Fix It

Replacing the exhaust manifolds on your Ford F-150 truck is a complicated process that varies greatly depending not only on the year of the truck but also the type of engine. The manifolds are connected to the cylinder heads and the catalytic converters. You should talk with your mechanic before attempting this type of repair.

Instructions

V6 Engines

1

Disconnect the trucks negative battery cable, then raise the truck and securely support it on jack stands.

2

Disconnect the electrical connectors to the oxygen sensor.

3

Remove the nuts connecting the exhaust Y-pipe to the manifolds. Apply penetrating oil to the nuts and studs, if necessary.

4

Remove the engine lifting bracket. For the drivers side manifold, remove the dipstick tube from the oil pan by removing its nut and pulling it out. For the passengers side manifold, disconnect the EGR pipe from the manifold.

5

Disconnect the six mounting nuts for the exhaust manifold. Separate the manifold from the cylinder head and remove the old gaskets.

6

Place the replacement exhaust manifold with new gaskets onto the cylinder head. Install the mounting nuts with a torque wrench, tightening the center nuts first, followed by the front pair and the rear pair.

7

Reconnect and install the other components in the reverse order of removal--this can include the engine lifting bracket, oil dipstick tube, EGR pipe and oxygen sensor electrical connector.

8

Lower the truck and reconnect the battery cable.

V8 Engines

9

Disconnect the negative battery cable, raise the truck and support it on jack stands. Remove the inner splash shield from the fender well.

10

Disconnect the EGR pipe at the EGR valve and exhaust manifold if you are removing the drivers side manifold on a 4.6 liter engine. On a 5.4 liter, remove the front and rear heated oxygen sensors and the exhaust support bracket.

11

Remove the starter if youre removing the passengers side manifold. Also remove the stabilizer bar on a 5.4 liter engine.

12

Disconnect the catalytic converter assemblies from the manifold on a 5.4 liter engine by removing their nuts, then move the assemblies to the rear of the truck.

13

Remove the mounting nuts from the exhaust manifold and remove it. Remove the studs from the cylinder heads and discard them and the nuts.

14

Clean the mating surface on the cylinder heads, using a gasket scraper to remove any carbon deposits. Install new studs into the cylinder heads.

15

Place the exhaust manifold over the studs with new gaskets. Install new mounting nuts, working from the rear to the front and alternating between the top and bottom rows.

16

Install the remaining components in the reverse order of removal and lower the truck. If you need to reconnect the EGR pipe, apply a small amount of anti-seize compound on the threads.

The water pump in a 1990 Ford F-150 Lariat keeps the engine cool by circulating water and coolant throughout the engine. A malfunctioning water pump can cause the engines temperature to increase, even when the radiator has sufficient coolant. This may eventually result in permanent damage to the engine. The pump attaches to the timing chain cover on the front of the engine block. You will need to drain the cooling system when replacing the pump.

Instructions

1

Position a sealable container under the radiator drain hole and remove the drain plug. Wait for the coolant to drain into the container. Seal the container for later use. Replace the drain plug.

2

Remove the mounting bolts for the cooling fan shroud with a socket wrench. Disconnect the shroud from the radiator. Detach the radiator hose, bypass hose and heater hose from the water pump. Disconnect the drive belt and the cooling fan assembly, including the fan spacer and pulley.

3

Remove the alternator mounting bolts with a socket wrench, and move the alternator out of the way to access the water pump. You may also need to remove the power steering pump bracket if the vehicle is so equipped. Disconnect the mounting bolts for the water pump and detach the pump from the timing chain cover. Discard the water pump gasket.

4

Apply a thin layer of sealer to the new gasket. Install the new pump and gasket to the timing chain cover. Tighten the mounting bolts for the water pump to 18 foot-pounds with a torque wrench.

5

Repeat steps two and three in reverse order to complete the installation of the new water pump. Replace the coolant in the radiator.

The flashers, also called blinkers or turn signals, as well as the hazard lights on the Ford F-150 pickup truck are all controlled by one simple relay module. If you have a front or rear flasher that isnt working, chances are you need to replace a simple five-pin relay module located on your steering column. The part costs very little, and replacing it will take just a few minutes of your time.

Instructions

1

Use a flat-head screwdriver to gently pry the clam-shell door open. The door is located under the instrument panel on the top of the steering column between the instrument panel and the steering wheel.

2

Remove the door and set it in a safe place.

3

Remove the blue five-pin relay from the column by pulling it gently from the plug.

4

Remove the screw from the top of the relay.

5

Replace the screw on the top of the relay.

6

Replace the relay with the new one (part number F65B-13350-AA). Plug the new relay in where you removed the old one.

7

Close the clam-shell door by lining it up and pressing down until it snaps in place.

The drive cycle is a process where the vehicle is driven from a cold start and operated for a specific period of time, and at certain speeds, in order to allow the powertrain control module, or PCM, to perform certain diagnostic procedures and gather performance data. In order to reset the process and start from the beginning of the drive cycle, a number of steps must be completed. Failure to follow the specific procedure for resetting the drive cycle can delay the programming and configuration of certain modules, as well as alter previously gathered diagnostic data.

Instructions

1

Fill the fuel tank at least 15 percent full, but no more than 85 percent full. Having the tank too low or completely full will prevent the PCM from properly completing the drive cycle.

2

Park the vehicle and turn off the engine. Turn the ignition on and connect a scan tool to the vehicle. Clear any existing diagnostic trouble codes from the PCMs memory.

3

Turn the ignition completely off and allow the vehicle to cool for at least eight hours. The engine and the vehicle must be at room temperature to ensure a cold start at the beginning of the drive cycle. This can take up to eight hours.

4

Start the engine and confirm that the malfunction indicator lamp, or MIL, is not illuminated. Immediately turn off all accessories, such as the air conditioner and blower fan. The vehicle is now ready to begin a fresh OBD-II drive cycle.

Replacing the taillight cover or lens on your 2005 Ford F-150 truck requires replacing the entire taillight assembly. The assembly and lens are molded together and cannot be separated. Replacement taillight assemblies are available from Ford, most auto parts stores, salvage yards and some specialty parts retailers. Replacement of the assembly takes about 10 minutes with the use of basic tools. Check the bulbs while you have the taillight covers off, and replace any bulbs that are not working.

Instructions

1

Open the tailgate of your 2005 F-150, allowing the tailgate to rest on the support cables. Locate the two retaining screws in the bedside where the tailgate closes. The retaining screws are threaded into the taillight assembly.

2

Remove the two screws with a Phillips screwdriver and set them aside. Grasp the taillight assembly from the rear and pull it straight back, removing it from the truck. Do not pull it out so far that you damage the wires behind it.

3

Locate the bulb sockets on the rear of the assembly. Turn the bulb sockets counterclockwise, and remove them from the assembly. Discard the old assembly.

4

Install the bulb sockets in the rear of the new taillight assembly, turning them clockwise to lock them into place. Slide the new assembly into place on the truck. Push the assembly in until is seats completely.

5

Install the two retaining screws, and tighten them with a Phillips screwdriver. Do not tighten the screws so much that they thread into plastic, which could crack the housing. Close the tailgate.

The 2003 Ford F-150 truck is equipped with one high-tone and one low-tone horn. The horns are mounted on the passenger side of the truck behind the front bumper on a pair of horn brackets. Because of the exposed location of the horns, they are prone to failure because of water and grit entering the horn body. Replace the horns using common tools.

Instructions

1

Locate the horns behind the passenger side of the front bumper. Pull the electrical connectors off the male spade terminals on the horns.

2

Remove the nut from the mounting stud that holds each horn onto its horn bracket, using a combination wrench. Remove the horns and washers from their brackets.

3

Install the new horns onto the brackets. Install the washers and nuts on the horn mounting studs and tighten them securely, using a combination wrench.

4

Plug the electrical connectors onto the male spade terminals on the horn body. Test the horns for proper operation before driving in traffic.

The F series is a line of pickup trucks that Ford has manufactured since 1948. The 1988 models belong to the eighth generation of this series, which Ford made from 1987 to 1991. The procedure for replacing the water pump is generally the same for all Ford F-150s within this model-year range. The water pump for a Ford F-150 is located on the front of the engine block, and its accessible from the engine compartment.

Instructions

1

Place a container under the radiator and remove the drain cock. Drain the coolant into the container and replace the drain cock. Store the coolant for later use.

2

Disconnect the mounting bolts for the shroud on the cooling fan with a socket wrench, if your F-150 is so equipped. Remove the shroud and disconnect the hoses from the water pump. Remove the accessory drive belt, cooling fan, cooling fan pulley and fan spacer.

3

Remove the pivot bolt for the alternator and the mounting bolt for the alternator adjusting arm with a socket wrench. Disconnect the bracket for the power steering pump if your F-150 has power steering.

4

Remove the bolts that attach the water pump to the cover of the timing chain, using a socket wrench. Disconnect the water pump and discard its gasket.

5

Coat the new gasket with sealer and install the new gasket into its mounting groove on the timing chain cover. Connect the new water pump and tighten its mounting bolts to 18 foot-pounds with a torque wrench.

6

Connect the hoses to the water pump and install the shroud for the cooling fan if your vehicle is so equipped. Attach the cooling fan, the cooling fan pulley and the cooling fan spacer. Install the accessory drive belt. Replace the coolant in the radiator.

The Ford F series is a group of full-size pickups manufactured by Ford Motor Company. The model number indicates the nominal carrying capacity of the vehicle, such that an F350 is a 3/4-ton pickup truck. A 2005 F350 typically has a 6.0-liter turbo diesel engine with fuel injection. The fuel injectors deliver a precise ratio of fuel and air to the engine in a specific sequence. The replacement of the fuel injectors in an F350 will also require you to remove additional components.

Instructions

1

Remove the valve cover for the fuel injectors with a socket wrench and detach the electrical connector for the fuel injector. Disconnect the mounting bolts for the crankcase-to-head tube assembly and remove the assembly. Remove the mounting bolts for the oil rail and disconnect the oil rail.

2

Push the electrical connector for the fuel injector out of the rocker arm carrier with a small pry tool. Plug the holes for the oil drain that are next to the each glow plug with clean shop towels. Remove the mounting bolt for the fuel injector with a socket wrench and release the hold down clamp for the fuel injector. Disconnect the fuel injector and unplug the oil drain holes.

3

Install new O-rings and washers onto the new fuel injector and apply a liberal coat of clean engine oil to the fuel injector. Install the fuel injector and attach the hold-down clamp for the fuel injector. Torque the mounting bolt for the fuel injector to 24 foot-pounds with a torque wrench.

4

Place the electrical connector for the fuel injector into the rocker arm carrier with the pry tool. Lubricate the O-rings on the top of the fuel injector with clean engine oil.

5

Place the oil rail into position onto the fuel injectors and press down on the oil rail to secure it in place. Torque the mounting bolts for the oil rail to 10 foot-pounds with a torque wrench.

6

Attach the crankcase-to-head tube assembly to the engine and torque the mounting bolts to 60 foot-pounds with a torque wrench. Connect the electrical connector for the fuel injector and install the valve covers with a socket wrench.

The Ford F-series of full-size pickup trucks is arguably the best-known car series ever produced. According to TruckTrend.com, the Ford F-series has been the best-selling pickup truck in the United States for more than 30 years. The 1994 Ford F-150 certainly doesnt disappoint. The pickup features a rugged chassis powered by large 4.9-liter six-cylinder engine.

Engine and Transmission

Pickups typically come with powerful engines, and the engine of the 1994 Ford F-150 is no exception. The 4.9 liter V6, 145-horsepower engine was standard, though variants with a 5.0-liter V8, 195 hp and

5.8-liter V8, 210 hp were also available. The 145 hp engine had a maximum torque of 265 foot/pounds at 2,000 rpm, which allowed the pickup to tow up to 7,500 pounds of weight. The vehicle came with a standard five-speed manual or an optional four speed automatic transmission.

Physical Measurements and Capacities

The pickup was rather large. The 1994 Ford F-150 was 213.3 inches long, 79 inches wide and 70.8 inches tall. The wheelbase measured 133 inches. The cabin of the pickup had two doors and could provide seats for up to three people. The 1994 Ford F-150 weighed 5,450 pounds.

Fuel

Fuel economy clearly wasnt a priority for the engineers of the 1994 Ford F-150. The truck made a meager 13 mpg in the city and 17 mpg on the highway. However, because the vehicle was equipped with a rather large 19 gallon fuel tank, it had a much more respectable full tank range of 247 miles in the city and 323 miles on the highway.

The Ford F-series includes pickup trucks in a variety of sizes. The F-350 is a full-size pickup that is classified as a 1-ton truck, although its actual carrying capacity is much larger. A 1995 Ford F-350 has several choices of engines, with the most common being an 8-cylinder 7.3-liter diesel engine. The oil pump in this vehicle is attached to the bottom of the engine block. The oil pump installation procedure also requires you to drain the oil from the engine.

Instructions

1

Ensure the engine is completely cold to avoid injury from hot oil. Place a drain pan under the engine oil and remove the drain bolt on the oil pan with a socket wrench. Let the oil drain into the drain pan and replace the drain bolt. Store the oil for later use.

2

Remove the mounting bolts for the oil pan with a socket wrench and disconnect the oil pan from the bottom of the engine. Detach the oil pick-up tube from the oil pump.

3

Remove the mounting bolts that fasten the oil pump to the bottom of the engine with a socket wrench. Detach the oil pump from the engine and discard the oil pump gasket.

4

Mount a new gasket to the new oil pump and mount the new oil pump to the bottom of the engine. Tighten the mounting bolts to 14 foot-pounds with a torque wrench. Attach the oil pickup tube to the oil pump.

5

Install the oil pan and fasten the mounting bolts with a socket wrench. Replace the oil that you previously drained from the engine.