2005 FORD F150 F250 EXPEDITION NAVIGATOR Service Repair Manual

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Text of 2005 FORD F150 F250 EXPEDITION NAVIGATOR Service Repair Manual

  • FORD PICK-UPS/EXPEDITION/NAVIGATOR 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.

    ABODE FGHIJ KLM

    Manufactured in USA ©2009 Haynes North America, Inc. ISBN-13:978-1 -56392-792-8 ISBN-10:1-56392-792-6 Library of Congress Control Number: 2009935558

    Haynes Publishing Group Sparkford Nr Yeovil Somerset BA22 7JJ England

    Haynes North America, Inc 861 Lawrence Drive Newbury Park California 91320 USA 8M10-2

    Chilton is a registered trademark of W.G. Nichols, Inc., and has been licensed to Haynes North America, Inc.

  • Contents

    INTRODUCTORY PAGES

    About this manual - 0-5 Introduction - 0-5 Vehicle identification'numbers - 0-6 Buying parts - 0-7 Maintenance techniques, tools and

    working facilities-0-8 Jacking and towing-0-16

    Booster battery (jump) starting - 0-17 Conversion factors-0-18 Fraction/decimal/millimeter

    equivalents-0-19 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

    BODY-11-1

    CHASSIS ELECTRICAL SYSTEM -12-1 WIRING DIAGRAMS-12-25

    GLOSSARY - GL-1 GLOSSARY

    MASTER INDEX - IND-1 MASTER

    INDEX

  • INTRODUCTION

    About this manual

    ITS PURPOSE

    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 paragraphs.

    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 Section.

    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- ter.

    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.

    f-NOTE

    A Note provides information necessary to properly complete a procedure or information which will make the procedure easier to understand.

    ** CAUTION 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.

    ** WARNING 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 body styles.

    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

    independent driveaxles. 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 style.

    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 codes are:

    4.2L V6 4.6L (Romeo) V8 4.6L (Windsor) V8 5.4L V8, 2V 5.4L V8, 4V 5.4LV8.3V

    2 W 6 L R 5

    On the models covered by this manual the model year codes are:

    v W :

    X

    Y 1 2 3 4 5 6 7

    9 . .

    VEHICLE CERTIFICATION LABEL

    1997 1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009

    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 engine block.

    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 NUMBER

    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).

    VEHIC