3. Raise and safely support the vehicle.
    4.  
    5. Drain the oil.
    6.  
    7. Remove or disconnect the following:

      Intake manifold
       
      Fan shroud and the engine cooling fan
       
      Alternator
       

    8.  
    9. Install an engine support device.

      Two bolts from the engine mounts
       

    10.  
    11. Raise the engine 2.5 inches (63.5mm).
      NOTE
      Be careful when removing oil pan gasket. It is re-usable if not damaged.



      Bolts, oil pan and gasket
       

    12.  
    13. Inspect the oil pan gasket for damage.
    14.  

    To install:


    WARNING
    Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all traces of old sealant.

    1. Clean the oil pan mating surfaces.
      NOTE
      If the oil pan and the oil pan gasket are not secured within four minutes, the sealant must be removed and the sealing area cleaned with Metal Surface Cleaner F4AZ-19A536-RA. Allow to dry until there is no sign of wetness, or four minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.

    2.  
    3. Apply the silicone Gasket and Sealant F7AZ-19554-EA at the rear oil seal retainer-to-cylinder block sealing surface.
    4.  
    5. Install the oil pan gasket and the oil pan and loosely install the 16 bolts. Tighten the bolts in three steps, in the sequence illustrated as follows:
      1. Step 1: 18 inch lbs. (2 Nm).
      2.  
      3. Step 2: 15 ft. lbs. (20 Nm).
      4.  
      5. Step 3: an additional 60 degrees.

        Click image to see an enlarged view

        Fig. Tighten the oil pan bolts in the sequence shown

      6.  

    6.  
    7. Lower the vehicle, then the engine.
    8.  
    9. Remove the engine support
    10.  
    11. Install or connect the following:

      Two bolts for the engine mounts and tighten to 59 ft. lbs. (80 Nm)
       
      Alternator
       
      Cooling fan
       
      Lower intake manifold
       

    12.  
    13. Refill the engine crankcase with clean engine oil.
    14.  

    4x2 Models With SOHC Engines
    1. Before servicing the vehicle, refer to the precautions section.
    2.  
    3. Raise and safely support the vehicle.
    4.  
    5. Drain the oil and cooling system,
    6.  
    7. Remove or disconnect the following:

      Negative battery cable
       
      Radiator air deflector
       
      Accelerator cable snow shield
       
      Accelerator cable
       
      Speed control actuator cable
       
      Accelerator return spring
       
      Accelerator cable bracket bolts and position the bracket and cables aside
       
      Main vacuum harness
       
      Throttle Position (TP) sensor and engine vacuum regulator connectors
       
      Fuel pressure regulator vacuum line
       
      Vapor management valve vacuum line
       
      Differential pressure feedback Exhaust Gas Recirculation (EGR) connector
       
      Brake booster vacuum line and bracket
       
      Fuel lines
       
      Idle Air Control (IAC) motor electrical connector
       
      EGR valve-to-exhaust manifold tube aside
       
      Positive Crankcase Ventilation (PCV) hose
       
      Throttle body adapter
       
      Upper and lower power steering reservoir bolts and position the reservoir aside
       
      Fuel injector connections
       
      Ignition coils
       
      Alternator
       

    8.  
    9. Install an Engine Support Bracket on the engine using the alternator mounting bolts.

      Right and left hand motor mount bolts
       

    10.  
    11. Raise the engine using the Engine Support.
      NOTE
      Be careful when removing the oil pan gasket. The oil pan gasket is reusable if it is not damaged.



      Oil pan bolts and pan
       

    12.  
    13. Position the oil pan aside to gain access to the oil pump screen cover and tube .

      Bolt securing the rear of the oil pump screen cover and tube
       
      Bolts securing the front of the oil pump screen cover and tube
       

    14.  

    To install:


    WARNING
    Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all traces of old sealant.

    1. Clean and inspect the mating surfaces.
    2.  
    3. Install or connect the following:
      NOTE
      If the oil pan is not secured within four minutes, the sealant must be removed and the sealing area cleaned with Metal Surface Cleaner. Allow to dry until there is no sign of wetness, or four minutes, whichever is longer. Failure to follow this procedure may result in future oil leakage.



      Oil pan gasket, the oil pan and the oil pump screen cover and tube together to the cylinder block
       
      Bolts securing the front of the oil pump screen cover and tube and tighten to 71-107 inch lbs. (8-12 Nm)
       

    4.  
    5. Apply the silicone Gasket and Sealant F7AZ-19554-EA at the rear oil seal retainer-to-cylinder block sealing surface.
    6.  
    7. Install the oil pan gasket and the oil pan and loosely install the 16 bolts. Tighten the bolts in three steps, in the sequence illustrated as follows:
      1. Step 1: 18 inch lbs. (2 Nm).
      2.  
      3. Step 2: 15 ft. lbs. (20 Nm).
      4.  
      5. Step 3: an additional 60 degrees.
      6.  

    8.  
    9. Remove the Engine Support.

      Right and left hand motor mount bolts and tighten to 50-68 ft. lbs. (68-92 Nm)
       
      Alternator
       
      Fan shroud
       
      Throttle body adapter and the four bolts. Tighten the bolts to 89 inch lbs. (10 Nm).
       
      EGR valve-to-exhaust manifold tube
       
      All vacuum hoses, fuel lines and electrical connections
       
      Accelerator cable bracket and the bolts
       
      Accelerator cable, speed control actuator cable and the throttle return spring
       
      Accelerator cable snow shield and the bolts
       
      Upper radiator hose and position the clamp
       
      Air cleaner assembly
       
      Radiator air deflector
       
      Negative battery cable
       

    10.  
    11. Refill and bleed the cooling system.
    12.  
    13. Refill the engine crankcase with clean engine oil.
    14.  

    4x4 Models With DOHC Engines
    1. Before servicing the vehicle, refer to the precautions section.
    2.  
    3. Raise and safely support the vehicle.
    4.  
    5. Drain the oil.
    6.  
    7. Remove or disconnect the following:
      NOTE
      Be careful when removing oil pan gasket. It is re-usable if not damaged.



      Front drive axle assembly
       



      Bolts, oil pan and gasket
       

    8.  
    9. Inspect the oil pan gasket for damage.
    10.  

    To install:


    WARNING
    Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all traces of old sealant.

    1. Clean the oil pan mating surfaces.
      NOTE
      If the oil pan and the oil pan gasket are not secured within four minutes, the sealant must be removed and the sealing area cleaned with Metal Surface Cleaner F4AZ-19A536-RA. Allow to dry until there is no sign of wetness, or four minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.

    2.  
    3. Apply the silicone Gasket and Sealant F7AZ-19554-EA at the rear oil seal retainer-to-cylinder block sealing surface.
    4.  
    5. Install the oil pan gasket and the oil pan and loosely install the 16 bolts. Tighten the bolts in three steps, in the sequence illustrated as follows:
      1. Step 1: 18 inch lbs. (2 Nm).
      2.  
      3. Step 2: 15 ft. lbs. (20 Nm).
      4.  
      5. Step 3: an additional 60 degrees.
      6.  

    6.  
    7. Install the front drive axle assembly.
    8.  
    9. Refill the engine crankcase with clean engine oil.
    10.  

    4x4 Models With SOHC Engines
    1. Before servicing the vehicle, refer to the precautions section.
    2.  
    3. Raise and safely support the vehicle.
    4.  
    5. Drain the oil.
      CAUTION
      The air suspension switch must be turned off prior to raising the vehicle. Failure to do so can result in unexpected inflation or deflation of the air springs, which could result in shifting of the vehicle during the repair operation.

    6.  
    7. Turn the air suspension switch off.
    8.  
    9. Support the front axle housing with a jackstand.
    10.  
    11. Remove or disconnect the following:
      CAUTION
      Use care when lowering the front axle housing, or the vacuum lines to the axle solenoid may become disconnected or damaged.



      Negative battery cable
       
      Front axle mount bolt
       
      Front axle support bolts and the support
       



      Right and front axle housing mount bolts and lower the axle to allow clearance for the oil pan to be removed
       
      Oil pan and gasket
       

    12.  

    To install:


    WARNING
    Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all traces of old sealant.

    1. Clean the oil pan mating surfaces.
      NOTE
      If the oil pan and the oil pan gasket are not secured within four minutes, the sealant must be removed and the sealing area cleaned with Metal Surface Cleaner F4AZ-19A536-RA. Allow to dry until there is no sign of wetness, or four minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.

    2.  
    3. Apply the silicone Gasket and Sealant F7AZ-19554-EA at the rear oil seal retainer-to-cylinder block sealing surface.
    4.  
    5. Install or connect the following:

      New oil pan gasket and the oil pan and loosely install the bolts
       

    6.  
    7. Tighten the bolts in three steps in the sequence illustrated as follows:
      1. Step 1: 18 inch lbs. (2 Nm).
      2.  
      3. Step 2: 15 ft. lbs. (20 Nm).
      4.  
      5. Step 3: an additional 60 degrees.
      6.  

    8.  
    9. Install or connect the following:

      Front axle housing and loosely install the bolts
       
      Axle support and tighten the bolts to 56 ft. lbs. (90 Nm)
       

    10.  
    11. Refill the engine crankcase with clean engine oil.
    12.  
    13. Turn on the air suspension switch.
    14.  

     
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