FORD PICK-UPS/EXPEDITION/NAVIGATOR1997-09 REPAIR MANUAL
Covers U.S. and Canadian models ofFord F-150 ('97-'03), F-150 Heritage ('04) and
F-250 Pick-Ups ('97-'99); Ford Expedition ('97-'09)and Lincoln Navigator ('98-'09);
2 and 4 wheel drive, gasoline enginesDoes nof include diesel engine, F-250HD, Super Duty, F-350
or information specific to Lightning models
by Eric Michael Mihalyi, A.S.E., SAE, S.T.S.and Jay Storer
'If fF^f%Mf Automotiveml 1/W Books
PUBLISHED BY HAYNES NORTH AMERICA, Inc.
Manufactured in USA2009 Haynes North America, Inc.ISBN-13:978-1 -56392-792-8ISBN-10:1-56392-792-6Library of Congress Control Number: 2009935558
Haynes Publishing GroupSparkford Nr YeovilSomerset BA22 7JJ England
Haynes North America, Inc861 Lawrence DriveNewbury ParkCalifornia 91320 USA 8M10-2
Chilton is a registered trademark of W.G. Nichols, Inc., and has been licensed to Haynes North America, Inc.
About this manual - 0-5Introduction - 0-5Vehicle identification'numbers - 0-6Buying parts - 0-7Maintenance techniques, tools and
working facilities-0-8Jacking and towing-0-16
Booster battery (jump) starting - 0-17Conversion factors-0-18Fraction/decimal/millimeter
equivalents-0-19Automotive chemicals and lubricants - 0-20Safety first! - 0-21Troubleshooting - 0-22
TUNE-UP AND ROUTINE MAINTENANCE -1-1
V6 ENGINE - 2A-1V8 ENGINES - 2B-1GENERAL ENGINE OVERHAUL PROCEDURES - 2C-1
COOLING, HEATING AND AIR CONDITIONING SYSTEMS - 3-1
FUEL AND EXHAUST SYSTEMS - 4-1
ENGINE ELECTRICAL SYSTEMS - 5-1
EMISSIONS AND ENGINE CONTROL SYSTEMS - 6-1
MANUAL TRANSMISSION - 7A-1AUTOMATIC TRANSMISSION - 7B-1TRANSFER CASE - 7C-1
CLUTCH AND DRIVELINE - 8-1
BRAKES - 9-1
SUSPENSION AND STEERING SYSTEMS -10-1
CHASSIS ELECTRICAL SYSTEM -12-1WIRING DIAGRAMS-12-25
GLOSSARY - GL-1 GLOSSARY
MASTER INDEX - IND-1MASTER
About this manual
The purpose of this manual is to help you get the best value fromyour vehicle. It can do so in several ways. It can help you decide whatwork must be done, even if you choose to have it done by a dealerservice department or a repair shop; it provides information and pro-cedures for routine maintenance and servicing; and it offers diagnosticand repair procedures to follow when trouble occurs.
We hope you use the manual to tackle the work yourself. Formany simpler jobs, doing it yourself may be quicker than arrangingan appointment to get the vehicle into a shop and making the trips toleave it and pick it up. More importantly, a lot of money can be savedby avoiding the expense the shop must pass on to you to cover itslabor and overhead costs. An added benefit is the sense of satisfactionand accomplishment that you feel after doing the job yourself.
USING THE MANUAL
The manual is divided into Chapters. Each Chapter is divided into
numbered Sections. Each Section consists of consecutively numberedparagraphs.
At the beginning of each numbered Section you will be referred toany illustrations which apply to the procedures in that Section. Thereference numbers used in illustration captions pinpoint the pertinentSection and the Step within that Section. That is, illustration 3.2 meansthe illustration refers to Section 3 and Step (or paragraph) 2 within thatSection.
Procedures, once described in the text, are not normally repeated.When it's necessary to refer to another Chapter, the reference will begiven as Chapter and Section number. Cross references given withoutuse of the word "Chapter" apply to Sections and/or paragraphs in thesame Chapter. For example, "see Section 8" means in the same Chap-ter.
References to the left or right side of the vehicle assume you aresitting in the driver's seat, facing forward.
Even though we have prepared this manual with extreme care,neither the publisher nor the author can accept responsibility for anyerrors in, or omissions from, the information given.
A Note provides information necessary to properly complete a procedure or information whichwill make the procedure easier to understand.
** CAUTIONA Caution provides a special procedure or special steps which must be taken while completingthe procedure where the Caution is found. Not heeding a Caution can result in damage to theassembly being worked on.
** WARNINGA Warning provides a special procedure or special steps which must be taken while completingthe procedure where the Warning is found. Not heeding a Warning can result in personal injury.
Introduction to the F-150, F-250, Expedition and Navigator
These models are available in pick-up and four-door sport utilitybody styles.
Engines are either a fuel-injected 4.2L V6,4.6L V8 or 5.4L V8. Allmodels are equipped with the On Board Diagnostic Second-Generation(OBD-II) computerized engine management system that controls virtu-ally every aspect of engine operation. OBD-II monitors emissions sys-tem components for signs of degradation and engine operation for anymalfunction that could affect emissions, turning on the CHECK ENGINElight if any faults are detected.
Chassis layout is conventional, with the engine mounted at thefront and the power being transmitted through either a 5-speed manualor 4-speed automatic transmission and a driveshaft to the solid rearaxle. On 4WD models, a transfer case transmits power to a front dif-ferential by way of a driveshaft and then to the front wheels through
independent driveaxles.These models feature independent front suspension with torsion
bars (4WD) or coil springs (2WD) and shock absorbers and solid axlewith leaf springs and shock absorbers (pick-ups) or coil springs or airsprings (sport utility models) at the rear. On 2003 and later Expeditionand Navigator models, the rear suspension is independent via a solid-ly-mounted differential with driveaxles connecting the differential to therear wheels. The wheel assemblies are located by upper and lower con-trol arms and upper and lower trailing arms. Coil spring/shock units oroptional air shocks provide suspension.
The brakes are disc on the front and either drum or disc on the rearwheels, with an Anti-Lock Brake System (ABS) standard on most models.
The power-assisted recirculating ball-type steering is mounted onthe chassis frame rail to the left of the engine.
0-6 VEHICLE IDENTIFICATION NUMBERS
Vehicle Identification numbers
Modifications are a continuing and unpublicized process in vehiclemanufacturing. Since spare parts lists and manuals are compiled on anumerical basis, the individual vehicle numbers are necessary to cor-rectly identify the component required.
VEHICLE IDENTIFICATION NUMBER (VIN)
This very important identification number is stamped on a plateattached to the dashboard inside the windshield on the driver's side ofthe vehicle (see illustration). The VIN also appears on the Vehicle Cer-tificate of Title and Registration. It contains information such as whereand when the vehicle was manufactured, the model year and the bodystyle.
VIN ENGINE AND MODEL YEAR CODES
Two particularly important pieces of information found in the VINare the engine code and the model year code. Counting from the left,the engine code letter designation is the 8th digit and the model yearcode letter designation is the 10th digit.
The VIN is visible through the windshield on the driver's side
On the models covered by this manual the enginecodes are:
4.2L V64.6L (Romeo) V84.6L (Windsor) V85.4L V8, 2V5.4L V8, 4V5.4LV8.3V
On the models covered by this manual the model yearcodes are:
9 . .
VEHICLE CERTIFICATION LABEL
The Vehicle Certification Label is attached to the driver's side doorpillar (see illustration). Information on this label includes the name ofthe manufacturer, the month and year of production, as well as infor-mation on the options with which it is equipped. This label is espe-cially useful for matching the color and type of paint for repair work.
ENGINE IDENTIFICATION NUMBER
Labels containing the engine code, engine number and build datecan be found on the valve cover (see illustration). The engine numberis also stamped onto a machined pad on the external surface of theengine block.
The vehicle certification label is affixed to the driver's sidedoor pillar The engine identification label is affixed to the valve cover
VEHICLE IDENTIFICATION NUMBERS/BUYING PARTS 0-7
The manual transmission identification label is affixed to thepassenger side of the transmission case
AUTOMATIC TRANSMISSION IDENTIFICATIONNUMBER
The automatic transmission ID number is affixed to a label on theright side of the case.
MANUAL TRANSMISSION IDENTIFICATION NUMBER
The manual transmission ID number is affixed to a label on theright side of the case (see illustration).
TRANSFER CASE IDENTIFICATION NUMBER
The transfer case ID number is stamped on a tag which is bolted tothe rear cover (see illustration).
DIFFERENTIAL IDENTIFICATION NUMBER
The differential ID number is stamped on a tag which is bolted tothe differential cover (see illustration).
VEHICLE EMISSIONS CONTROL INFORMATION LABEL
This label is found in the engine compartment. See Chapter 6 formore information on this label.
The transfer case identification tag is retained by a bolt atthe rear of the transfer case
The differential identification tag is bolted to thedifferential cover
Replacement parts are available