Fix It

The Ford F150 is a series of 3/4 ton pickup trucks that Ford has manufactured since 1975, and an anti-lock braking system, or ABS, has been standard on the F150 since 1987. The driver in a vehicle with an ABS normally controls the braking force that the wheels receive. In an emergency stop, however, the ABS module controls the brakes to each wheel depending on the speed of the wheel. The ABS module is part of the hydraulic control unit, or HCU, located in the engine compartment under the air cleaner.

Instructions

1

Disconnect the cable to the negative battery terminal with a socket wrench to prevent an electrical discharge during the procedure. Remove the air cleaner from the engine.

2

Remove the four fittings for the brake lines with a socket wrench, and detach the brake lines from the HCU. Disconnect the electrical connector from the HCU. Remove the mounting bolts for the HCU, and disconnect the HCU from its bracket.

3

Disconnect the electrical connector from the ABS module. Remove the retaining screws from the ABS module, and disconnect the ABS module from the HCU.

4

Install the new ABS module to the HCU, and tighten the retaining screws to 27 inch-pounds with a torque wrench. Attach the electrical connector to the ABS module.

5

Mount the HCU to its bracket, and tighten the mounting bolts to 80 inch-pounds with a torque wrench. Install the HCU bracket to the frame of the vehicle, and tighten the bracket mounting bolts to 18 foot-pounds. Connect the brake lines to the HCU, and tighten the fittings to 13 foot-pounds.

6

Connect the air cleaner with a socket wrench. Attach the cable for the negative battery terminal.

When the exhaust manifold studs break on a Ford F150, the driver will notice a puttering sound on cold start-up because the backside of the exhaust manifold will vibrate, smacking into the engine head. Eventually the oxygen sensors can receive erroneous readings due to an increase in the oxygen passing over the sensor. This could possibly lead to engine performance problems from the change in fuel trim values. In extreme cases your check-engine light might pop on. With the use of pneumatic tools and a long afternoon you can take care of problem.

Instructions

Set Up

1




Determine which manifold is leaking by looking on the backside, closest to the passenger compartment, with a flashlight, for broken studs or visible black soot.

2




Evaluate condition of the nuts and bolts around the manifolds and the exhaust Y pipe, looking for rust. Spray all nuts and studs on the manifolds with a penetrating oil lubricant, such WD40.

3

Gather all of the tools and parts you will need to finalize the project so you dont need to worry about going out to get a tool or part once your Ford F150 is torn apart.

Preparation

4

Jack up the front of the Ford F150 onto jack stands.

5




Remove the wheel on the side where the manifold is leaking, using a socket and ratchet.

6




Remove plastic wheel wells, using ratchets and a pry bar.

Removal

7

Remove the four exhaust nuts that connect the Y pipe to the exhaust manifolds. Depending on the level of rust degradation on the nuts, it might be necessary to use extractor sockets to remove.

8

Remove the exhaust gas recirculation, or EGR, tube if you working on the left side of the manifold. Typically it will be so rusted you will need to cut the tube, using the metal hacksaw, as close to the manifold as possible. Otherwise skip to the next step.

9

Remove the all eight nuts from the exhaust manifold. When removing, dont be surprised if the stud turns and is removed with the nut or breaks off as you turn. Typically, the back nuts are the ones that will break off due to rust and fatigue. Then, remove any remaining exhaust studs that did not come off with the nuts.

10

Remove the exhaust manifold and discard the gasket.

11

Remove any broken studs by attempting to turn with extractor bits and a ratchet. If you are unable to extract, use the 90-degree drill, perably with counter-clockwise drill bits to assist in removal of studs, drilling a hole into the center of the stud, which might release it. Increase drill bit size, as necessary, to remove. Once the layer of rust on the stud is removed from the seat of the hole in the engine head, the stud will freely turn out.

EGR

12

Remove the top portion of the EGR tube from the EGR valve with a wrench, if you are working on the left manifold.

13

Replace the manifold if the EGR tube and nipple are so heavily rusted that you cant remove them.

14

Access the amount of rust and wear on the exhaust manifold. Replace if there is heavy rust build up on the face or clean by using the drill grinder.

Installation

15

Install new EGR tube and nipple if you are working on the left manifold.

16

Position new manifolds in place, over the gaskets, while lightly turning in the studs by hand.

17

Tighten the nuts top to bottom, right to left. In other words: tighten the top right, then the bottom right; tight the second from the right on the top followed by the second on the right bottom, and so on. Always start from the side closest to the back side of the engine.

18

Put the Y pipe back in place and tighten the bolts.

19

Reconnect the EGR valve to the exhaust manifold upper fitting.

The electrical systems of a Ford F-150 are protected by fuses and circuit breakers. Each fuse protects one or more circuits. Each circuit needs a specific amount of protection; do not replace a fuse with one of higher or lower amperage, as this can cause damage to the electrical system.

Location

Depending on the age of the Ford F1-50, there may be two fuse blocks in the vehicle. All F-150s have a fuse panel located under the dash on the left side of the steering column. Later models have a power distribution panel located in the engine compartment. This panel is mounted to the drivers side front fender.

Types of Fuses

Both the fuse panel and the power distribution panel use blade type fuses. These fuses are designed to be installed and removed without the need for tools. When removing a fuse, do not twist it from side to side; this may spread the terminals in the fuse panel too far and cause a bad connection.

Circuits

The cover of each fuse panel identifies which circuit a fuse protects. If an electrical component fails, always check the fuse first. If you replace a fuse and it immediately fails, do not replace the fuse again until you have located the source of the problem. Blown fuses are usually a result of a short circuit caused by deteriorated or broken wires.

In a perfect world, cars, trucks, and automotive components would last forever. But theres a delicate balance between cost and longevity, so vehicle manufacturers constantly push the engineering envelope as it relates to doing more with less. Although the headlight switch for your 2001 Ford F-150 is considered an electrical component, its mechanical aspect is susceptible to normal wear and tear after years of regular use. Replacing the defective headlight switch is easy, requiring minimal hand tools to get the job done.

Instructions

1

Connect a memory saver device to the vehicle, according to the products specific instructions. Although not absolutely needed to replace the headlight switch, using a memory saver will avoid short-term drivability issues after reconnecting the negative battery cable, in addition to saving you the hassle of reprogramming the vehicles stereo and other programmable features that depend on constant battery power. Open the hood and disconnect the negative battery cable with a socket and ratchet.

2

Insert a thin, non-marring plastic pry tool into the gap between the bottom right corner of the headlight switch assembly and the instrument panel trim. Carefully pry the assembly from the instrument panel. Disengage the locking tabs for the electrical connectors and then disconnect the connectors from the switch assembly.

3

Connect the electrical connectors to the replacement switch, then press-fit the assembly to the instrument panel. Make sure the new switch is in the off position. Reconnect the negative battery cable to the battery, then tighten the clamp. Use a flat-head screwdriver to spread the battery cable clamp, if necessary. Never attempt to pound or hammer a tight battery clamp onto a battery post.

4

Disconnect the memory saver device from the vehicle. Test the headlamp switch to complete the replacement process.

The exhaust system on your Ford F150 consists of the exhaust manifold, exhaust pipe, catalytic converter, muffler and tail pipe. With the exception of the tailpipe, all of these components are sealed together with gaskets. A leak in any of the gaskets will allow exhaust gases to escape from the system. Because the exhaust gases are no longer completely travelling through the muffler, they are no longer quieted or "muffled." This results in a louder exhaust note.

Instructions

1

Raise the hood of your F150 and start the engine. Locate the source of the exhaust leak by listening along the exhaust system. Do not use your hands to feel for the leak, as this will burn you.

2

Turn the vehicle off and allow the engine and exhaust to cool before working on it.

3

Return to the area of the exhaust leak. The most common area for an exhaust leak is where the exhaust manifold meets the exhaust pipe. If this is where the leak is, remove the bolts from the pipe mounting flange, by turning them counterclockwise with the socket. Install the new gasket, which is referred to as a "doughnut" because of its shape, and tighten the flange bolts by turning them clockwise.

4

Inspect the area where the exhaust manifold bolts onto the engine. If the leak is here, try to tighten the manifold bolts by turning them clockwise with the socket. This will often seal the leak. If this does not work, remove the manifold bolts by turning them counterclockwise with the socket. Pull the exhaust manifold from the engine and remove the mounting gasket. Use the gasket scraper to remove any gasket residue. Put the new gasket into place and tighten the manifold bolts, by turning them clockwise with the socket.

5

Inspect the catalytic converter flange and the muffler attachment for leaks. If any are found, remove the mounting bolts by turning them counterclockwise with the socket. Install the new gasket and tighten the mounting bolts by turning them clockwise with the socket.

The F150 is Fords full-size 3/4-ton pickup truck, which has been in production since 1975. All versions of the 2001 F150 have an anti-lock braking system, or ABS, as a standard feature. An ABS uses a brake controller, or control module, to determine the braking force that each wheel receives. The brake control module reduces the braking power to a wheel when that wheel moves more slowly than the other wheels. The procedure for installing a brake control module is similar for all F150 trucks made from 2001 to 2006.

Instructions

1

Remove the cable from the negative battery terminal with a socket wrench to prevent an electrical discharge during the procedure. Turn the vents in the center instrument panel inward, and hold the panel by the vents. Pull the center instrument panel outward.

2

Disconnect the upper cover from the steering column with a socket wrench. Turn off the selector switch for the bi-fuel tank, if your vehicle is so equipped. Remove the screws from the center instrument panel, and detach the electrical connector for the panel. Remove the instrument panel from the vehicle.

3

Detach the headlamp switch with a thin pry tool, and disconnect the electrical connectors for the headlamp switch. Unplug the electrical connector for the ABS control module, and remove the bolts from the module with a socket wrench. Detach the ABS control module from the vehicle.

4

Install the new ABS control module, and fasten the bolts to the module with a socket wrench. Attach the electrical connector to the ABS control module. Connect the electrical connector for the headlamp switch, and install the switch.

5

Mount the center instrument panel to the vehicle, and attach the electrical connector to the panel. Fasten the mounting screws for the center instrument panel with a socket wrench. Turn on the bi-fuel tank selector switch, and install the upper cover for the steering column.

6

Connect the cable to the negative battery terminal with a socket wrench.