Fan Clutch: Service and RepairCooling Fan

Special Tool(s)

Removal

WARNING: Do not run the engine while the protective components are removed. Failure to follow these instructions can result in personalinjury.

All vehicles1. Remove the air cleaner outlet pipe.

2. Disconnect the Mass Air Flow (MAF) sensor electrical connector.

3. Remove the outlet side of the air cleaner.4. Raise and support the vehicle.

5. If equipped, remove the skidplate.

6. Remove the screws and the lower section of the cooling fan shroud.7. Lower the vehicle.

Vehicles equipped with 5.4L 4V engines

8. Disconnect the accelerator cable, speed control cable, and the return spring.

9. Remove the bolts and position the cable and brackets out of the way.

Vehicles equipped with 4.6L engines

10. Remove the nut and the engine appearance cover bracket.

All vehicles

11. Remove the mounting bolts and the upper section of the cooling fan shroud.

12. Remove the fan blade and the fan clutch.1 Using the special tool, hold the coolant pump pulley steady.2 Using the special tool, remove the cooling fan assembly locknut.

13. Remove the bolts and separate the fan clutch from the fan blade.

InstallationAll vehicles

1. Assemble the fan clutch to the fan blade and install the bolts.

2. Using the special tools, install the cooling fan assembly.

3. Install the upper section of the fan shroud and mounting bolts.

Vehicles equipped with 4.6L engines

4. Install the engine appearance cover bracket and

Vehicles equipped with 5.4L 4V engines

5. Position the cables and bracket, and install the bolts.

6. Connect the accelerator cable, speed control cable and the return spring.

All vehicles7. Raise the vehicle.

8. Install the screws and the lower section of the cooling fan shroud.

9. If equipped, install the skidplate.10. Lower the vehicle.

11. Install the outlet side of the air cleaner.

12. Connect the Mass Air Flow (MAF) sensor electrical connector.13. Install the air cleaner outlet pipe.

2004 Ford Truck Expedition 2WD V8-5.4L SOHC VIN L Copyright © 2011, ALLDATA 10.50PE Page 1

Fan Clutch: Service and Repair

Cooling Fan

Special Tool(s)

Removal

WARNING: Do not run the engine while the protective components are removed. Failure to follow these instructions can result in personal

injury.

All vehicles

1.Remove the air cleaner outlet pipe.

2.Disconnect the Mass Air Flow (MAF) sensor electrical connector.

3.Remove the outlet side of the air cleaner.

4.Raise and support the vehicle.

2004 Ford Truck Expedition 2WD V8-5.4L SOHC VIN L Copyright © 2011, ALLDATA 10.50PE Page 2

5.If equipped, remove the skidplate.

6.Remove the screws and the lower section of the cooling fan shroud.

7.Lower the vehicle.

Vehicles equipped with 5.4L 4V engines

8.Disconnect the accelerator cable, speed control cable, and the return spring.

9.Remove the bolts and position the cable and brackets out of the way.

Vehicles equipped with 4.6L engines

2004 Ford Truck Expedition 2WD V8-5.4L SOHC VIN L Copyright © 2011, ALLDATA 10.50PE Page 3

10.Remove the nut and the engine appearance cover bracket.

All vehicles

11.Remove the mounting bolts and the upper section of the cooling fan shroud.

12.Remove the fan blade and the fan clutch.

1Using the special tool, hold the coolant pump pulley steady.

2Using the special tool, remove the cooling fan assembly locknut.

13.Remove the bolts and separate the fan clutch from the fan blade.

Installation

All vehicles

2004 Ford Truck Expedition 2WD V8-5.4L SOHC VIN L Copyright © 2011, ALLDATA 10.50PE Page 4

1.Assemble the fan clutch to the fan blade and install the bolts.

2.Using the special tools, install the cooling fan assembly.

3.Install the upper section of the fan shroud and mounting bolts.

Vehicles equipped with 4.6L engines

4.Install the engine appearance cover bracket and

Vehicles equipped with 5.4L 4V engines

2004 Ford Truck Expedition 2WD V8-5.4L SOHC VIN L Copyright © 2011, ALLDATA 10.50PE Page 5

5.Position the cables and bracket, and install the bolts.

6.Connect the accelerator cable, speed control cable and the return spring.

All vehicles

7.Raise the vehicle.

8.Install the screws and the lower section of the cooling fan shroud.

9.If equipped, install the skidplate.

10.Lower the vehicle.

2004 Ford Truck Expedition 2WD V8-5.4L SOHC VIN L Copyright © 2011, ALLDATA 10.50PE Page 6

11.Install the outlet side of the air cleaner.

12.Connect the Mass Air Flow (MAF) sensor electrical connector.

13.Install the air cleaner outlet pipe.