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    1999 Mercedes Benz E320 3.2L MFI SOHC 6cyl

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    1720 S RIDGEWOOD A
    (386) 427-1210

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    Lincoln Blackwood, Ford F-Series Pick-ups, Lincoln Mark LT 2001-2006

    Removal & Installation

    Print

    2001-03 F-150; 2004 Heritage Edition



    1. Before servicing the vehicle, refer to the Precautions Section.
    2.  
    3. If equipped with power seats, move the seats fully rearward.
    4.  
    5. Disconnect the negative battery cable.
      CAUTION
      After disconnecting the negative battery cable, wait for 1 minute for the SRS module to deplete its energy.

    6.  
    7. Drain the cooling system into a clean container for reuse.
    8.  
    9. Remove the instrument panel by performing the following procedure:
      1. If equipped with automatic transmission, move the shift lever to the 1 position to ease removal.
      2.  
      3. At the lower driver-s side instrument panel, release the electrical connector push button clip and move the connector aside.
      4.  
      5. Remove the fuse panel door.
      6.  
      7. Remove the hood latch release handle screws and move the hood release handle aside.
      8.  
      9. Remove the parking brake release handle screws and move the parking brake release handle aside.
      10.  
      11. If equipped, remove the 2 instrument panel floor duct panel push clips and release the expander clip.
      12.  
      13. Remove the lower steering column cover bolts and the cover.
      14.  
      15. Remove both front door scuff plates.
      16.  
      17. Remove both side cowl trim panels.
      18.  
      19. Disconnect the electrical connector from the Brake Pedal Position (BPP) switch.
      20.  
      21. Remove the radio ground and the GEM/CTM ground bolts.
      22.  
      23. Disconnect the left side instrument panel main wiring harness connector.
      24.  
      25. In the engine compartment, remove the bulkhead wiring harness connector bolts and disconnect the wiring connectors.
      26.  
      27. In the engine compartment, release the 6 locking tabs and remove the bulkhead electrical connector from the instrument panel.
      28.  
      29. Disconnect the air bag diagnostic monitor electrical connector.
      30.  
      31. Disconnect the inertia fuel shutoff switch electrical connector.
      32.  
      33. Remove the right side ground bolts.
      34.  
      35. Disconnect the right side instrument panel wiring harness connectors.
      36.  
      37. Disconnect the electronic blend door actuator electrical connector.
      38.  
      39. Disconnect the climate control head vacuum harness connector.
      40.  
      41. Remove the steering column opening cover reinforcement nuts and the cover reinforcement.
      42.  
      43. At the base of the steering column, disconnect the air bag sliding contact and the anti-theft sensor electrical connectors.
      44.  
      45. At the steering column, disconnect the remaining electrical connectors.
      46.  
      47. If equipped with a transmission range indicator, remove the bolt and disconnect the cable.
      48.  
      49. Remove the steering column-to-instrument panel nuts and lower the steering column.
      50.  
      51. Remove and disconnect the radio.
      52.  
      53. Remove the instrument panel relay cover and disconnect the autolamp sensor electrical connector.
      54.  
      55. Remove the glove box.
      56.  
      57. At the passenger-s air bag module, remove the screws, disconnect the electrical connector and remove the air bag module.
      58.  

    10.  

    Place the air bag module in a safe place with the front facing upward.

    1. Remove the right side assist handle screw covers, the screws and the handle.
    2.  
    3. At both doors, pull back the weatherstrip seals and remove the windshield garnish moldings.
    4.  
    5. Remove the instrument panel reinforcement bolt below the left side corner of the glove box.
    6.  
    7. Through the air bag module opening, remove the instrument panel bolts.
    8.  
    9. Remove the upper instrument panel cowl covers and bolts.
    10.  
    11. At the relay bracket, remove the instrument panel bolt.
    12.  
    13. At the lower left side of the cigar lighter, remove the instrument panel bolt.
    14.  
    15. At the both sides, remove the instrument panel-to-cowl side nuts.
    16.  
    17. At the steering column opening, remove the instrument panel bolts.
    18.  
    19. Remove the upper instrument panel floor brace bolt.
    20.  
    21. Loosen the instrument panel brace bolts and nut.
    22.  
    23. Using an assistant, remove the instrument panel.
    24.  

    1. Compress the holding tabs and disconnect the heater hoses from the heater core.
    2.  
    3. Remove the air conditioning plenum screw and the air conditioning plenum demister adapter.
    4.  
    5. Disconnect the vacuum line.
    6.  
    7. Remove the heater core bracket screws and the bracket.
    8.  
    9. Remove the 13 heater housing plenum camber cover screws and the heater housing plenum chamber cover.
    10.  
    11. Remove the blend door assembly from the heater housing.
    12.  
    13. Remove the heater core.

      Click image to see an enlarged view

      Fig. Exploded view of the instrument panel components-2001-03 Ford F-150 and Blackwood; 2004 Heritage Edition



      Click image to see an enlarged view

      Fig. View of the heater core-2001-03 Ford F-150 and Blackwood; 2004 Heritage Edition

    14.  

    To install:

    1. Install the heater core.
    2.  
    3. Install the blend door assembly to the heater housing.
    4.  
    5. Install the 13 heater housing plenum camber cover and the heater housing plenum chamber cover screws.
    6.  
    7. Install the heater core bracket and the bracket screws.
    8.  
    9. Connect the vacuum line.
    10.  
    11. Install the air conditioning plenum demister adapter and the air conditioning plenum screw.
    12.  
    13. Connect the heater hoses to the heater core.
    14.  
    15. Install the instrument panel by performing the following procedure:
      1. Using an assistant, install the instrument panel.
      2.  
      3. Tighten the instrument panel brace bolts and nut.
      4.  
      5. Install the upper instrument panel floor brace bolt.
      6.  
      7. At the steering column opening, install the instrument panel bolts.
      8.  
      9. At the both sides, install the instrument panel-to-cowl side nuts.
      10.  
      11. At the lower left side of the cigar lighter, install the instrument panel bolt.
      12.  
      13. At the relay bracket, install the instrument panel bolt.
      14.  
      15. Install the upper instrument panel cowl bolts and covers.
      16.  
      17. Through the air bag module opening, install the instrument panel bolts.
      18.  
      19. Install the instrument panel reinforcement bolt below the left side corner of the glove box.
      20.  
      21. At both doors, install the windshield garnish moldings and the weatherstrip seals.
      22.  
      23. Install the right side assist handle, the screws and the handle screw covers.
      24.  
      25. At the passenger-s air bag module, connect the electrical connector and install the air bag module.
      26.  
      27. Install the glove box.
      28.  
      29. Install the instrument panel relay cover and connect the autolamp sensor electrical connector.
      30.  
      31. Install and connect the radio.
      32.  
      33. Install the steering column-to-instrument panel and the steering column nuts.
      34.  
      35. If equipped with a transmission range indicator, connect the cable and install the bolt.
      36.  
      37. At the steering column, connect the remaining electrical connectors.
      38.  
      39. At the base of the steering column, connect the air bag sliding contact and the anti-theft sensor electrical connectors.
      40.  
      41. Install the steering column opening cover reinforcement and the cover reinforcement nuts.
      42.  
      43. Connect the climate control head vacuum harness connector.
      44.  
      45. Connect the electronic blend door actuator electrical connector.
      46.  
      47. Connect the right side instrument panel wiring harness connectors.
      48.  
      49. Install the right side ground bolts.
      50.  
      51. Connect the inertia fuel shutoff switch electrical connector.
      52.  
      53. Connect the air bag diagnostic monitor electrical connector.
      54.  
      55. In the driver-s compartment, install the bulkhead electrical connector to the instrument panel.
      56.  
      57. In the engine compartment, install the bulkhead wiring harness connector bolts and connect the wiring connectors.
      58.  
      59. Connect the left side instrument panel main wiring harness connector.
      60.  
      61. Install the radio ground and the GEM/CTM ground bolts.
      62.  
      63. Connect the electrical connector to the Brake Pedal Position (BPP) switch.
      64.  
      65. Install both side cowl trim panels.
      66.  
      67. Install both front door scuff plates.
      68.  
      69. Install the lower steering column cover and the cover bolts.
      70.  
      71. If equipped, install the 2 instrument panel floor duct panel push clips and the expander clip.
      72.  
      73. Install the parking brake release handle and the parking brake release handle aside screws.
      74.  
      75. Install the hood latch release handle screws.
      76.  
      77. Install the fuse panel door.
      78.  
      79. At the lower driver-s side instrument panel, install the connectors.
      80.  

    16.  
    17. Refill the cooling system.
    18.  
    19. Connect the negative battery cable.
    20.  
    21. Run the engine to normal operating temperatures; then, check the climate control operation and check for leaks.
    22.  

    2001-03 F-250



    1. Before servicing the vehicle, refer to the Precautions Section.
    2.  
    3. If equipped with power seats, move the seats fully rearward.
    4.  
    5. Disconnect the negative battery cable.
      CAUTION
      After disconnecting the negative battery cable, wait for 1 minute for the SRS module to deplete its energy.

    6.  
    7. Drain the cooling system into a clean container for reuse.
    8.  
    9. Remove the instrument panel by performing the following procedure:
      1. If equipped with automatic transmission, move the shift lever to the 1 position to ease removal.
      2.  
      3. At the lower driver-s side instrument panel, release the electrical connector push button clip and move the connector aside.
      4.  
      5. Remove the fuse panel door.
      6.  
      7. Remove the hood latch release handle screws and move the hood release handle aside.
      8.  
      9. Remove the parking brake release handle screws and move the parking brake release handle aside.
      10.  
      11. If equipped, remove the 2 instrument panel floor duct panel push clips and release the expander clip.
      12.  
      13. Remove the lower steering column cover bolts and the cover.
      14.  
      15. Remove both front door scuff plates.
      16.  
      17. Remove both side cowl trim panels.
      18.  
      19. Disconnect the electrical connector from the Brake Pedal Position (BPP) switch.
      20.  
      21. Remove the radio ground and the GEM/CTM ground bolts.
      22.  
      23. Disconnect the left side instrument panel main wiring harness connector.
      24.  
      25. In the engine compartment, remove the bulkhead wiring harness connector bolts and disconnect the wiring connectors.
      26.  
      27. In the engine compartment, release the 6 locking tabs and remove the bulkhead electrical connector from the instrument panel.
      28.  
      29. Disconnect the air bag diagnostic monitor electrical connector.
      30.  
      31. Disconnect the inertia fuel shutoff switch electrical connector.
      32.  
      33. Remove the right side ground bolts.
      34.  
      35. Disconnect the right side instrument panel wiring harness connectors.
      36.  
      37. Disconnect the electronic blend door actuator electrical connector.
      38.  
      39. Disconnect the climate control head vacuum harness connector.
      40.  
      41. Remove the steering column opening cover reinforcement nuts and the cover reinforcement.
      42.  
      43. At the base of the steering column, disconnect the air bag sliding contact and the anti-theft sensor electrical connectors.
      44.  
      45. At the steering column, disconnect the remaining electrical connectors.
      46.  
      47. If equipped with a transmission range indicator, remove the bolt and disconnect the cable.
      48.  
      49. Remove the steering column-to-instrument panel nuts and lower the steering column.
      50.  
      51. Remove and disconnect the radio.
      52.  
      53. Remove the instrument panel relay cover and disconnect the autolamp sensor electrical connector.
      54.  
      55. Remove the glove box.
      56.  
      57. At the passenger-s air bag module, remove the screws, disconnect the electrical connector and remove the air bag module.
      58.  

    10.  

    Place the air bag module in a safe place with the front facing upward.

    1. Remove the right side assist handle screw covers, the screws and the handle.
    2.  
    3. At both doors, pull back the weatherstrip seals and remove the windshield garnish moldings.
    4.  
    5. Remove the instrument panel reinforcement bolt below the left side corner of the glove box.
    6.  
    7. Through the air bag module opening, remove the instrument panel bolts.
    8.  
    9. Remove the upper instrument panel cowl covers and bolts.
    10.  
    11. At the relay bracket, remove the instrument panel bolt.
    12.  
    13. At the lower left side of the cigar lighter, remove the instrument panel bolt.
    14.  
    15. At the both sides, remove the instrument panel-to-cowl side nuts.
    16.  
    17. At the steering column opening, remove the instrument panel bolts.
    18.  
    19. Remove the upper instrument panel floor brace bolt.
    20.  
    21. Loosen the instrument panel brace bolts and nut.
    22.  
    23. Using an assistant, remove the instrument panel.
    24.  

    1. Compress the holding tabs and disconnect the heater hoses from the heater core.
    2.  
    3. Remove the air conditioning plenum screw and the air conditioning plenum demister adapter.
    4.  
    5. Disconnect the vacuum line.
    6.  
    7. Remove the heater core bracket screws and the bracket.
    8.  
    9. Remove the 13 heater housing plenum camber cover screws and the heater housing plenum chamber cover.
    10.  
    11. Remove the blend door assembly from the heater housing.
    12.  
    13. Remove the heater core.

      Click image to see an enlarged view

      Fig. Exploded view of the instrument panel components-2001-03 F-250



      Click image to see an enlarged view

      Fig. Heater core removal-2001-03 F-250, 350

    14.  

    To install:

    1. Install the heater core.
    2.  
    3. Install the blend door assembly to the heater housing.
    4.  
    5. Install the 13 heater housing plenum camber cover and the heater housing plenum chamber cover screws.
    6.  
    7. Install the heater core bracket and the bracket screws.
    8.  
    9. Connect the vacuum line.
    10.  
    11. Install the air conditioning plenum demister adapter and the air conditioning plenum screw.
    12.  
    13. Connect the heater hoses to the heater core.
    14.  
    15. Install the instrument panel by performing the following procedure:
      1. Using an assistant, install the instrument panel.
      2.  
      3. Tighten the instrument panel brace bolts and nut.
      4.  
      5. Install the upper instrument panel floor brace bolt.
      6.  
      7. At the steering column opening, install the instrument panel bolts.
      8.  
      9. At the both sides, install the instrument panel-to-cowl side nuts.
      10.  
      11. At the lower left side of the cigar lighter, install the instrument panel bolt.
      12.  
      13. At the relay bracket, install the instrument panel bolt.
      14.  
      15. Install the upper instrument panel cowl bolts and covers.
      16.  
      17. Through the air bag module opening, install the instrument panel bolts.
      18.  
      19. Install the instrument panel reinforcement bolt below the left side corner of the glove box.
      20.  
      21. At both doors, install the windshield garnish moldings and the weatherstrip seals.
      22.  
      23. Install the right side assist handle, the screws and the handle screw covers.
      24.  
      25. At the passenger-s air bag module, connect the electrical connector and install the air bag module.
      26.  
      27. Install the glove box.
      28.  
      29. Install the instrument panel relay cover and connect the autolamp sensor electrical connector.
      30.  
      31. Install and connect the radio.
      32.  
      33. Install the steering column-to-instrument panel and the steering column nuts.
      34.  
      35. If equipped with a transmission range indicator, connect the cable and install the bolt.
      36.  
      37. At the steering column, connect the remaining electrical connectors.
      38.  
      39. At the base of the steering column, connect the air bag sliding contact and the anti-theft sensor electrical connectors.
      40.  
      41. Install the steering column opening cover reinforcement and the cover reinforcement nuts.
      42.  
      43. Connect the climate control head vacuum harness connector.
      44.  
      45. Connect the electronic blend door actuator electrical connector.
      46.  
      47. Connect the right side instrument panel wiring harness connectors.
      48.  
      49. Install the right side ground bolts.
      50.  
      51. Connect the inertia fuel shutoff switch electrical connector.
      52.  
      53. Connect the air bag diagnostic monitor electrical connector.
      54.  
      55. In the driver-s compartment, install the bulkhead electrical connector to the instrument panel.
      56.  
      57. In the engine compartment, install the bulkhead wiring harness connector bolts and connect the wiring connectors.
      58.  
      59. Connect the left side instrument panel main wiring harness connector.
      60.  
      61. Install the radio ground and the GEM/CTM ground bolts.
      62.  
      63. Connect the electrical connector to the Brake Pedal Position (BPP) switch.
      64.  
      65. Install both side cowl trim panels.
      66.  
      67. Install both front door scuff plates.
      68.  
      69. Install the lower steering column cover and the cover bolts.
      70.  
      71. If equipped, install the 2 instrument panel floor duct panel push clips and the expander clip.
      72.  
      73. Install the parking brake release handle and the parking brake release handle aside screws.
      74.  
      75. Install the hood latch release handle screws.
      76.  
      77. Install the fuse panel door.
      78.  
      79. At the lower driver-s side instrument panel, install the connectors.
      80.  

    16.  
    17. Refill the cooling system.
    18.  
    19. Connect the negative battery cable.
    20.  
    21. Run the engine to normal operating temperatures; then, check the climate control operation and check for leaks.
    22.  

    2001-03 F-350



    1. Before servicing the vehicle, refer to the Precautions Section.
    2.  
    3. If equipped with power seats, move the seats fully rearward.
    4.  
    5. Disconnect the negative battery cable.
      CAUTION
      After disconnecting the negative battery cable, wait for 1 minute for the SRS module to deplete its energy.

    6.  
    7. Drain the cooling system into a clean container for reuse.
    8.  
    9. Remove the instrument panel by performing the following procedure:
      1. If equipped with automatic transmission, move the shift lever to the 1 position to ease removal.
      2.  
      3. At the lower driver-s side instrument panel, release the electrical connector push button clip and move the connector aside.
      4.  
      5. Remove the fuse panel door.
      6.  
      7. Remove the hood latch release handle screws and move the hood release handle aside.
      8.  
      9. Remove the parking brake release handle screws and move the parking brake release handle aside.
      10.  
      11. If equipped, remove the 2 instrument panel floor duct panel push clips and release the expander clip.
      12.  
      13. Remove the lower steering column cover bolts and the cover.
      14.  
      15. Remove both front door scuff plates.
      16.  
      17. Remove both side cowl trim panels.
      18.  
      19. Disconnect the electrical connector from the Brake Pedal Position (BPP) switch.
      20.  
      21. Remove the radio ground and the GEM/CTM ground bolts.
      22.  
      23. Disconnect the left side instrument panel main wiring harness connector.
      24.  
      25. In the engine compartment, remove the bulkhead wiring harness connector bolts and disconnect the wiring connectors.
      26.  
      27. In the engine compartment, release the 6 locking tabs and remove the bulkhead electrical connector from the instrument panel.
      28.  
      29. Disconnect the air bag diagnostic monitor electrical connector.
      30.  
      31. Disconnect the inertia fuel shutoff switch electrical connector.
      32.  
      33. Remove the right side ground bolts.
      34.  
      35. Disconnect the right side instrument panel wiring harness connectors.
      36.  
      37. Disconnect the electronic blend door actuator electrical connector.
      38.  
      39. Disconnect the climate control head vacuum harness connector.
      40.  
      41. Remove the steering column opening cover reinforcement nuts and the cover reinforcement.
      42.  
      43. At the base of the steering column, disconnect the air bag sliding contact and the anti-theft sensor electrical connectors.
      44.  
      45. At the steering column, disconnect the remaining electrical connectors.
      46.  
      47. If equipped with a transmission range indicator, remove the bolt and disconnect the cable.
      48.  
      49. Remove the steering column-to-instrument panel nuts and lower the steering column.
      50.  
      51. Remove and disconnect the radio.
      52.  
      53. Remove the instrument panel relay cover and disconnect the autolamp sensor electrical connector.
      54.  
      55. Remove the glove box.
      56.  
      57. At the passenger-s air bag module, remove the screws, disconnect the electrical connector and remove the air bag module.
      58.  

    10.  

    Place the air bag module in a safe place with the front facing upward.

    1. Remove the right side assist handle screw covers, the screws and the handle.
    2.  
    3. At both doors, pull back the weatherstrip seals and remove the windshield garnish moldings.
    4.  
    5. Remove the instrument panel reinforcement bolt below the left side corner of the glove box.
    6.  
    7. Through the air bag module opening, remove the instrument panel bolts.
    8.  
    9. Remove the upper instrument panel cowl covers and bolts.
    10.  
    11. At the relay bracket, remove the instrument panel bolt.
    12.  
    13. At the lower left side of the cigar lighter, remove the instrument panel bolt.
    14.  
    15. At the both sides, remove the instrument panel-to-cowl side nuts.
    16.  
    17. At the steering column opening, remove the instrument panel bolts.
    18.  
    19. Remove the upper instrument panel floor brace bolt.
    20.  
    21. Loosen the instrument panel brace bolts and nut.
    22.  
    23. Using an assistant, remove the instrument panel.
    24.  

    1. Compress the holding tabs and disconnect the heater hoses from the heater core.
    2.  
    3. Remove the air conditioning plenum screw and the air conditioning plenum demister adapter.
    4.  
    5. Disconnect the vacuum line.
    6.  
    7. Remove the heater core bracket screws and the bracket.
    8.  
    9. Remove the 13 heater housing plenum camber cover screws and the heater housing plenum chamber cover.
    10.  
    11. Remove the blend door assembly from the heater housing.
    12.  
    13. Remove the heater core.

      Click image to see an enlarged view

      Fig. Instrument panel installation-2001-03 250HD, F-350 and F-Super Duty

    14.  

    To install:

    1. Install the heater core.
    2.  
    3. Install the blend door assembly to the heater housing.
    4.  
    5. Install the 13 heater housing plenum camber cover and the heater housing plenum chamber cover screws.
    6.  
    7. Install the heater core bracket and the bracket screws.
    8.  
    9. Connect the vacuum line.
    10.  
    11. Install the air conditioning plenum demister adapter and the air conditioning plenum screw.
    12.  
    13. Connect the heater hoses to the heater core.
    14.  
    15. Install the instrument panel by performing the following procedure:
      1. Using an assistant, install the instrument panel.
      2.  
      3. Tighten the instrument panel brace bolts and nut.
      4.  
      5. Install the upper instrument panel floor brace bolt.
      6.  
      7. At the steering column opening, install the instrument panel bolts.
      8.  
      9. At the both sides, install the instrument panel-to-cowl side nuts.
      10.  
      11. At the lower left side of the cigar lighter, install the instrument panel bolt.
      12.  
      13. At the relay bracket, install the instrument panel bolt.
      14.  
      15. Install the upper instrument panel cowl bolts and covers.
      16.  
      17. Through the air bag module opening, install the instrument panel bolts.
      18.  
      19. Install the instrument panel reinforcement bolt below the left side corner of the glove box.
      20.  
      21. At both doors, install the windshield garnish moldings and the weatherstrip seals.
      22.  
      23. Install the right side assist handle, the screws and the handle screw covers.
      24.  
      25. At the passenger-s air bag module, connect the electrical connector and install the air bag module.
      26.  
      27. Install the glove box.
      28.  
      29. Install the instrument panel relay cover and connect the autolamp sensor electrical connector.
      30.  
      31. Install and connect the radio.
      32.  
      33. Install the steering column-to-instrument panel and the steering column nuts.
      34.  
      35. If equipped with a transmission range indicator, connect the cable and install the bolt.
      36.  
      37. At the steering column, connect the remaining electrical connectors.
      38.  
      39. At the base of the steering column, connect the air bag sliding contact and the anti-theft sensor electrical connectors.
      40.  
      41. Install the steering column opening cover reinforcement and the cover reinforcement nuts.
      42.  
      43. Connect the climate control head vacuum harness connector.
      44.  
      45. Connect the electronic blend door actuator electrical connector.
      46.  
      47. Connect the right side instrument panel wiring harness connectors.
      48.  
      49. Install the right side ground bolts.
      50.  
      51. Connect the inertia fuel shutoff switch electrical connector.
      52.  
      53. Connect the air bag diagnostic monitor electrical connector.
      54.  
      55. In the driver-s compartment, install the bulkhead electrical connector to the instrument panel.
      56.  
      57. In the engine compartment, install the bulkhead wiring harness connector bolts and connect the wiring connectors.
      58.  
      59. Connect the left side instrument panel main wiring harness connector.
      60.  
      61. Install the radio ground and the GEM/CTM ground bolts.
      62.  
      63. Connect the electrical connector to the Brake Pedal Position (BPP) switch.
      64.  
      65. Install both side cowl trim panels.
      66.  
      67. Install both front door scuff plates.
      68.  
      69. Install the lower steering column cover and the cover bolts.
      70.  
      71. If equipped, install the 2 instrument panel floor duct panel push clips and the expander clip.
      72.  
      73. Install the parking brake release handle and the parking brake release handle aside screws.
      74.  
      75. Install the hood latch release handle screws.
      76.  
      77. Install the fuse panel door.
      78.  
      79. At the lower driver-s side instrument panel, install the connectors.
      80.  

    16.  
    17. Refill the cooling system.
    18.  
    19. Connect the negative battery cable.
    20.  
    21. Run the engine to normal operating temperatures; then, check the climate control operation and check for leaks.
    22.  

    2004 F-150, Exc. Heritage Edition



    1. Before servicing the vehicle, refer to the Precautions Section.
      NOTE
      Lubricate the coolant hoses with plain water only if needed.


      WARNING
      To reduce the risk of serious personal injury, read and follow all warnings, cautions, notes and instructions in the supplemental restraint system (SRS) deactivation/reactivation procedure.

    2.  
    3. Remove the driver and passenger air bag modules.
    4.  
    5. Remove the A-pillar trim panels and right cowl side trim panel.
    6.  
    7. If equipped with a floor console, remove the floor console.
    8.  
    9. Remove the steering column opening cover.
    10.  
    11. Remove the steering column lower cover.
    12.  
    13. Remove the steering column upper cover.
    14.  
    15. Remove the instrument panel center finish panel
    16.  
    17. Remove the instrument panel finish panel.
    18.  
    19. Parking brake release handle.
    20.  
    21. Remove the hood release handle.
    22.  
    23. Remove the electrical connectors.
    24.  
    25. Remove the center brace.
    26.  
    27. Remove the transmission range cable.
    28.  
    29. Remove the pinch bolt.
    30.  
    31. Remove the defrost grilles.
    32.  
    33. Remove the instrument panel bolt.
    34.  
    35. Remove the instrument panel.
      NOTE
      New O-ring seals, lubricated in clean mineral oil, must be installed before reconnecting any A/C fitting which has been disconnected.

    36.  
    37. Recover the refrigerant.
    38.  
    39. Remove the powertrain control module (PCM).
    40.  
    41. Remove the battery and battery tray.
    42.  
    43. Remove the PCM bracket.
    44.  
    45. Remove the heater hoses
    46.  
    47. Remove the heater/evaporator core housing nuts.
    48.  
    49. Remove the heater/evaporator core housing.
    50.  
    51. Discard the O-rings.
    52.  
    53. Remove the heater core.
    54.  
    55. To install, reverse the removal procedure.
    56.  
    57. Fill the engine cooling system.
    58.  

    2004-05 F-250 & 350



    1. Before servicing the vehicle, refer to the Precautions Section.
    2.  
    3. Clamp off and disconnect the heater water hoses from the heater core.
    4.  
    5. Disengage the stops and lower the glove compartment door.
      NOTE
      Do not attempt to bend any part of the panel/floor door lever. It is brittle and will break.

    6.  
    7. Remove the panel/floor door vacuum control motor.
    8.  
    9. Remove the electronic blend door actuator and bracket assembly.
    10.  
    11. Remove the core cover screws.
      NOTE
      The heater core cover must be raised vertically before removal to avoid damage to the heater core housing.



      Click image to see an enlarged view

      Fig. Remove the heater core cover-2004-05 F-250/350



      Click image to see an enlarged view

      Fig. Remove the heater core-2004-05 F-250/350

    12.  
    13. Raise the heater core cover.
    14.  
    15. Remove the heater core cover.
    16.  
    17. Remove the heater core.
      NOTE
      Position the temperature blend door manually to correctly align the actuator and the door. Do not power the actuator electrically. If it is not engaged with the temperature blend door, damage to the actuator can occur.


      NOTE
      Add gasket between housing and cover before installing cover.

    18.  
    19. To install, reverse the removal procedure.
    20.  
    21. Fill the engine cooling system.
    22.  

    2005 F-150 And 2006 Mark LT



    1. Before servicing the vehicle, refer to the Precautions Section.
    2.  
    3. If equipped with adjustable pedals, move the pedals to the full forward position.
    4.  
    5. If equipped with a floor console:
      1. Remove the 3 floor trim panel push pins.
      2.  
      3. Remove the 2 floor trim panels.
      4.  
      5. Remove the shifter trim panel.

        Click image to see an enlarged view

        Fig. Instrument panel exploded view-2005 F-150 and 2006 Mark LT



        Click image to see an enlarged view

        Fig. Heater/Evaporator housing-2005 F-150 and 2006 Mark LT



        Click image to see an enlarged view

        Fig. Floor console-2005 F-150 and 2006 Mark LT



        Click image to see an enlarged view

        Fig. Driver-s air bag module-2005 F-150 and 2006 Mark LT



        Click image to see an enlarged view

        Fig. Suction accumulator-2005 F-150 and 2006 Mark LT



        Click image to see an enlarged view

        Fig. Heater core removal-2005 F-150 and 2006 Mark LT



        Click image to see an enlarged view

        Fig. Clockspring-2005 F-150 and 2006 Mark LT

      6.  
      7. Disconnect the shifter cable.
      8.  
      9. Disconnect the floor console electrical connector.
      10.  
      11. Remove the 4 floor console bolts.
      12.  
      13. Remove the floor console.
        CAUTION
        To reduce the risk of serious personal injury, read and follow all warnings, cautions, notes and instructions in the supplemental restraint system (SRS) deactivation/reactivation procedure.

      14.  

    6.  
    7. De-power the supplemental restraint system (SRS). For additional information, refer to Steering.
    8.  
    9. Position the left and right door weatherstrip seals aside.
    10.  
    11. Remove the A-pillar trim panels and right cowl side trim panel.
    12.  
    13. Remove the left and right instrument panel side finish panels.
    14.  
    15. Remove the 2 steering column opening trim screws.
    16.  
    17. Remove the steering column opening trim.
      WARNING
      Removing the steering wheel without using a puller can damage the column bearings.


      WARNING
      Do not allow the steering column shaft to rotate while the intermediate shaft is disconnected or damage to the clockspring can result. If there is evidence that the shaft has rotated, the clockspring must be removed and re-centered.

    18.  
    19. Place the steering wheel in the straight-ahead position and turn the ignition switch to the OFF position.
      CAUTION
      Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment.


      CAUTION
      Carry a live air bag module with the air bag and trim cover pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment.


      CAUTION
      Do not set a live air bag module down with the trim cover face down. This will reduce the risk of injury in the event of an accidental deployment.


      CAUTION
      After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the gas generant combustion that is irritating to the skin. Wash your hands with soap and water afterwards.


      CAUTION
      Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury.


      CAUTION
      Air bag modules with discolored or damaged trim covers must be replaced, not repainted.


      CAUTION
      To reduce the risk of personal injury, do not use any memory saver devices.


      NOTE
      The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault.


      NOTE
      The SRS must be fully operational and free of faults before releasing the vehicle to the customer.


      NOTE
      Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again.

    20.  
    21. Remove the 2 steering wheel back cover plugs.
    22.  
    23. Remove the 2 driver-s air bag module bolts.
    24.  
    25. Partially remove the driver-s air bag module from the steering wheel.
      WARNING
      The clockspring electrical connectors are unique and cannot be reversed when connected to the driver-s air bag module. Match the electrical connector key to the keyway in the driver-s air bag module. Do not force the electrical connectors into the driver-s air bag module during installation.

    26.  
    27. Disconnect the driver-s air bag module electrical connectors.
    28.  
    29. Disconnect the horn switch electrical connector and remove the driver-s air bag module.
      NOTE
      Do not remove the bolt until the steering wheel has been separated from the column.

    30.  
    31. Loosen the steering wheel bolt.
    32.  
    33. Using a puller, separate the steering wheel from the steering column assembly.
    34.  
    35. Remove the steering wheel bolt and the steering wheel.
    36.  
    37. Remove the lower steering column cover screw.
    38.  
    39. Remove the lower steering column cover.
    40.  
    41. Remove the 2 upper steering column cover screws.
    42.  
    43. Remove the upper steering column cover.
    44.  
    45. Remove the instrument cluster finish panel.
    46.  
    47. Remove the instrument panel center finish panel.
    48.  
    49. Remove the instrument cluster center finish panel.
    50.  
    51. Remove the parking brake release handle bolt.
    52.  
    53. Position aside the parking brake release handle. Remove the parking brake release handle pin-type retainer.
    54.  
    55. Remove the hood release handle bolt.
    56.  
    57. Position aside the hood release handle.
    58.  
    59. Loosen the electrical connector screw and disconnect the bulkhead electrical connector.
    60.  
    61. Remove the ground bolt.
    62.  
    63. Disconnect the electrical connectors.
    64.  
    65. Position aside the front carpet.
    66.  
    67. Remove the 4 left center brace bolts.
    68.  
    69. Remove the left center brace.
    70.  
    71. If equipped, disconnect the transmission range indicator cable and position aside.
      WARNING
      To avoid damage to the clockspring, do not allow the steering column shaft to rotate while the intermediate shaft is disconnected.

    72.  
    73. Remove the steering column pinch bolt and disconnect the steering column intermediate shaft.
    74.  
    75. Disconnect the steering column electrical connector.
    76.  
    77. Remove the ground bolt.
    78.  
    79. Disconnect the radio antenna.
    80.  
    81. Disconnect the 4 PDB (B1, B2, L1 and L2) electrical connectors.
    82.  
    83. Disconnect the ETAC electrical connector.
    84.  
    85. Disconnect the instrument panel electrical connectors.
    86.  
    87. Position aside the front carpet.
    88.  
    89. Remove the 4 right center brace bolts.
    90.  
    91. Remove the right center brace.
      NOTE
      If equipped with a floor console, remove the third center brace.

    92.  
    93. If equipped, remove the 4 third center brace bolts.
    94.  
    95. If equipped, remove the third center brace.
    96.  
    97. Remove the 2 defrost grilles.
    98.  
    99. Disconnect the wiring harness pin-type retainer.
      WARNING
      To avoid damage to the instrument panel, an assistant is required to support the panel before carrying out this step.

    100.  
    101. Remove the 9 instrument panel bolts.
      WARNING
      Before removing the instrument panel, make sure all electrical connector wiring is free and not hindered.

    102.  
    103. Remove the instrument panel.
      NOTE
      Installation of a new suction accumulator is not required when repairing the air conditioning system, except when there is physical evidence of contamination from a failed A/C compressor or damage to the suction accumulator.

    104.  
    105. Recover the refrigerant.
    106.  
    107. Remove the powertrain control module (PCM).
    108.  
    109. Remove the battery and battery tray.
    110.  
    111. Remove the PCM bracket.
    112.  
    113. Remove the suction accumulator outlet fitting nut and disconnect the fitting.
    114.  
    115. Discard the O-ring seal.
    116.  
    117. Disconnect the suction accumulator inlet fitting. Discard the O-ring seals.
    118.  
    119. Remove the 2 suction accumulator bracket nuts.
    120.  
    121. Remove the suction accumulator.
    122.  
    123. Disconnect the evaporator core spring lock coupling. Discard the O-ring seals.
    124.  
    125. Clamp off and disconnect the 2 heater core quick disconnect fittings.
    126.  
    127. Remove the 3 heater core and evaporator core housing nuts.
    128.  
    129. Disconnect the 2 harness electrical connectors.
    130.  
    131. Remove the air inlet duct bracket nut.
    132.  
    133. Remove the bolt and position the junction box aside.
    134.  
    135. Loosen the nut and remove the heater core and evaporator core housing.
    136.  
    137. Remove the dash panel seal from the heater core tubes.
    138.  
    139. Position the temperature blend door actuator aside.
    140.  
    141. Remove the heater core cover.
    142.  
    143. Remove the heater core.
      NOTE
      The heater core seal must be correctly installed to prevent airflow from bypassing the heater core.


      CAUTION
      Incorrect centralization may result in premature component failure. If in doubt when centralizing the clockspring, repeat the centralizing procedure. Failure to follow this instruction may result in personal injury.


      WARNING
      Make sure the road wheels are in the straight-ahead position.

    144.  
    145. If the vehicle's clockspring has rotated out of center, follow these steps to center the clockspring.
      1. Hold the clockspring outer housing stationary.
        WARNING
        Overturning will destroy the clockspring. The internal ribbon wire acts as the stop and can be broken from its internal connection.

      2.  
      3. While turning the rotor counterclockwise, carefully feel for the ribbon wire to run out of length and for a slight resistance. Stop turning at this point.
      4.  
      5. Turn the clockspring clockwise approximately 3 turns. This is the center point of the clockspring. Do not allow the rotor to turn from this position. To prevent accidental rotation until the clockspring is installed, 2 pieces of tape may be applied to the clockspring.
        NOTE
        Slight turning of the clockspring rotor is allowable for alignment purposes to the steering column.

      6.  
      7. With the flats of the clockspring aligned to the flats of the steering column, slide the clockspring onto the steering column. For vehicles receiving a new clockspring, remove the retaining pin. For vehicles reusing the clockspring that was removed, remove the tape.
      8.  

    146.  
    147. To install, reverse the removal procedure. Evacuate, charge and leak test the system. Install new O-ring seals. Lubricate the refrigerant system with the correct amount of clean PAG oil.
    148.  
    149. Observe the following torques:

      Heater core nut: 62 inch lbs. (7 Nm)
       
      Air inlet duct bracket: 62 inch lbs. (7 Nm)
       
      Heater core and evaporator core housing nuts: 80 inch lbs. (9 Nm)
       
      Suction accumulator bracket nuts: 53 inch lbs. (6 Nm)
       
      Suction accumulator outlet fitting nut: 71 inch lbs. (8 Nm)
       
      PCM bracket: 89 inch lbs. (10 Nm)
       
      Instrument panel bolts: 15 ft. lbs. (20 Nm)
       
      Steering column pinch bolt: 30 ft. lbs. (40 Nm)
       
      Steering wheel bolt and the steering wheel: 30 ft. lbs. (40 Nm)
       
      Driver-s air bag module bolts: 89 inch lbs. (10 Nm)
       

    150.  
    151. Fill the engine cooling system.
    152.  

    Blackwood



    1. Before servicing the vehicle, refer to the Precautions Section.
      NOTE
      If a heater core leak is suspected, the heater core must be pressure leak tested before it is removed from the vehicle.

    2.  
    3. Drain the radiator.
      WARNING
      Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage may result.

    4.  
    5. Move the adjustable pedals to the full forward position.
    6.  
    7. Position the seats as needed to remove the console.
    8.  
    9. Remove the console finish panel, disconnect the wiring and remove the 4 bolts.
      CAUTION
      Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment.  


      CAUTION
      Carry a live air bag module with the air bag and deployment door pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment.  


      CAUTION
      Do not set a live air bag module down with the deployment door face down. This will reduce the risk of injury in the event of an accidental deployment.  


      CAUTION
      After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the gas generant combustion that is irritating to the skin. Wash your hands with soap and water afterwards.  


      CAUTION
      Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury.  


      CAUTION
      Air bag modules with discolored or damaged deployment doors must be installed new, not repainted.


      CAUTION
      To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches.

    10.  

    The side air bag sensors are located at or near the base of the B-pillar.

    To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped).

    1. Disconnect the battery ground cable and wait at least one minute.
      CAUTION
      To reduce the risk of serious personal injury, read and follow all warnings, cautions, notes, and instructions in the supplemental restraint system (SRS) deactivation/reactivation procedure.

    2.  
    3. Deactivate the supplemental restraint system (SRS). For additional information, refer to Suspension and Steering.
    4.  
    5. Release the passenger air bag module electrical connector pin-type retainer.
    6.  
    7. Remove the bolt.
    8.  
    9. Push in the two glove compartment door tabs and position downward.
    10.  
    11. Remove the two lower passenger air bag module retaining bolts.
    12.  
    13. Remove the passenger air bag module.
    14.  
    15. Remove the steering column.
      1. Remove the two back cover plugs from the steering wheel.
      2.  
      3. Remove the two driver air bag module retaining bolts.
      4.  
      5. Disconnect the driver air bag module electrical connector.
      6.  
      7. Disconnect the horn switch electrical connector.
      8.  
      9. Remove the driver air bag module.
      10.  
      11. Turn the steering wheel to the straight ahead position and turn the ignition switch to the OFF position.
      12.  
      13. Remove the steering wheel bolt.
        WARNING
        Removing the steering wheel without using a puller can damage the column bearings.

      14.  
      15. Use a puller to remove the steering wheel.
      16.  
      17. Remove the clockspring.
        WARNING
        Do not allow the steering column shaft to rotate while the intermediate shaft is disconnected or damage to the clockspring can result.

      18.  
      19. If there is evidence that the shaft has rotated, the clockspring must be removed and re-centered.
      20.  
      21. Remove the reinforcement.
      22.  
      23. Remove the multifunction switch.
      24.  
      25. Remove the ignition switch connector.
      26.  
      27. Remove the selector lever indicator cable.
      28.  
      29. Remove the intermediate shaft bolt.
      30.  
      31. Remove all electrical connectors.
      32.  
      33. Remove the column mounting nuts (4).
      34.  
      35. Remove the shift cable.
      36.  
      37. Remove the column.
      38.  

    16.  
    17. Remove the junction block splash shield.
    18.  
    19. Remove the bolts and disconnect the cable ends from the starter relay.
    20.  
    21. Remove the bolts and position aside the junction block bracket.
    22.  
    23. Disconnect the heater core hose couplings.
    24.  
    25. Remove the A/C plenum demister adapter.
    26.  
    27. Remove the screws and position aside the relay bracket.
    28.  
    29. Disconnect the vacuum line.
    30.  
    31. Remove the plenum chamber top.
    32.  
    33. Remove the blend door assembly from the case.
    34.  
    35. Remove the heater core.
    36.  
    37. To install, reverse the removal procedure. Lubricate the coolant hoses with coolant hose lubricant or plain water only, if needed. Observe the following torques:

      Steering wheel bolt: 28 ft. lbs. (38 Nm)
       
      Intermediate shaft bolt: 35 ft. lbs. (48 Nm)
       

    38.  

     
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