1997-09 REPAIR MANUAL
Covers U.S. and Canadian models of
Ford 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 engines
Does 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 Automotive
ml 1/W Books
PUBLISHED BY HAYNES NORTH AMERICA, Inc.
Manufactured in USA
©2009 Haynes North America, Inc.
Library of Congress Control Number: 2009935558
Haynes Publishing Group
Sparkford Nr Yeovil
Somerset BA22 7JJ England
Haynes North America, Inc
861 Lawrence Drive
California 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 - 0-5
Introduction - 0-5
Vehicle identification'numbers - 0-6
Buying parts - 0-7
Maintenance techniques, tools and
Jacking and towing-0-16
Booster battery (jump) starting - 0-17
Automotive chemicals and lubricants - 0-20
Safety first! - 0-21
Troubleshooting - 0-22
TUNE-UP AND ROUTINE MAINTENANCE -1-1
V6 ENGINE - 2A-1
V8 ENGINES - 2B-1
GENERAL 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-1
AUTOMATIC TRANSMISSION - 7B-1
TRANSFER CASE - 7C-1
CLUTCH AND DRIVELINE - 8-1
BRAKES - 9-1
SUSPENSION AND STEERING SYSTEMS -10-1
CHASSIS ELECTRICAL SYSTEM -12-1
GLOSSARY - GL-1 GLOSSARY
MASTER INDEX - IND-1
About this manual
The purpose of this manual is to help you get the best value from
your vehicle. It can do so in several ways. It can help you decide what
work must be done, even if you choose to have it done by a dealer
service department or a repair shop; it provides information and pro-
cedures for routine maintenance and servicing; and it offers diagnostic
and repair procedures to follow when trouble occurs.
We hope you use the manual to tackle the work yourself. For
many simpler jobs, doing it yourself may be quicker than arranging
an appointment to get the vehicle into a shop and making the trips to
leave it and pick it up. More importantly, a lot of money can be saved
by avoiding the expense the shop must pass on to you to cover its
labor and overhead costs. An added benefit is the sense of satisfaction
and 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 numbered
At the beginning of each numbered Section you will be referred to
any illustrations which apply to the procedures in that Section. The
reference numbers used in illustration captions pinpoint the pertinent
Section and the Step within that Section. That is, illustration 3.2 means
the illustration refers to Section 3 and Step (or paragraph) 2 within that
Procedures, once described in the text, are not normally repeated.
When it's necessary to refer to another Chapter, the reference will be
given as Chapter and Section number. Cross references given without
use of the word "Chapter" apply to Sections and/or paragraphs in the
same Chapter. For example, "see Section 8" means in the same Chap-
References to the left or right side of the vehicle assume you are
sitting 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 any
errors in, or omissions from, the information given.
A Note provides information necessary to properly complete a procedure or information which
will make the procedure easier to understand.
A Caution provides a special procedure or special steps which must be taken while completing
the procedure where the Caution is found. Not heeding a Caution can result in damage to the
assembly being worked on.
A Warning provides a special procedure or special steps which must be taken while completing
the 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 utility
Engines are either a fuel-injected 4.2L V6,4.6L V8 or 5.4L V8. All
models 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 any
malfunction that could affect emissions, turning on the CHECK ENGINE
light if any faults are detected.
Chassis layout is conventional, with the engine mounted at the
front and the power being transmitted through either a 5-speed manual
or 4-speed automatic transmission and a driveshaft to the solid rear
axle. 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
These models feature independent front suspension with torsion
bars (4WD) or coil springs (2WD) and shock absorbers and solid axle
with leaf springs and shock absorbers (pick-ups) or coil springs or air
springs (sport utility models) at the rear. On 2003 and later Expedition
and Navigator models, the rear suspension is independent via a solid-
ly-mounted differential with driveaxles connecting the differential to the
rear wheels. The wheel assemblies are located by upper and lower con-
trol arms and upper and lower trailing arms. Coil spring/shock units or
optional air shocks provide suspension.
The brakes are disc on the front and either drum or disc on the rear
wheels, with an Anti-Lock Brake System (ABS) standard on most models.
The power-assisted recirculating ball-type steering is mounted on
the 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 vehicle
manufacturing. Since spare parts lists and manuals are compiled on a
numerical 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 plate
attached to the dashboard inside the windshield on the driver's side of
the vehicle (see illustration). The VIN also appears on the Vehicle Cer-
tificate of Title and Registration. It contains information such as where
and when the vehicle was manufactured, the model year and the body
VIN ENGINE AND MODEL YEAR CODES
Two particularly important pieces of information found in the VIN
are the engine code and the model year code. Counting from the left,
the engine code letter designation is the 8th digit and the model year
code 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 engine
4.6L (Romeo) V8
4.6L (Windsor) V8
5.4L V8, 2V
5.4L V8, 4V
On the models covered by this manual the model year
9 . .
VEHICLE CERTIFICATION LABEL
The Vehicle Certification Label is attached to the driver's side door
pillar (see illustration). Information on this label includes the name of
the 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 date
can be found on the valve cover (see illustration). The engine number
is also stamped onto a machined pad on the external surface of the
The vehicle certification label is affixed to the driver's side
door 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 the
passenger side of the transmission case
AUTOMATIC TRANSMISSION IDENTIFICATION
The automatic transmission ID number is affixed to a label on the
right side of the case.
MANUAL TRANSMISSION IDENTIFICATION NUMBER
The manual transmission ID number is affixed to a label on the
right side of the case (see illustration).
TRANSFER CASE IDENTIFICATION NUMBER
The transfer case ID number is stamped on a tag which is bolted to
the rear cover (see illustration).
DIFFERENTIAL IDENTIFICATION NUMBER
The differential ID number is stamped on a tag which is bolted to
the differential cover (see illustration).