Installation

Oil Pan

Special Tools:

Installation

All Vehicles

NOTE: The oil pan gasket must be installed within four minutes after applying the silicone.

1. Apply sealant in the six positions shown.
- Use Silicone Gasket and Sealant F7AZ-19554-EA or equivalent meeting FORD specification WSE-M4G323-A4.






2. Install the oil pan gasket.






NOTE: The oil pan must be installed within four minutes after applying the silicone.

3. Apply sealant in the four positions shown.
- Use Silicone Gasket and Sealant F7AZ-19554-EA or equivalent meeting FORD specification WSE-M4G323-A4.






NOTE: The oil pan and the oil pump must be installed as an assembly.

4. Install the oil pump.






5. Install the oil pan and the reinforcement rails.
- Tighten the four end bolts.
- Tighten the remaining 18 bolts.






CAUTION: Failure to properly position the O-ring seal can cause an engine oil leak.

NOTE: Coat the O-ring seal with petroleum jelly to hold the O-ring in place during installation.

6. Install the oil bypass assembly.
- Position the O-ring Seal into the groove on the adapter.
- Install the bolt.






7. Install the oil filter assembly.






4X4 VEHICLES

NOTE: Remove the plug set used to plug the axle openings.

8. Secure the front axle housing to a suitable lift.

9. Position the front axle close to the installed position.






10. Connect the vent hose to the front axle.






CAUTION: A new circlip must be installed on the end of the halfshaft.

NOTE: LH halfshaft will not fully seat into the front axle at this time.

11. Guide the LH halfshaft into the front axle.

12. Raise the front axle to the fully installed position.

CAUTION: Make sure the halfshaft circlip fully seats.

13. Completely install the LH halfshaft.

14. Install the front axle housing top bolt.






15. Using new bolts, install the remaining front axle housing bolts.

CAUTION: A new circlip must be installed on the end of the halfshaft.






CAUTION: Make sure the halfshaft circlip fully seats.

16. Install the RH halfshaft.

17. Using new bolts, install the front driveshaft.






18. Connect the upper ball joints and install the pinch bolts.






19. Install both front calipers.






ALL VEHICLES

20. Using the special tool, install new seals on the power steering return hose and the power steering pressure hose.






NOTE: Make sure the steering gear input shaft is turned to the left until the stop is reached.

NOTE: Handle the steering gear with caution to avoid damage to fluid transfer tubes and to avoid dimples in the tie-rod boots.

21. Turn the steering gear input shaft to the right until the stop is reached. Note the number of turns required.






NOTE: Make sure the steering gear control valve housing is turned toward the front of the vehicle.

22. Install the steering gear into the RH opening of the crossmember.






23. Move the steering gear as far to the RH side of the vehicle as possible.






24. Move the LH front wheel spindle tie-rod into the opening in the crossmember and move the steering gear into position.






25. To place the steering gear in the straight ahead position, turn the steering gear input shaft to the left by half the number of turns recorded previously.

26. Install the steering gear-to-crossmember insulator bushings as shown.
- The large end of the metal sleeve must be positioned downward.
- Check that the mounting surfaces on the crossmember are clean and free of debris.






27. Install the steering gear-to-crossmember washers and stud bolts.

CAUTION: Hold the tops of the steering gear-to-crossmember stud bolts to avoid damaging the steering gear fluid transfer tubes.

28. Install the nuts.






29. Lower the engine.

CAUTION: Do not rotate the steering wheel when the lower steering column shaft is disconnected, or damage to the clockspring will result.

30. Connect the intermediate shaft to the steering gear input shaft. Install the pinch bolt.






31. Connect the steering gear hoses.
- Connect the power steering return hose.
- Connect the power steering pressure hose.






32. Install the front stabilizer bar.
- Position the front stabilizer bar as noted during removal.

33. Install the tie-rod end.
- Rotate the tie-rod end the number of turns recorded during removal.






34. Connect the tie-rod ends to the steering knuckles.
- Position the tie-rod ends to the steering knuckles.
- Install the castellated nuts.
- Install the new cotter pins.
- Check that the brake dust shields are not bent and are not in contact with the outer tie-rod boot seals.






35. Tighten the LH tie-rod end jam nut.






36. Install the radiator air deflector.






37. Install the top engine mount nuts.






38. Install the inner fender splash shields.

39. Install the front wheel and tire assemblies.

40. Install the power steering fluid cooler and connect the power steering return hose.






41. Install the power steering fluid cooler crossmember nuts.






42. Connect the power steering return hose.






43. Install the wire harness and bracket.






CAUTION: Do not allow the transmission to hang freely.

44. Position the High-Lift Transmission Jack under the transmission.
- Lift the transmission.






45. Remove the crossmember.
- Remove the six bolts.
- Remove the crossmember.






NOTE: The RH is shown, the LH side is similar.

46. Install the tree-way catalytic converter (TWC).






47. Connect the heated oxygen sensors (HO2S).






48. Install the support insulator bracket.






49. Install the transfer case skid plate, if equipped.






50. Install the crossmember.
- Position the crossmember.
- Install the six bolts.







51. Lower the transmission onto the crossmember and install the nuts.






52. Position the High-Lift Transmission Jack aside.

53. Lower the vehicle.

54. Fill the engine crankcase with clean oil meeting FORD specification WSS-M2C153-G.

55. Fill and leak check the power steering system.

56. Connect the battery ground cable.