Front Suspension 2015 E-Series REMOVAL AND INSTALLATION Procedure revision date: 08/11/2014. Axle

Transcription

1 Front Suspension 2015 E-Series REMOVAL AND INSTALLATION Procedure revision date: 08/11/2014 Axle 1 N Axle pivot nut 2 N Axle pivot bolt LH/ 3006 RH LH/ 3006 RH Axle Removal NOTICE: Suspension fasteners are critical parts that affect the performance of vital components and systems. Failure can result in major service expense. When replacing suspension fasteners, use the same part number or an equivalent part number. Do not use a replacement part of lesser quality or substitute design. Torque values must be used as specified during reassembly to make sure of correct retention of these parts. 1. Remove the wheel spindle. For additional information, refer to Wheel Spindle in this section. 2. Remove the radius arm. For additional information, refer to Radius Arm in this section. 3. NOTE: In order to obtain clearance for the pivot bolt removal when servicing the RH front axle, it may be necessary to raise the LH side of the vehicle to relieve the weight on the suspension. Installation Remove and discard the axle pivot nut and bolt and remove the axle. 1. NOTE: Do not tighten the nut at this time. Position the axle and install a new axle pivot bolt and nut. 2. Install the radius arm. For additional information, refer to Radius Arm in this section. 3. Install the wheel spindle. For additional information, refer to Wheel Spindle in this section. 4. With the weight of the vehicle on the wheels, tighten the axle pivot nut to 175 Nm (129 lb-ft). 5. Check and, if necessary, align the front end. For additional information, refer to Section Copyright 2015 Ford Motor Company

2 Front Suspension 2015 E-Series REMOVAL AND INSTALLATION Procedure revision date: 08/11/2014 Radius Arm 1 W Radius arm rearward flag bolt 2 N Radius arm rearward nut Shock absorber 4 N Shock absorber lower nut 5 N Radius arm-to-axle bolt 6 N Radius arm-to-axle nut 7 3A292 LH/ 3405 RH LH/ 3405 RH Radius arm Removal and Installation NOTICE: Suspension fasteners are critical parts because they affect performance of vital components and systems and their failure may result in major service expense. New parts must be installed with the same part numbers or equivalent part, if replacement is necessary. Do not use a replacement part of lesser quality or substitute design. Torque values must be used as specified during reassembly to make sure correct retention of these parts. 1. Remove the front spring. For additional information, refer to Spring in this section. 2. Remove and discard the shock absorber lower nut and disconnect the shock absorber from the radius arm. To install, tighten the new nut to 80 Nm (59 lb-ft). 3. Remove and discard the radius arm rearward nut and flag bolt. To install, tighten the new nut to 350 Nm (258 lb-ft). 4. Remove the radius arm-to-axle nut and bolt, the spring retainer and the insulator. Discard the nut and bolt. To install, tighten the new nut to 400 Nm (295 lb-ft). 5. NOTE: Inspect the spring and radius arm insulators and install new as necessary. To install, reverse the removal procedure. Copyright 2015 Ford Motor Company

3 Front Suspension 2015 E-Series REMOVAL AND INSTALLATION Procedure revision date: 08/11/2014 NOTE: LH shown, RH similar. Shock Absorber 1 18A192 Shock absorber upper nut, washer and bushing assembly Shock absorber 3 W Shock absorber lower nut and washer NOTE: Vehicles with 6.8L engine, RH side only. 1 W Shock absorber upper heat shield bolt 2 3C428 Shock absorber heat shield Removal WARNING: Do not apply heat or flame to the shock absorber or strut tube. The shock absorber and strut tube are gas pressurized and could explode if heated. Failure to follow this instruction may result in serious personal injury. NOTICE: Suspension fasteners are critical parts that affect the performance of vital components and systems. Failure can result in major service expense. When replacing suspension fasteners, use the same part number or an equivalent part number. Do not use a replacement part of lesser quality or substitute design. Torque values must be used as specified during reassembly to make sure of correct retention of these parts. 1. NOTE: This step is required for RH shock absorber only. If equipped with a 6.8L engine, remove the RH shock absorber upper heat shield bolt and heat shield. NOTICE: Do not allow the shaft to turn while removing the nut. Hold the flats on the shock rod using a suitable wrench or damage to the shock absorber can result. 2. Remove and discard the shock absorber upper nut, washer and bushing assembly. 3. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Section Remove and discard the shock absorber lower nut and washer. 5. Remove the shock absorber. Installation 1. NOTE: Do not tighten the shock absorber lower nut at this time. Position the shock absorber and loosely install the new lower nut and washer. 2. NOTE: When tightening the shock absorber upper nut, make sure the upper shock rod is centered and flush with the frame. Do not allow the shaft to turn while installing the nut. Hold the flats on the shock rod using a suitable wrench or damage to the shock absorber can result. Position the shock absorber assembly up into the frame hole and install the new shock absorber upper nut washer and bushing assembly. Tighten to 63 Nm (46 lb-ft).

4 3. Tighten the shock absorber lower nut and washer to 80 Nm (59 lb-ft). 4. NOTE: This step is required for RH shock absorber only. If equipped with a 6.8L engine, install the RH shock absorber upper heat shield and heat shield bolt. Tighten to 23 Nm (17 lb-ft). Copyright 2015 Ford Motor Company

5 Front Suspension 2015 E-Series REMOVAL AND INSTALLATION Procedure revision date: 08/11/2014 Spring 1 18A192 Shock absorber upper nut and bushing Shock absorber 3 5K483 Stabilizer bar link 4 W Stabilizer bar link nut Spring 6 5A333 Spring upper bracket 7 W Spring upper bracket bolt NOTE: Vehicles with 6.8L engine, RH side only. 8 W Shock absorber upper heat shield bolt 9 3C428 Shock absorber upper heat shield Removal and Installation NOTICE: Suspension fasteners are critical parts because they affect performance of vital components and systems and their failure may result in major service expense. New parts must be installed with the same part numbers or equivalent part, if replacement is necessary. Do not use a replacement part of lesser quality or substitute design. Torque values must be used as specified during reassembly to make sure correct retention of these parts. 1. Remove and discard the stabilizer bar link lower nut and disconnect the link from the axle. To install, tighten the new nut to 80 Nm (59 lb-ft). 2. NOTICE: The axle must be supported throughout the procedure to prevent damage to the front brake hose. Using a suitable jack, support the front axle. 3. NOTE: This step is required for RH spring only. If equipped with a 6.8L engine, remove the RH side heat shield bolt and heat shield. To install, tighten the new bolt to 23 Nm (17 lb-ft). 4. NOTE: When tightening the shock absorber upper nut, make sure that the upper shock rod is centered in the frame. Remove and discard the shock absorber upper nut and bushing. To install, tighten the new nut to 63 Nm (46 lb-ft). 5. Remove and discard the spring upper bracket bolt and remove the spring upper bracket. To install, tighten the new bolt to 23 Nm (17 lb-ft). 6. NOTICE: Use care when lowering the jack, or damage to the front brake hose may occur. Using the jack, lower the front axle and remove the spring. 7. To install, reverse the removal procedure.

6 Front Suspension 2015 E-Series REMOVAL AND INSTALLATION Procedure revision date: 08/11/2014 Stabilizer Bar Link 1 W Stabilizer bar link lower nut (2 required) 2 W Stabilizer bar link upper nut (2 required) 3 5K483 Stabilizer bar link Removal and Installation NOTICE: Suspension fasteners are critical parts because they affect performance of vital components and systems and their failure may result in major service expense. New parts must be installed with the same part numbers or equivalent part, if replacement is necessary. Do not use a replacement part of lesser quality or substitute design. Torque values must be used as specified during reassembly to make sure correct retention of these parts. 1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Section NOTE: Use the hex-holding feature to prevent the stud from turning while removing the nut. Remove and discard the stabilizer link upper nut. To install, tighten the new nut to 80 Nm (59 lb-ft). 3. NOTE: Use the hex-holding feature to prevent the stud from turning while removing the nut. Remove and discard the stabilizer link lower nut and remove the stabilizer bar link. To install, tighten the new nut to 80 Nm (59 lb-ft). 4. To install, reverse the removal procedure. Copyright 2015 Ford Motor Company

7 Front Suspension 2015 E-Series REMOVAL AND INSTALLATION Procedure revision date: 08/11/2014 Stabilizer Bar Stabilizer bar 2 W Stabilizer bar link lower nut (2 required) Stabilizer bar bracket (2 required) 4 N Stabilizer bar bracket rearward bolt (2 required) 5 W Stabilizer bar bracket forward bolt (2 required) Stabilizer bar bushing (2 required) Removal and Installation NOTICE: Suspension fasteners are critical parts because they affect performance of vital components and systems and their failure may result in major service expense. New parts must be installed with the same part numbers or equivalent part, if replacement is necessary. Do not use a replacement part of lesser quality or substitute design. Torque values must be used as specified during reassembly to make sure correct retention of these parts. 1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Section Remove and discard the 2 stabilizer bar link lower nuts. To install, tighten the new nuts to 80 Nm (59 lb-ft). 3. Remove the 2 stabilizer bar bracket rearward bolts. Discard the 2 bolts. To install, tighten to 25 Nm (18 lb-ft). 4. Remove the 2 stabilizer bar bracket forward bolts and the 2 stabilizer bar brackets. Discard the 2 bolts. To install, tighten to 150 Nm (111 lb-ft). 5. Remove the stabilizer bar. 6. To install, reverse the removal procedure. Copyright 2015 Ford Motor Company

8 Front Suspension 2015 E-Series REMOVAL AND INSTALLATION Procedure revision date: 08/11/2014 Wheel Spindle Special Tool(s) Separator, Ball Joint N Cotter pin 2 W Cotter pin retainer 3 W Outer tie-rod end nut 4 N Upper ball joint bolt 5 N Cotter pin Lower ball joint nut LH/ 3105 RH LH/ 3105 RH Wheel spindle 8 Wheel speed sensor harness (part of 2C205) Removal and Installation NOTICE: Suspension fasteners are critical parts because they affect performance of vital components and systems and their failure may result in major service expense. New parts must be installed with the same part numbers or equivalent part, if replacement is necessary. Do not use a replacement part of lesser quality or substitute design. Torque values must be used as specified during reassembly to make sure correct retention of these parts. 1. NOTE: It is not necessary to remove the brake disc when removing the wheel spindle to service the ball joints. If installing a new wheel spindle, remove the brake disc. If the wheel spindle is being removed to service the ball joints, remove the brake pads. For additional information, refer to Section Disconnect the wheel speed sensor electrical connector and detach the sensor harness from the brake hose.

9 3. Remove the outer tie-rod end cotter pin, retainer and nut. Discard the cotter pin. To install, tighten to 103 Nm (76 lb-ft). 4. Using the Ball Joint Separator, disconnect the outer tie-rod end. 5. Remove and discard the upper ball joint bolt. To install, tighten the new bolt to 103 Nm (76 lb-ft). 6. Remove and discard the lower ball joint cotter pin and nut. To install, tighten the new nut to 150 Nm (111 lb-ft). Install a new cotter pin. 7. NOTICE: To prevent damage to the ball joint boot and socket, do not use a pickle fork-type remover to loosen the ball joints. Remove the wheel spindle in the following sequence. 1. Strike the lower end of the axle to loosen the ball joint. 2. Remove the wheel spindle. 8. NOTE: Before securing the upper ball joint pinch joint, make sure the lower ball joint is fully tightened and the cotter pin is installed. Once the lower ball joint is secured, check the position of the alignment slug making sure it is not in contact with the upper ball joint seal. Tighten the upper pinch joint. To install, reverse the removal procedure. 9. NOTE: This step is only necessary if the wheel spindle has been replaced. Check and, if necessary, align the front end. For additional information, refer to Section Copyright 2015 Ford Motor Company

10 Rear Suspension 2015 E-Series REMOVAL AND INSTALLATION Procedure revision date: 08/11/2014 Spring 1 W U-bolt nut (4 required) 2 N U-bolt (2 required) (E-150, E-250 and E-350 van and wagon) U-bolt (2 required) (E-450) 2 N U-bolt (2 required) (E-350 stripped chassis and cutaway) U-bolt plate 4 W Leaf spring front bracket bolt 5 N Leaf spring front bracket flagnut (RH side) 5 2B615 Leaf spring front bracket flagnut (LH side) 6 N Leaf spring shackle-to-bracket bolt 7 N Leaf spring shackle-to-bracket flagnut Leaf spring 9 W Leaf spring-to-shackle bolt 10 W Shackle-to-leaf spring nut Leaf spring shackle Shock absorber 13 W Shock absorber lower nut 14 W Shock absorber lower bolt Removal NOTICE: Suspension fasteners are critical parts because they affect performance of vital components and systems and their failure may result in major service expense. New parts must be installed with the same part numbers or equivalent part, if replacement is necessary. Do not use a replacement part of lesser quality or substitute design. Torque values must be used as specified during reassembly to make sure of correct retention of these parts. 1. Remove the wheel and tire. For additional information, refer to Section Using a suitable jack, support the rear axle. 3. Remove and discard the shock absorber lower nut and bolt. 4. Remove and discard the 4 U-bolt nuts, the plate and the 2 U-bolts. 5. Remove and discard the leaf spring front bracket bolt and flagnut. 6. Remove and discard the leaf spring shackle-to-bracket bolt and flagnut, then remove the leaf spring assembly. 7. Remove the shackle-to-leaf spring nut, bolt and shackle. Discard the bolt and nut. Installation 1. Position the leaf spring shackle and install the new bolt and nut. Tighten until snug.

11 2. Position the leaf spring and install the new shackle-to-bracket bolt and flagnut. Tighten until snug. 3. Install the new spring-to-front bracket bolt and flagnut. Tighten until snug. 4. NOTE: When installing new U-bolts, the measurement between A and B should be 107 mm (4.21 in) ± 3 mm (0.12 in) for E150/E250/E350 vehicles and 112 mm (4.41 in) ± 3 mm (0.12 in) for E450 vehicles. This is important for providing the correct U-bolt clamp load and retention of parts. Position the spring upper plate and install the U-bolts and nuts. Tighten until snug. 5. Install the new shock absorber lower nut and bolt. Tighten until snug. 6. Install the wheel and tire. For additional information, refer to Section Lower the vehicle until the weight of the vehicle is resting on the wheels and tires (curb height). 8. Tighten the new leaf spring shackle-to-bracket bolt to 133 Nm (98 lb-ft). 9. Tighten the shackle-to-leaf spring nut to 133 Nm (98 lb-ft). 10. Tighten the leaf spring front bracket bolt to 350 Nm (258 lb-ft). 11. Tighten the U-bolt nuts evenly in an X-type pattern in 5 stages. Stage 1: Tighten to 50 Nm (37 lb-ft). Stage 2: Tighten to 100 Nm (74 lb-ft). Stage 3: Tighten to 150 Nm (111 lb-ft). Stage 4: Tighten to 200 Nm (148 lb-ft). 12. Tighten the shock absorber lower nut to 103 Nm (76 lb-ft). Copyright 2015 Ford Motor Company

12 Rear Suspension 2015 E-Series REMOVAL AND INSTALLATION Procedure revision date: 08/11/2014 Stabilizer Bar and Link Stabilizer link lower nut (2 required) A Link insulators (4 required) Link washers (4 required) 4 N Stabilizer link upper bolt (2 required) Link upper washer (2 required) 6 N Link upper nut (2 required) 7 5K484 Stabilizer bar link 8 N Stabilizer bar bracket bolts (4 required) Stabilizer bar brackets 10 5A772 Stabilizer bar B Stabilizer bar bushings (2 required) Removal and Installation NOTICE: Suspension fasteners are critical parts because they affect performance of vital components and systems and their failure may result in major service expense. New parts must be installed with the same part numbers or equivalent part, if replacement is necessary. Do not use a replacement part of lesser quality or substitute design. Torque values must be used as specified during reassembly to make sure of correct retention of these parts. 1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Section Remove the 2 stabilizer link upper bolts, washers and nuts. Discard the bolts and nuts. To install, tighten the new nuts and bolts to 70 Nm (52 lb-ft). 3. Remove the 2 stabilizer link lower nuts, washers and insulators. Discard the nuts. To install, tighten the new nuts to 28 Nm (21 lb-ft). 4. Remove the 2 stabilizer bar links, washers and insulators. 5. Remove the 4 stabilizer bar bracket bolts, the 2 brackets and the stabilizer bar. Discard the bolts. To install, tighten the new bolts to 48 Nm (35 lb-ft). 6. To install, reverse the removal procedure. Copyright 2015 Ford Motor Company

13 Wheels and Tires 2015 E-Series DISASSEMBLY AND ASSEMBLY Procedure revision date: 08/11/2014 Wheel and Tire Valve Stem Mounted Tire Pressure Monitoring System (TPMS) Sensor Special Tool(s) Digital Tire Gauge Item Part Number Tire Wheel Valve stem and screw (also part of 1A189) Disassembly Description 4 1A189 Tire Pressure Monitoring System (TPMS) sensor (a new sensor assembly includes W screw and 1700 valve stem and cap) 5 Valve stem-to-tpms sensor screw (part of 1700) 6 1A163 Valve stem cap (also part of 1A189) WARNING: The tire pressure monitoring system (TPMS) sensor battery may release hazardous chemicals if exposed to extreme mechanical damage. If these chemicals contact the skin or eyes, flush immediately with water for a minimum of 15 minutes and get prompt medical attention. If any part of the battery is swallowed, contact a physician immediately. When disposing of TPMS sensors, follow the correct procedures for hazardous material disposal. Failure to follow these instructions may result in serious personal injury. NOTICE: Failure to follow the instructions below may result in damage to the Tire Pressure Monitoring System (TPMS) sensor. NOTICE: The Tire Pressure Monitoring System (TPMS) sensor is mounted to the valve stem. Removal of the valve stem requires dismounting the tire from the wheel and removal of the TPMS sensor. NOTE: There are 2 different types of Tire Pressure Monitoring System (TPMS) sensors available on E-Series vehicles. The valve stem appearance can be used to determine the type of sensor that is used in the wheel. For additional information on how to determine sensor type, refer to the TPMS Pressure Sensor portion of Wheels And Tires in this section. NOTE: Use only the Digital Tire Gauge any time tire pressures are measured to be sure that accurate values are obtained. 1. Remove the wheel and tire. For additional information, refer to Wheel and Tire Single Rear Wheel (SRW) in this section. 2. NOTICE: The valve stem is connected to the Tire Pressure Monitoring System (TPMS) sensor. Do not pull the valve stem from the wheel, or damage to the sensor will occur. Remove the valve stem core and fully deflate all air from the tire. If a new TPMS sensor is being installed, remove the valve stem-to-sensor screw and discard the sensor. NOTICE: Do not allow the tire beads to move beyond the wheel mid-plane (middle of the wheel) when separating the beads from the wheels, damage to the Tire Pressure Monitoring System (TPMS) sensor may occur. 3. NOTICE: Tire and valve stem position is critical to prevent damage to the Tire Pressure Monitoring System (TPMS) sensor when using a paddletype bead separator. NOTE: Some machines may have a nylon roller bead separator at the 12 o'clock position instead of the paddle-type bead separator at the 3 o'clock position. Position the wheel and tire assembly on a suitable tire machine and separate both beads of the tire from the wheel. For a paddle-type tire machine, position the valve stem at the 12 o'clock or 6 o'clock position and the paddle at the 3 o'clock position. For a roller-type tire machine, align the valve stem with the roller at any position.

14 4. NOTE: Index-mark the valve stem and wheel weight positions on the tire. Place the wheel and tire assembly on the turntable of the tire machine with the valve stem at the 11:30 position and the machine arm at the 12 o'clock position and dismount the outer bead from the wheel. 5. Reset the wheel and tire assembly on the turntable of the tire machine with the valve stem at the 11:30 position and the machine arm at the 12 o'clock position and dismount the inner bead from the wheel. 6. NOTE: A new valve stem must be installed whenever a new tire or wheel is installed. Remove the TPMS sensor in the following sequence. 1. Using a T10 Torx, remove the valve stem-to-tpms sensor screw. 2. Carefully and firmly, pull the sensor straight down and separate it from the valve stem. 7. NOTICE: Use care not to damage the wheel surface when removing the valve stem. Using a suitable valve stem puller and a wood block, remove the valve stem from the wheel. 8. NOTE: When installing a new wheel, always install a new valve stem and reuse the TPMS sensor from the previous wheel if possible. The TPMS will not have to be trained if the sensor is reused. Assembly If the TPMS sensor is being reused, inspect the TPMS sensor for damage and install new parts as necessary. NOTICE: Damage to the Tire Pressure Monitoring System (TPMS) sensor may result if the tire mounting is not carried out as instructed. 1. NOTICE: To prevent Tire Pressure Monitoring System (TPMS) sensor and valve stem damage, the valve stem must be installed onto the TPMS sensor and then installed into the wheel as an assembly.

15 Install a new valve stem onto the TPMS sensor. Tighten the valve stem-to-tpms sensor screw to 1.5 Nm (13 lb-in). 2. NOTICE: It is important to pull the valve stem and Tire Pressure Monitoring System (TPMS) sensor assembly through the wheel rim hole in a direction parallel to the valve stem hole axis. If the assembly is pulled through at an angle, damage to the valve stem and sensor assembly may occur. NOTICE: Use care not to damage the wheel surface when installing the valve stem and Tire Pressure Monitoring System (TPMS) sensor assembly. Lubricate the valve stem with soapy water and install the valve stem and TPMS sensor assembly into the wheel using a block of wood and a suitable valve stem installer. 3. Make sure the valve stem rubber is fully seated against the wheel. 4. NOTICE: Use only a soap and water solution to lubricate the tire. Use of anything other than soap and water may result in damage to the Tire Pressure Monitoring System (TPMS) sensor. NOTE: Do not mount the tire at this time. Position the wheel on the turntable of the tire machine, then lubricate and position the bottom bead of the tire on the wheel. 5. Position the wheel to align the valve stem with the machine arm, at the 6 o'clock position, and mount the bottom bead of the tire. 6. Reposition the wheel to align the valve stem with the machine arm at the 6 o'clock position, and mount the top bead of the tire. 7. NOTE: Use only the Digital Tire Gauge any time tire pressures are measured to make sure that accurate values are obtained. Inflate the tire to the pressure specified on the Vehicle Certification (VC) label located on the driver door or door pillar. Proceed to Step 8 if the tire beads do not seat at the specified inflation pressure. 8. WARNING: If there is a need to exceed the maximum pressure indicated on the sidewall of the tire in order to seat the beads, follow all steps listed below. Failure to follow these steps may result in serious personal injury. The following steps should only be carried out if the tire beads cannot be seated by inflating the tire up to the maximum inflation pressure listed on the tire sidewall. 1. Relubricate the tire bead and wheel bead seat area. 2. Install a remote valve and pressure gauge. 3. Wear eye and ear protection and stand at a minimum of 3.65 m (12 ft) away from the wheel and tire assembly. 4. Inflate the tire using the remote valve and tire gauge until the beads have seated or until the pressure gauge is 138 kpa (20 psi) more than maximum inflation pressure on tire sidewall. If beads have not seated, deflate the tire and proceed to the next step. 5. Place the wheel and tire assembly in an OSHA-approved tire safety cage. 6. Inflate the tire using the remote valve and pressure gauge until the beads have seated or until the pressure gauge is 276 kpa (40 psi) more than maximum inflation pressure on the tire sidewall. Do not exceed 276 kpa (40 psi) above the maximum pressure on tire sidewall. Install a new tire if the beads do not seat at this pressure. 9. Install the wheel and tire. For additional information, refer to Wheel and Tire Single Rear Wheel (SRW) in this section. Copyright 2015 Ford Motor Company

16 Driveshaft 2015 E-Series DISASSEMBLY AND ASSEMBLY Procedure revision date: 08/11/2014 Driveshaft Rear, One-Piece Driveshaft Exploded View 1 Driveshaft rear axle pinion flange Driveshaft flange yoke U-joints 4 Snap rings (part of 4635) 5 Bearing cups (part of 4635) 6 Seals (part of 4635) 7 Spiders (part of 4635) Driveshaft Driveshaft slip-yoke Driveshaft Rear, Two-Piece U-joints 2 Snap rings (part of 4635) 3 Bearing cups (part of 4635) 4 Seals (part of 4635) 5 Spiders (part of 4635) Driveshaft

17 7 4K227 Driveshaft slip-yoke boot clamp (large) U-joint slip-yoke boot 9 4K227 Driveshaft slip-yoke boot clamp (small) Driveshaft slip-yoke 11 Rubber insulator (part of 4800) 12 Bearing (part of 4800) 13 Bearing shield (part of 4800) 14 4A449 Driveshaft center bearing bracket Driveshaft 1. Driveshafts differ in length, diameter, material, number of pieces and the type of slip yokes to accommodate various wheel bases and powertrain combinations. Copyright 2015 Ford Motor Company

18 Driveshaft 2015 E-Series DISASSEMBLY AND ASSEMBLY Procedure revision date: 08/11/2014 Driveshaft Center Bearing Coupling shaft Driveshaft center bearing assembly 3 4K227 Driveshaft slip-yoke boot clamp Driveshaft slip-yoke boot 5 4K227 Driveshaft slip-yoke boot clamp Driveshaft slip-yoke Disassembly 1. Remove the driveshaft from the vehicle. For additional information, refer to Driveshaft Rear Two-Piece in this section. 2. NOTICE: Do not, under any circumstance, clamp the driveshaft or the coupling shaft in the jaws of a vise or similar holding fixture. Damage or localizing fracture may result, causing driveshaft failure during vehicle operation. Place the driveshaft assembly on a suitable workbench. Do not damage the tubes. 3. Remove the driveshaft slip-yoke from the coupling shaft in the following sequence. 1. Cut and discard the driveshaft slip-yoke boot clamps. 2. Remove the driveshaft slip-yoke from the coupling shaft. 4. Remove the slip-yoke boot from the coupling shaft. Inspect the boot for damage. Install a new slip-yoke boot as necessary. 5. Inspect the lubricant on the coupling shaft splines and in the driveshaft slip-yoke for contamination. If contaminated, inspect the coupling shaft splines and the driveshaft slip-yoke for wear or damage. Install new components as necessary. 6. Remove the center bearing retainer, the center bearing bracket and the rubber insulator from the coupling shaft. 1. Remove the center bearing retainer. 2. Remove the center bearing bracket. 3. Remove the rubber insulator.

19 7. Using a suitable press, remove the center bearing and bearing retainer from the coupling shaft. 8. Press the dust slinger off the coupling shaft. Assembly 1. Press the dust slinger on the coupling shaft. 2. NOTE: Install the bearing on the coupling shaft with the turned-in lip toward the dust slinger. NOTE: Install the center bearing bracket with the deep flange facing rearward. Install the center bearing support on the coupling shaft. 1. Install the rubber insulator in the driveshaft center bearing bracket. 2. Using a suitable press, install the center bearing assembly on the coupling shaft. 3. Install the center bearing retainer.

20 4. Position the slip-yoke boot clamp on the coupling shaft stub shaft. 5. Slide the small opening end of the slip-yoke boot on the coupling shaft stub shaft, as far as it will travel. 6. Using boot clamp pliers, crimp the slip-yoke boot clamp. 7. Install the slip-yoke on the coupling shaft. 8. Using boot clamp pliers, crimp the large slip-yoke boot clamp. 9. Install the driveshaft. For additional information, refer to Driveshaft Rear Two-Piece in this section. Copyright 2015 Ford Motor Company

21 Driveshaft 2015 E-Series DISASSEMBLY AND ASSEMBLY Procedure revision date: 08/11/2014 Driveshaft Slip Yoke Material Item Motorcraft Premium Long-Life Grease XG-1-E1 Specification ESA-M1C75-B Coupling shaft 2 4K227 Driveshaft slip yoke boot clamp Driveshaft slip yoke boot 4 4K227 Driveshaft slip yoke boot clamp Driveshaft slip-yoke Disassembly 1. NOTICE: Do not, under any circumstance, clamp the driveshaft in the jaws of a vise or similar holding fixture. Denting or localizing fracture can result, causing driveshaft failure during vehicle operation. Place the driveshaft on a suitable workbench. Do not damage the tubes. 2. Remove the slip-yoke from the driveshaft. 1. Cut and discard the slip-yoke boot clamps. 2. Remove the slip-yoke from the driveshaft. 3. Remove the slip-yoke boot from the driveshaft. Inspect the boot for wear or damage. Install a new slip-yoke boot as necessary. 4. Inspect the lubricant on the driveshaft splines and in the driveshaft slip-yoke for contamination. If contaminated, inspect the driveshaft splines and the slip-yoke for wear. Install new components as necessary. Assembly 1. Position the new small slip-yoke boot clamp on the driveshaft stub shaft. 2. Slide the small opening end of the slip-yoke boot on the driveshaft stub shaft, as far as it will travel.

22 3. Using boot clamp pliers, crimp the slip-yoke boot clamp. 4. Install the slip-yoke on the driveshaft. 1. Pull the slip-yoke boot toward the driveshaft. Lubricate the driveshaft splines with approximately 10 g (0.24 oz) of grease. 2. Position the new large slip-yoke boot clamp. 3. Align the blind splines and install the slip-yoke on the driveshaft. 5. Set the driveshaft assembled length to specification. 1. Remove any excess grease from the slip-yoke boot and driveshaft slip-yoke surfaces. 2. Position the slip-yoke boot in the slip-yoke boot groove. 3. Set the driveshaft assembled length to specification. Measure from the stub shaft weld to the U-joint centerline. 4. Bleed the air from the slip-yoke boot. 6. Using boot clamp pliers, crimp the large slip-yoke boot clamp. Copyright 2015 Ford Motor Company

23 Driveshaft 2015 E-Series DISASSEMBLY AND ASSEMBLY Procedure revision date: 08/11/2014 Driveshaft Universal Joint Single Cardan, Flange Yoke Special Tool(s) Installer/Remover, C-Frame and Screw (T74P-4635-C) Disassembly Initial disassembly 1. NOTICE: Do not, under any circumstance, clamp the driveshaft in the jaws of a vise or similar holding fixture. Denting or localizing fracture may result, causing driveshaft failure during vehicle operation. NOTICE: Because the driveshaft is precisely balanced, even a slight dent can cause noise and vibration. Place the driveshaft on a suitable workbench. Do not damage the tube. 2. Index-mark the driveshaft components. 3. Remove and discard the 4 snap rings. 4. Clamp the C-Frame and Screw Installer/Remover in a vise. Bearing cup removal 5. NOTE: If necessary, use a pair of pliers to remove a bearing cup that fails to press out all the way. Remove the bearing cups and the flange. 1. Position the flange in the C-Frame and Screw Installer/Remover. 2. Press out a bearing cup. 3. Rotate the flange 180 degrees. 4. Press on the spider using the C-Frame and Screw Installer/Remover to remove the remaining bearing cup. 5. Remove the flange. Final disassembly 6. Repeat bearing cup removal in this procedure to remove the remaining bearing cups and the spider from the driveshaft.

24 7. Clean the yoke area at the end of the driveshaft. Assembly Bearing cup installation 1. NOTE: Install the U-joint kits as complete assemblies only. Do not mix components from other kits. Install a new spider and bearing cups. 1. Start a new bearing cup in the driveshaft yoke. Check the needle bearings for correct positioning. 2. Position the new spider in the driveshaft yoke. 3. Position the driveshaft yoke in the C-Frame and Screw Installer/Remover. 4. Using the C-Frame and Screw Installer/Remover, press the bearing cup to just below the snap ring groove. Repeat to install the new bearing cup on the opposite side of the driveshaft yoke. Flange installation 2. Inspect the flange. Install a new flange, if necessary. 3. Install the new bearing cups and the flange. 1. Start a new bearing cup in the flange. Check the needle bearings for correct positioning. 2. Position the flange on the spider. 3. Position the assembly in the C-Frame and Screw Installer/Remover. 4. Using the C-Frame and Screw Installer/Remover, press the bearing cup to just below the snap ring groove. Repeat to install the new bearing cup on the opposite side of the flange. Final assembly 4. NOTE: Use the yellow snap rings supplied in the kit to assemble the U-joint. If difficulty is encountered with the yellow snap rings, install the black snap rings. Remove the driveshaft from the C-Frame and Screw Installer/Remover and install the 4 new snap rings. 5. NOTICE: Do not strike the bearings. Damage to the bearings may occur. Check the U-joint for freedom of movement. If binding, strike the yoke with a brass or plastic hammer. Copyright 2015 Ford Motor Company

25 Driveshaft 2015 E-Series DISASSEMBLY AND ASSEMBLY Procedure revision date: 08/11/2014 Driveshaft Universal Joint Single Cardan, Slip Yoke Special Tool(s) Installer/Remover, C-Frame and Screw (T74P-4635-C) U-Joint Driveshaft slip yoke 2 Snap rings (part of 4635) (4 required) 3 Bearing cups (part of 4635) 4 Spiders (part of 4635) Driveshaft Driveshaft centering socket flange Disassembly Initial disassembly 1. NOTICE: Do not, under any circumstance, clamp the shaft in the jaws of a vise or similar holding fixture. Denting or localizing fracture may result, causing shaft failure during vehicle operation. NOTICE: Because the driveshaft is precisely balanced, even a slight dent can cause noise and vibration. Place the shaft on a suitable workbench. Do not damage the tube. 2. Remove and discard the 2 snap rings. 3. Clamp the C-Frame and Screw Installer/Remover in a vise. Bearing cup removal 4. NOTE: If necessary, use a pair of pliers to remove a bearing cup that fails to press out all the way. Remove the bearing cups and the slip-yoke. 1. Position the yoke in the C-Frame and Screw Installer/Remover. 2. Press out a bearing cup. 3. Rotate the driveshaft slip-yoke 180 degrees. 4. Press on the spider to remove the remaining bearing cup and the U-joint.

26 5. Clean the driveshaft slip-yoke. Inspect the driveshaft slip-yoke. Install a new yoke as necessary. Assembly Bearing cup installation 1. NOTE: Install the U-joint kits as complete assemblies only. Do not mix components from other kits. Install a new spider and bearing cup. 1. Start a new bearing cup in the shaft yoke. Check the needle bearings for correct positioning. 2. Position the new spider in the shaft yoke. 3. Press the bearing cup to just below the snap ring groove using the C-Frame and Screw Installer/Remover. 2. NOTE: Use the yellow snap rings supplied in the kit to assemble the U-joint. If difficulty is encountered with the yellow snap rings, install the black snap rings. Remove the shaft from the C-Frame and Screw Installer/Remover and install the new snap ring. Opposite bearing cup installation 3. Repeat bearing cup installation in this procedure to install the new bearing cup and snap ring on the opposite side of the shaft yoke. 4. Remove the shaft from the C-Frame and Screw Installer/Remover and install the new snap ring. 5. NOTICE: Do not strike the bearings. Damage to the bearings may occur. Check the U-joint for freedom of movement. If binding, strike the yoke with a brass or plastic hammer.

27 Copyright 2015 Ford Motor Company

28 205-02A Rear Drive Axle/Differential Dana 60 and E-Series DISASSEMBLY AND ASSEMBLY Procedure revision date: 08/11/2014 Differential Case and Ring Gear Model 60, Limited Slip Special Tool(s) Limited Slip Preload Tool 205-D060 (D83T-4205-C1) or equivalent (Part of Limited Slip Rotating Tool 205-DS059 [D83T-4205-C]) Rotating Handle 205-D062 (D83T-4205-C3) or equivalent (Part of Limited Slip Rotating Tool 205-DS059 [D83T-4205-C]) Step Plate 205-D061 (D83T-4205-C2) or equivalent (Part of Limited Slip Rotating Tool 205-DS059 [D83T-4205-C]) Material Item Motorcraft Additive Friction Modifier XL-3 (US); CXL-3 (Canada) Motorcraft Premium Long-Life Grease XG-1-E1 Specification EST-M2C118-A ESA-M1C75-B Two-Pinion Limited-Slip Differential Model 60-1U Trac-Lok (Full-Floating Axle), Exploded View Differential case Differential pinion shaft lock pin Differential side gear 4 Retainer clip (part of 4880) Differential pinion thrust washer Differential pinion gear 7 Plate preload spacer (part of 4880) 8 Clutch disc (part of 4880) 9 Clutch plate (part of 4880) Differential pinion shaft Disassembly NOTE: When refilling the axle with lubricant, first add 0.15L (6 oz) of friction modifier. 1. NOTE: It is not necessary to remove the differential bearings to overhaul the limited-slip differential. NOTE: In most cases it is possible to disassemble the unit without removing the differential ring gear, which saves the cost of new bolts. If necessary, remove and discard the 12 differential ring gear bolts. Remove the gear.

29 2. NOTE: An axle shaft held in a vise, with the shaft splines extending not more than 76.2 mm (3 in) above the vise jaws, makes an excellent holding fixture for the differential case. Remove the differential pinion shaft lockpin. 3. Using a hammer and drift, remove the differential pinion shaft. 4. Position the Step Plate in the bottom differential side gear bore. Apply a small amount of grease to the Step Plate centering hole. 5. Screw the Limited Slip Preload Tool into the step plate. 6. NOTICE: Do not overtighten the Limited Slip Preload Tool. Overtightening can damage the rear axle disc and plate kit. Tighten the Limited Slip Preload Tool enough to move the differential side gears away from the differential pinion gears and relieve the normal loaded condition. 7. Using a mm (0.030 in) thick piece of shim or gauge stock, push the differential pinion thrust washers out from behind the differential pinion gears and remove them. 8. NOTE: Carrying out this step releases pressure from the rear axle disc and plate kit. Loosen the Limited Slip Preload Tool.

30 9. NOTE: When attempting to rotate the differential side gears, tighten or loosen the Limited Slip Preload Tool as necessary to permit gear movement. Tighten the Limited Slip Preload Tool until the differential pinion gears move slightly. 10. Insert the Rotating Handle into the differential pinion shaft bore. Rotate the differential case to position the differential pinion gears in the large differential case openings. Remove the differential pinion gears. 11. Hold the top differential side gear and rear axle disc and plate kit in the differential case and remove the Limited Slip Preload Tool. 12. Continue to hold the differential side gear and the rear axle disc and plate kit and remove the Rotating Handle. 13. Remove the top differential side gear and the rear axle disc and plate kit. 14. Turn the differential case so that the flange or differential ring gear side is facing upward. Ease the Step Plate, differential side gear and rear axle disc and plate kit out of the differential case. 15. NOTICE: Keep the stack of clutch plates and clutch discs in the exact order as removed or damage to the component may occur. Remove the retainer clips from both rear axle disc and plate kits to allow separation of the clutch discs and clutch plates for cleaning and inspection.

31 16. Inspect the following components. The clutch plates and clutch discs for cracks, excessive wear and distortion. Install an entirely new stack of clutch plates and discs on both sides if discarding one or more of the clutch plates or clutch discs. The differential pinion shaft and the differential case for excessive wear and pitting. The differential side gear and differential pinion gear teeth. Assembly 1. NOTICE: Always install an entirely new stack of clutch plates and discs on both sides if discarding one or more of the clutch plates or clutch discs or damage to the component may occur. Soak the clutch packs for 20 minutes in friction modifier. 2. NOTICE: Assemble the rear axle disc and plate kits to the differential side gears in exactly the same order as removed or damage to the component may occur. Prelubricate the differential side gear thrust faces and assemble the clutch plates and clutch discs onto the differential side gears. Prelubricate each component of both stacks with rear axle lubricant or with friction modifier. Refer to Specifications for the correct type of axle lubricant. 3. Assemble the retainer clips to the clutch plate ears. Both clips must seat completely onto the clutch plate ears. 4. NOTE: Hold the rear axle disc and plate kit to keep it from falling out of the differential case. Install the rear axle disc and plate kit and differential side gear in the differential case. The rear axle disc and plate kit must stay assembled to the differential side gear splines. The retainer clips must seat completely in the differential case pocket. 5. Install the bottom differential clutch pack and differential side gear in the differential case. The rear axle disc and plate kit must stay assembled to the differential side gear splines. The retainer clips must seat completely in the differential case pocket. 6. Install the Step Plate. Apply a small amount of grease to the centering hole of the Step Plate. 7. Screw the Limited Slip Preload Tool into the step plate. 8. Position the differential case onto the holding fixture.

32 9. Position both differential pinion gears opposite one another in the differential case. Align the differential pinion gear holes with each other. Hold the differential pinion gears in place by hand. 10. Tighten the Limited Slip Preload Tool enough so that the differential side gears move away from the differential pinion gears and relieve the loaded condition. 11. NOTE: Slightly loosen or tighten the Limited Slip Preload Tool to apply the necessary load to allow the differential side gears and differential pinion gears to rotate. While holding the differential pinion gears in place, insert the Rotating Handle into the differential pinion shaft bore. Rotate the differential case until the holes of both differential pinion gears align with those in the differential case. 12. NOTICE: Do not overtighten the Limited Slip Preload Tool. Overtightening can damage the rear axle disc and plate kit. Tighten the Limited Slip Preload Tool enough to allow clearance to assemble the differential pinion thrust washers. 13. NOTE: During assembly, the differential pinion thrust washer and the differential pinion gear holes must align exactly with those in the differential case. Assemble the differential pinion gear thrust washers into the differential case. Use a very small screwdriver to push the washers into place. 14. Remove all the tools from the differential case. 15. Install the differential pinion shaft.

33 16. Install the differential pinion shaft lock screw. Tighten to 27 Nm (20 lb-ft). 17. If removed, install the differential ring gear. Tighten the new 12 Grade 9 bolts to 215 Nm (158 lb-ft). Copyright 2015 Ford Motor Company

34 205-02A Rear Drive Axle/Differential Dana 60 and E-Series REMOVAL AND INSTALLATION Procedure revision date: 08/11/2014 Axle Assembly Brake tube bracket bolt Axle housing vent 3 W Lower shock absorber nuts 4 W Lower shock absorber bolts 5 N U-bolts (E-150, E-250 and E-350 Van and wagon) (2 required) U-bolt (E-450) (2 required) 5 N U-bolt (E-350 regular cab and cutaway) (2 required) 6 W U-bolt nuts (4 required) 7 W Parking brake cable retainer bolt Removal and Installation NOTICE: Suspension fasteners are critical parts because they affect performance of vital components and systems and their failure may result in major service expense. New parts must be installed with the same part numbers or equivalent part, if replacement is necessary. Do not use a replacement part of lesser quality or substitute design. Torque values must be used as specified during reassembly to make sure of correct retention of these parts. 1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Section Remove the wheels and tires. For additional information, refer to Section NOTICE: Do not allow the caliper and anchor plate assembly to hang from the brake hose or damage to the hose can occur. Remove the 2 brake caliper anchor plate bolts and position the brake caliper and anchor plate assembly aside. Support the brake caliper and anchor plate assembly using mechanic's wire. To install, tighten to 225 Nm (166 lb-ft). 4. Disconnect the parking brake cable from the parking brake. Repeat for the opposite side. Position the cables aside. 5. Disconnect the axle vent tube.

35 6. Disconnect the axle vent. To install, tighten to 3 Nm (27 lb-in). 7. Remove the brake tube bracket bolt. To install, tighten to 18 Nm (159 lb-in). 8. Remove the park brake cable retainer bolt. To install, tighten to 15 Nm (133 lb-in). 9. Disconnect the wheel speed sensor harness clips. 10. Remove the rear wheel speed sensor bolt, and position the sensor and spacer aside. To install, tighten to 25 Nm (18 lb-ft). 11. Position the brake tube, harness and cable aside. 12. To maintain driveline balance, index-mark the driveshaft flange yoke and the pinion flange. 13. Remove the 4 driveshaft flange yoke bolts. To install, tighten to 112 Nm (83 lb-ft).

36 14. NOTE: The driveshaft flange yoke fits tightly on the pinion flange yoke. Never hammer on the driveshaft or any of its components to disconnect the yoke from the flange. Pry only in the area shown, with a suitable tool, to disconnect the yoke from the flange. Using a suitable tool as shown, disconnect the driveshaft flange yoke from the pinion flange and support the driveshaft using mechanic's wire. 15. Use a suitable transmission jack to support the axle. 16. Remove and discard the shock absorber lower nuts and bolts. To install, tighten to 103 Nm (76 lb-ft). 17. NOTE: When installing new U-bolts, the measurement between A and B should be 107 mm (4.21 in) ± 3 mm (0.12 in) for E150/E250/E350 vehicles and 112 mm (4.41 in) ± 3 mm (0.12 in) for E450 vehicles. This is important for providing the correct U-bolt clamp load and retention of parts. Remove and discard the 8 nuts and the 4 axle U-bolts. To install, tighten until snug. Tighten the U-bolt nuts evenly in an X-type pattern in 5 stages. Stage 1: Tighten to 50 Nm (37 lb-ft). Stage 2: Tighten to 100 Nm (74 lb-ft). Stage 3: Tighten to 150 Nm (111 lb-ft). Stage 4: Tighten to 200 Nm (148 lb-ft). Stage 5: Tighten to 225 Nm (166 lb-ft). 18. NOTE: Watch for obstructions while lowering and raising the axle. Lower the axle from the vehicle. 19. To install, reverse the removal procedure. Install new fasteners where discarded.

37 Copyright 2015 Ford Motor Company

38 Front Disc Brake 2015 E-Series REMOVAL AND INSTALLATION Procedure revision date: 08/11/2014 Front Disc Brake (View 1 of 2) NOTE: Dual Rear Wheels (DRW) shown, Single Rear Wheel (SRW) similar. Disc Brake System Exploded View 1 2C534 Brake caliper guide pin bolts (2 required) 2 2B120 Brake caliper Brake pads 4 2B164 Brake pad anti-rattle clips (4 required) 5 2B292 Brake caliper anchor plate 6 N Brake caliper anchor plate bolts (2 required) Hub grease cap 8 N Cotter pin Spindle nut retainer Spindle nut Outer wheel bearing retainer washer Outer wheel bearing Brake disc and hub Inner wheel bearing Grease seal Front Disc Brake (View 2 of 2)

39 Brake flexible hose retaining clip 2 2C204 RH/ 2C205 LH RH/ 2C205 LH Wheel speed sensor Brake flexible hose Copper washers (2 required) Brake caliper flow bolt 6 Brake tube fitting (part of 2263 RH/2264 LH) 1. For additional information, refer to the procedures in this section. Copyright 2015 Ford Motor Company

40 Rear Disc Brake 2015 E-Series REMOVAL AND INSTALLATION Procedure revision date: 08/11/2014 Rear Disc Brakes (View 1 of 3) NOTE: RH side shown, LH side similar. Disc Brake System Exploded View 1 W Brake caliper anchor plate bolt (2 required) 2 Brake caliper guide pin cap (2 required) (part of 2C150) 3 2C150 Brake caliper guide pin bolt (2 required) Brake caliper Brake pad (2 required) 6 Spring clips (4 required) (part of 2200) 7 2B582 Brake caliper anchor plate

41 Rear Disc Brakes (View 2 of 3) Brake caliper flow bolts Copper washers (2 required) 10 N Brake flexible hose bracket bolt 11 RH brake flexible hose tube fitting (part of 2A442) 12 2A442 LH brake flexible hose assembly 13 2A442 RH brake flexible hose assembly Brake flexible hose retaining clip 15 2C008 LH brake flexible hose tube fitting Axle vent Rear Disc Brakes (View 3 of 3) NOTE: RH side shown, LH side similar.

42 17 W Brake caliper support bracket bolts 18 2C461 Brake caliper support bracket 19 Parking brake cable and conduit (part of 2A635) 1. For additional information, refer to the procedures in this section. Copyright 2015 Ford Motor Company

43 Parking Brake and Actuation 2015 E-Series REMOVAL AND INSTALLATION Procedure revision date: 08/11/2014 Parking Brake Control Parking brake control 2 W Parking brake control nut (3 required) 3 Parking brake switch electrical connector (part of 14401) Front parking brake cable and conduit Removal and Installation 1. Release the parking brake cable tension. For additional information, refer to Parking Brake Cable Tension Release in this section. 2. Remove the steering column opening cover. 3. Remove the 2 bolts and position the Data Link Connector (DLC) aside. 4. Remove the instrument panel LH knee bolster assembly. For additional information, refer to Instrument Panel Exploded View in Section Remove the LH front door scuff plate. 6. Remove the hood release handle bezel from the LH A-pillar lower trim panel, then remove the LH A-pillar lower trim panel. 7. Disconnect the electrical connector from the parking brake switch. 8. Remove the 3 parking brake control nuts and position the parking brake control to access the front parking brake cable. To install, tighten to 23 Nm (17 lb-ft). 9. Disconnect the front cable from the parking brake control.

44 10. Disconnect the front parking brake cable conduit from the parking brake control. 1. Using a box-end wrench, compress the fingers of the parking brake cable conduit. 2. Remove the front parking brake cable and conduit from the parking brake control. 11. To install, reverse the removal procedure. Copyright 2015 Ford Motor Company

45 Power Steering 2015 E-Series REMOVAL AND INSTALLATION Procedure revision date: 08/11/2014 Power Steering Pump 1 3A719 Pressure line clamp plate bolt 2 3A719 Pressure line 3 W Power steering pump bolt (3 required) 4 3C750 Clamp Supply hose 6 3A696 Power steering pump and pully assembly Removal and Installation NOTICE: While repairing the power steering system, care should be taken to prevent the entry of foreign material or failure of the power steering components may occur. 1. Using a suction device, remove the power steering fluid from the fluid reservoir. 2. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Section Rotate the accessory drive belt tensioner and postion the accessory drive belt away from the power steering pump pulley. For additional information, refer to front end accessory drive Front End Accessory Drive (FEAD) Exploded View in Section Disconnect the supply hose. 5. Remove the pressure line clamp plate bolt and disconnect the pressure line from the pump. Discard the bolt. To install, tighten the new bolt to 25 Nm (18 lb-ft). 6. Remove the 3 power steering pump bolts and the pump. To install, tighten to 25 Nm (18 lb-ft). 7. To install, reverse the removal procedure. 8. Fill the power steering system. For additional information, refer to Section Copyright 2015 Ford Motor Company

46 Steering Linkage 2015 E-Series REMOVAL AND INSTALLATION Procedure revision date: 08/11/2014 NOTE: Dual Rear Wheels (DRW) shown, Single Rear Wheel (SRW) similar. Steering Linkage Exploded View 1 N Cotter pins (3 required) 2 W Drag link-to-sector shaft arm nut retainer 3 3N807 Drag link-to-sector shaft arm nut 4 N Steering linkage damper-to-drag link bracket nut 5 3E651 Steering linkage damper 6 3A130A Inner tie-rod end 7 N Inner tie-rod end-to-drag link nut Sector shaft arm drag link Adjusting sleeve (2 required) 10 Adjusting sleeve clamp bolts (4 required) (part of 3281) 11 3A130 Outer tie-rod end (2 required) 12 W Adjusting sleeve clamp nuts (4 required) (also part of 3281) 13 N Outer tie-rod end nut (2 required) 14 W Outer tie-rod end nut retainer (2 required) 15 N Steering linkage damper-to-drag link bracket U-bolts (2 required) 16 3E652B Steering linkage damper-to-drag link bracket 17 N Steering linkage damper-to-drag link bracket U-bolt nuts (4 required) 18 3E652A Steering linkage damper frame bracket 19 W Steering linkage damper frame bracket bolts (3 required) 20 N Steering linkage damper-to-frame bracket nut 21 N Steering linkage damper-to-frame bracket bolt 1. For additional information, refer to the procedures in this section. Copyright 2015 Ford Motor Company

47 Steering Column 2015 E-Series REMOVAL AND INSTALLATION Procedure revision date: 08/11/2014 Removal and Installation NOTE: Cutaway chassis shown, stripped chassis similar. Steering Column 1 Pin-type retainer (part of ) 2 Brake Shift Interlock Actuator (BSIA) electrical connector (part of 14489) 3 Overdrive cancel switch electrical connector (part of 7210) 4 Passive Anti-Theft System (PATS) electrical connector (part of ) 5 Ignition switch electrical connector (part of 14A200) 6 14A206 Steering column wiring connector bracket 7 Clockspring electrical connector (part of 14A644) 8 Clockspring electrical connector (part of 14A644) 9 Pin-type retainer (4 required) (part of 14A644) 10 N Steering column shaft bolt (stripped chassis) 10 N Steering column coupling bolt (cutaway chassis) 11 3F723 Steering column 12 N Steering column nuts (4 required) 13 7E395 Selector lever cable 14 Roll Stability Control (RSC ) electrical connector (part of 14A459) NOTE: All steering column components are assembled with specific fasteners. They are designed with a thread-locking system to prevent loosening due to vibrations associated with normal vehicle operation. All vehicles 1. Remove the steering wheel. For additional information, refer to Steering Wheel in this section. 2. Remove the 2 Data Link Connector (DLC) screws and position the DLC aside.

48 3. Remove the steering column opening cover and the instrument panel LH knee bolster. For additional information, refer to Instrument Panel Exploded View in Section Remove the multifunction switch. For additional information, refer to Section Reinstall the ignition lock cylinder and remove the key. Stripped chassis 6. Remove the 2 lower steering column support bracket nuts. To install, tighten to 18 Nm (159 lb-in). 7. Remove the 2 upper steering column support bracket nuts and the steering column support bracket. To install, tighten to 18 Nm (159 lb-in). All vehicles 8. Disconnect the Brake Shift Interlock Actuator (BSIA) electrical connector and detach the pin-type retainer from the steering column wiring connector bracket. Stripped chassis 9. NOTICE: Do not allow the steering column to rotate while the steering column shaft is disconnected or damage to the clockspring may result. If there is evidence that the steering column has rotated, the clockspring must be removed and recentered. For additional information, refer to Section B. Remove the bolt and detach the upper steering column shaft from the steering column. To install, tighten to 40 Nm (30 lb-ft). Cutaway chassis 10. NOTICE: Do not allow the steering column to rotate while the steering column shaft is disconnected or damage to the clockspring can result. If there is evidence that the steering column has rotated, the clockspring must be removed and recentered. For additional information, refer to Section B. All vehicles Remove the bolt and detach the steering column coupling and shaft from the steering column. To install, tighten to 25 Nm (18 lb-ft). 11. Disconnect the selector lever cable from the selector lever pivot arm. 12. Remove the selector lever cable from the steering column by pushing the tab on the cable in and sliding the cable off the mounting bracket. 13. Disconnect the Passive Anti-Theft System (PATS) electrical connector. Detach the PATS electrical connector pin-type retainer from the instrument panel support bracket. 14. Disconnect the ignition switch electrical connector. 15. Disconnect the overdrive cancel switch electrical connector and the 2 clockspring electrical connectors at the base of the steering column. 16. Detach the 2 clockspring electrical connector pin-type retainers from the steering column wiring connector bracket. 17. If equipped, disconnect the Roll Stability Control (RSC ) electrical connector and detach the pin-type retainer from the steering column wiring connector bracket. 18. Detach the steering column wiring connector bracket from the steering column and position it aside. 19. While supporting the steering column, remove the 4 nuts and the steering column. To install, tighten to 15 Nm (133 lb-in). 20. To install, reverse the removal procedure. Copyright 2015 Ford Motor Company

49 Steering Column Switches 2015 E-Series REMOVAL AND INSTALLATION Procedure revision date: 08/11/2014 Ignition Switch 1 Ignition switch electrical connector 2 Ignition switch screws (2 required) 3 3D568 Ignition switch Removal and Installation 1. Depower the Supplemental Restraint System (SRS). For additional information, refer to Section B. 2. Remove the steering column opening cover and the instrument panel LH knee bolster. For additional information, refer to Instrument Panel Exploded View in Section Disconnect the ignition switch electrical connector. 4. Remove the 2 ignition switch screws and the ignition switch. To install, align the ignition switch with the slot and index mark on the steering column and tighten the screws to 6 Nm (53 lb-in). 5. To install, reverse the removal procedure. 6. Repower the SRS. For additional information, refer to Section B. Copyright 2015 Ford Motor Company

50 303-01A Engine 5.4L (2V) 2015 E-Series IN-VEHICLE REPAIR Procedure revision date: 08/11/2014 Valve Train Components Exploded View 1 6C501 Hydraulic lash adjuster (16 required) Roller follower (16 required) 3 W Camshaft sprocket bolt (2 required) 4 N Camshaft sprocket washer (2 required) LH camshaft sprocket 6 6B284 Camshaft bearing cap (2 required) Camshaft sprocket spacer (2 required) 8 6B280 Camshaft bearing cap (10 required) 9 N Camshaft bearing cap bolt (26 required) 10 6A274 LH camshaft Valve spring retainer key (32 required) Valve spring retainer (16 required) Valve spring (16 required) 14 6A517 Valve stem seal (16 required) LH cylinder head Intake valve (8 required) Exhaust valve (8 required) RH cylinder head RH camshaft sprocket RH camshaft 1. For additional information, refer to the procedures in this section. Copyright 2015 Ford Motor Company

51 303-01A Engine 5.4L (2V) 2015 E-Series IN-VEHICLE REPAIR Procedure revision date: 08/11/2014 Engine Lubrication Components Exploded View 1 W Oil pan bolt (16 required) Oil pan Oil pan gasket 4 N Oil pump screen and pickup tube-to-spacer bolt 5 N Oil pump screen and pickup tube bolts (2 required) Oil pump screen and pickup tube 7 N Oil pump bolt (3 required) Oil pump 1. For additional information, refer to the procedures in this section. Copyright 2015 Ford Motor Company

52 303-01A Engine 5.4L (2V) 2015 E-Series IN-VEHICLE REPAIR Procedure revision date: 08/11/2014 Flexplate or Flywheel and Crankshaft Rear Seal Exploded View 1 N Flexplate bolt (8 required) Flexplate 3 6A373 Rear cover plate Crankshaft oil slinger Crankshaft rear seal 6 N Crankshaft rear seal retainer plate bolt (6 required) 7 6K318 Crankshaft rear seal retainer plate 1. For additional information, refer to the procedures in this section. Copyright 2015 Ford Motor Company

53 Engine Cooling 2015 E-Series REMOVAL AND INSTALLATION Procedure revision date: 08/11/2014 Radiator and Cooling Fan Exploded View 1 N Cooling fan-to-cooling fan clutch bolt (4 required) Cooling fan 3 8A616 Cooling fan clutch 4 N Cooling fan shroud bolt (2 required) Cooling fan shroud 6 8B274 Upper radiator hose Upper radiator hose clamp 8 8W005 Degas bottle coolant hose Lower radiator hose assembly Lower radiator hose clamp 11 8B204 Lower radiator insulator (2 required) Radiator 13 N RH radiator support bracket bolts (2 required) 14 8B359 RH radiator support bracket 15 8B204 RH upper radiator insulator 16 N LH radiator support bracket bolts (2 required) 17 8B359 LH radiator support bracket 18 8B204 LH upper radiator insulator 1. For additional information, refer to the procedures in this section. Copyright 2015 Ford Motor Company

54 303-04A Fuel Charging and Controls 5.4L (2V) 2015 E-Series REMOVAL AND INSTALLATION Procedure revision date: 08/11/2014 Throttle Body 1 Electronic Throttle Control (ETC) electrical connector (part of 12C508) 2 Throttle Position (TP) sensor electrical connector (part of 12C508) 3 W Throttle Body (TB) bolt (4 required) 4 9F991 TB 5 9E930 TB gasket Removal 1. Remove the Air Cleaner (ACL) assembly and ACL outlet tube. For additional information, refer to Section NOTE: The red clip must be pulled out before disconnecting the electrical connector. Disconnect the Electronic Throttle Control (ETC) electrical connector. 3. NOTE: The red clip must be pulled out before disconnecting the electrical connector. Disconnect the Throttle Position (TP) sensor electrical connector. 4. Remove the 4 bolts and the Throttle Body (TB). Discard the TB gasket. Installation 1. Install a new TB gasket, position the TB and tighten the 4 bolts in 2 stages. Stage 1: Tighten to 9 Nm (80 lb-in). Stage 2: Tighten an additional 90 degrees. 2. Connect the TP sensor electrical connector. Push back the red clip. 3. Connect the ETC electrical connector. Push back the red clip. 4. Install the ACL assembly and ACL outlet tube. For additional information, refer to Section Copyright 2015 Ford Motor Company

55 303-04A Fuel Charging and Controls 5.4L (2V) 2015 E-Series REMOVAL AND INSTALLATION Procedure revision date: 08/11/2014 Fuel Rail and Fuel Injector Exploded View 1 9J274 Fuel supply tube quick connect coupling 2 6K817 PCV tube 3 Fuel injector electrical connector (part of 12C508) (8 required) 4 W Fuel rail bolt (4 required) 5 9F792 Fuel rail Fuel injector-to-fuel rail O-ring seal (8 required) 7 9F593 Fuel injector (8 required) Fuel injector-to-intake manifold O-ring seal (8 required) 9 Fuel pressure relief valve cap (part of 9H323) 10 9H321 Fuel pressure relief valve 1. For additional information, refer to the procedures in this section. Copyright 2015 Ford Motor Company

56 Accessory Drive 2015 E-Series REMOVAL AND INSTALLATION Procedure revision date: 08/11/2014 Front End Accessory Drive (FEAD) Exploded View NOTE: It is necessary to remove the Air Cleaner (ACL) assembly to gain access to the accessory drive belt and accessory drive belt tensioner. For additional information, refer to Section Accessory drive belt 2 N Accessory drive belt tensioner bolt (3 required) 3 6B209 Accessory drive belt tensioner 4 N Accessory drive belt idler pulley bolt 5 19A216 Accessory drive belt idler pulley NOTE: It is necessary to remove the Air Cleaner (ACL) assembly to gain access to the accessory drive belt and accessory drive belt tensioner. For additional information, refer to Section Accessory drive belt 2 N Accessory drive belt tensioner bolt (3 required) 3 6B209 Accessory drive belt tensioner 4 N Accessory drive belt idler pulley bolt 5 19A216 Accessory drive belt idler pulley 1. Refer to the procedures and/or exploded views in this section for any Warnings, Notices, Notes, Materials, Specifications, and Special Tools. Items in the exploded views may not be listed in order of removal. Copyright 2015 Ford Motor Company

57 Starting System 2015 E-Series REMOVAL AND INSTALLATION Procedure revision date: 08/11/2014 Starter Motor 1 Terminal cover (part of 14463) 2 W Starter solenoid S-terminal nut Starter solenoid S-terminal eyelet 4 W Starter solenoid B-terminal nut Starter solenoid B-terminal eyelet 6 N Starter motor ground cable nut Starter motor ground cable eyelet 8 W Starter motor mounting stud bolt 9 W Starter motor mounting bolts (2 required) Starter motor Removal and Installation WARNING: Always disconnect the battery ground cable at the battery before disconnecting the starter motor battery terminal lead. If a tool is shorted at the starter motor battery terminal, the tool can quickly heat enough to cause a skin burn. Failure to follow this instruction may result in serious personal injury. 1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Section Disconnect the battery ground cable. For additional information, refer to Section NOTE: The starter motor terminal cover is attached to the wiring harness. Detach the starter motor solenoid terminal cover. 4. Remove the starter solenoid S-terminal nut and disconnect the S-terminal eyelet. To install, tighten to 6 Nm (53 lb-in). 5. Remove the starter solenoid B-terminal nut and disconnect the B-terminal eyelet. To install, tighten to 12 Nm (106 lb-in). 6. Remove the starter motor ground cable nut and disconnect the ground cable eyelet. To install, tighten to 25 Nm (18 lb-ft). 7. Remove the bolts, the stud bolt and the starter motor. To install, tighten the upper bolt before tightening the lower fasteners. To install, tighten to 25 Nm (18 lb-ft). 8. To install, reverse the removal procedure. Copyright 2015 Ford Motor Company

58 303-07A Engine Ignition 5.4L (2V) 2015 E-Series REMOVAL AND INSTALLATION Procedure revision date: 08/11/2014 Engine Ignition Components Exploded View 1 Ignition coil electrical connector (part of 12C508) (8 required) 2 W Ignition coil retaining bolt (8 required) 3 12A366 Ignition coil (8 required) Spark plug (8 required) 1. For additional information, refer to the procedures in this section. Copyright 2015 Ford Motor Company

59 303-07B Engine Ignition 6.8L (2V) 2015 E-Series REMOVAL AND INSTALLATION Procedure revision date: 08/11/2014 NOTE: LH shown, RH similar. Engine Ignition Components Exploded View 1 LH ignition coil electrical connector (part of 12C503) (5 required) 2 W LH ignition coil retaining bolt (5 required) 3 12A366 LH ignition coil (5 required) LH spark plug (5 required) 1. For additional information, refer to the procedures in this section. Copyright 2015 Ford Motor Company

60 Engine Emission Control 2015 E-Series REMOVAL AND INSTALLATION Procedure revision date: 08/11/2014 Positive Crankcase Ventilation (PCV) Valve 5.4L 1 6A664 PCV hose quick connect fitting 2 6A666 PCV valve 1. Remove the engine cover. For additional information, refer to Section Disconnect the PCV valve tube quick-connect fitting and position the PCV tube aside. 3. NOTICE: A new Positive Crankcase Ventilation (PCV) valve must be installed if removed. When removed, the plastic retaining ears of the PCV valve are sheared. Rotate the PCV valve counterclockwise and remove the PCV valve. Discard the PCV valve. 4. To install, reverse the removal procedure. Install a new PCV valve. Copyright 2015 Ford Motor Company

61 Intake Air Distribution and Filtering 2015 E-Series REMOVAL AND INSTALLATION Procedure revision date: 08/11/2014 NOTE: 5.4L and 6.8L. Intake Air System Components Exploded View 1 9F823 Air Cleaner (ACL) inlet 2 9A612 ACL tray ACL element ACL clamp 5 9A628 Mass Air Flow (MAF) sensor body 6 Engine harness-to-maf sensor pigtail electrical connector (part of 12A581) 7 12A690 MAF sensor pigtail electrical connector 8 W MAF sensor screw (2 required) 9 12B579 MAF sensor 10 N ACL cover bolt (4 required) ACL cover 12 9C632 Clamp 13 9B659 ACL outlet pipe 14 9C632 Clamp 15 9F763 Resonator 16 9C632 Clamp (5.4L) 17 6C342 Vapor tube quick connect fitting (5.4L) 18 9B642 TB inlet pipe (5.4L) 19 9C632 Clamp (5.4L) 20 9F991 TB (5.4L) 21 9C632 Clamp (6.8L) 22 6C342 Vapor tube quick connect fitting (6.8L) 23 9B642 TB inlet pipe (6.8L) 24 9C632 Clamp (6.8L) 25 9F991 TB (6.8L) 1. For additional information, refer to the procedures in this section. Copyright 2015 Ford Motor Company

62 Evaporative Emissions 2015 E-Series REMOVAL AND INSTALLATION Procedure revision date: 08/11/2014 Evaporative Emission (EVAP) System Components Exploded View Aft-of-Axle Fuel Tank Evaporative Emission (EVAP) Canister Assembly Removal NOTE: Vehicle body removed from art for clarity. 1 9D653 Evaporative Emission (EVAP) canister assembly 2 W EVAP canister assembly bracket bolts (5 required) 3 Fuel vapor tube-to-evap canister assembly quick connect coupling (part of 9L291) 4 Fuel vapor tube-to-evap canister assembly quick connect coupling (part of 9L291) 5 Pushpin retainer 6 EVAP canister vent solenoid electrical connector (part of (9F759) Aft-of-Axle Fuel Tank Evaporative Emission (EVAP) Canister, Bracket, Vent Solenoid and Dust Separator Assembly and Tube Item Part Number Description 1 W Evaporative Emission (EVAP) canister assembly-to-evap canister assembly bracket lower bolt (2 required)

63 2 9E817 EVAP canister assembly bracket 3 9D925 EVAP canister vent solenoid and dust separator assembly tube 4 9B328 EVAP canister vent solenoid and dust separator assembly 5 9C985 EVAP canister 6 9D665 EVAP canister assembly bracket 7 W EVAP canister assembly-to-evap canister assembly bracket upper bolt (2 required) Midship Fuel Tank Evaporative Emission (EVAP) Canister Assembly Removal NOTE: Vehicle body removed from art for clarity. 1 W EVAP canister bracket-to-fuel tank nut (4 required) 2 9D653 EVAP canister and bracket assembly 3 Fuel tank-to-evap canister vapor hose quick connect coupling (part of 9G271) 4 9G271 Fuel tank-to-evap canister vapor hose assembly Midship Fuel Tank Evaporative Emission (EVAP) Canister and Bracket Assembly 1 W Evaporative Emission (EVAP) canister front bracket-to-evap canister bolt (2 required) 2 9D665B EVAP canister front bracket 3 9R543 EVAP canister rear bracket-to-evap canister screw (2 required) 4 9D665A EVAP canister rear bracket 5 9C985 EVAP canister assembly Midship Fuel Tank Evaporative Emission (EVAP) Canister, Vent Solenoid and Dust Separator Assembly and Tube

64 1 9D925 Evaporative Emission (EVAP) canister vent solenoid and dust separator assembly tube 2 9B328 EVAP canister vent solenoid and dust separator assembly 3 9D653 EVAP canister 1. For additional information, refer to procedures in this section. Copyright 2015 Ford Motor Company

65 Electronic Engine Controls Gasoline Engines 2015 E-Series REMOVAL AND INSTALLATION Procedure revision date: 08/11/2014 E-150, E-250 and E-350 Vehicles Heated Oxygen Sensor (HO2S) and Catalyst Monitor Sensor Exploded View 1 RH Heated Oxygen Sensor (HO2S) electrical connector (part of 12B637) 2 9F472 RH HO2S 3 LH HO2S electrical connector (part of 12B637) 4 9F472 LH HO2S 5 LH Catalyst Monitor Sensor (CMS) electrical connector (part of 12B637) 6 9G444 LH CMS 7 RH CMS electrical connector (part of 12B637) 8 9G444 RH CMS E-450 Vehicles 1 RH HO2S electrical connector (part of 12B637) 2 9F472 RH HO2S 3 LH HO2S electrical connector (part of 12B637) 4 9F472 LH HO2S 5 Catalyst Monitor Sensor (CMS) electrical connector (part of 12B637) 6 9G444 CMS 1. For additional information, refer to the procedures in this section. Copyright 2015 Ford Motor Company

66 Automatic Transaxle/Transmission TorqShift 2015 E-Series ASSEMBLY Procedure revision date: 08/11/2014 Transmission Special Tool(s) Adapter for (use with ) Air Test Plate, Transmission Aligner, Clutch Spring Compressor Aligner, Transmission Fluid Pump (T89T B) Aligner, Valve Body Compressor, Clutch Spring (T65L A) Handle, Torque Converter (T81P-7902-C) Installer, Fluid Filler Tube Installer, Output Shaft Seal Installer, Output Shaft Seal/Housing Installer, Shift Shaft Fluid Seal (TOOL-77288) Installer, Transmission Extension Housing Seal Installer, Transmission Forward Clutch Assembly

67 Loading Fixture, Clutch 307-S383 Retainer, Torque Converter Retaining Ring Pliers (T95P AHR) Socket, Output Shaft Locknut Test Plate Screw Set, Transmission (T82P-7006-C) Material Item Motorcraft MERCON LV Automatic Transmission Fluid XT-10-QLVC (US); CXT-10-LV12 (Canada) Motorcraft Threadlock and Sealer TA-25-B Specification MERCON LV WSK-M2G351-A5 Transmission, Disassembled View

68

69 Flexplate-to-torque converter nut Torque converter assembly (model dependent) Shaft input 4 7L323 Seal stator support 5 7A248 Seal front pump support 6 7A248 Seal front pump 7 7N134 Bolt M8 x 70 hex flange head 8 7A103 Pump assembly front 9 N S2-S2 Bolts M8 x 1.25 x 45 front pump 10 7D014 Washer front pump support No. 1T 11 7A136 Gasket front pump 12 7G402 Seals coast clutch (2 required) 13 7C096 Race and bearing assembly sun gear thrust No. 2B and 3B 14 7A262 Piston overdrive clutch 15 7F222 Spring overdrive clutch piston return 16 7B164 Plates overdrive clutch internal spline friction 17 7B442 Plates overdrive clutch external spline steel 18 7B066 Plate overdrive clutch pressure 19 7D483 Ring overdrive clutch press plate retaining 20 7G387 Cylinder and bushing assembly coast clutch 21 7A262 Piston coast clutch 22 7G299 Spring coast clutch return 23 7A527 Ring coast clutch spring retaining 24 7B164 Plates coast clutch internal spline friction (model dependent) 25 7B442 Plates coast clutch external spline steel (model dependent) 26 7A089 Clutch assembly coast one-way 27 7D063 Gear overdrive sun 28 7A577 Ring retainer internal style No W S300-S300 Bolt coast clutch hub (4 required) 30 7H501 Hub assembly input coast clutch 31 7B446 Gear assembly overdrive planetary

70 32 7F240 Bearing and race assembly direct clutch No. 4B 33 7A153 Gear overdrive ring 34 7A658 Shaft overdrive center 35 7G375 Ring center support retaining 36 7G178 Bearing and race assembly sun gear thrust No. 5B 37 7D483 Ring overdrive ring gear retaining 38 7A130 Support assembly center 39 7N134 Bolt M12 x 1.75 x 31 hex flange head (intermediate clutch feed) 40 7N134 Bolt M12 x 1.75 x 31 hex flange head (forward clutch feed) 41 7D025 Seals Teflon (2 required) 42 7L326 Washer center support thrust No. 6T 43 7E005 Piston intermediate clutch 44 7F222 Support and spring assembly intermediate clutch 45 7D483 Ring intermediate clutch spring 46 7F219 Plates intermediate clutch internal spline (friction) 47 7B442 Plates intermediate clutch external spline (steel) 48 7B066 Plate intermediate clutch pressure 49 7F283 Cylinder and hub assembly direct clutch 50 7A262 Piston assembly direct clutch 51 7B070 Spring direct clutch piston return 52 7H359 Piston direct clutch balance 53 7C122 Ring direct clutch balance piston retaining 54 7B164 Plates direct clutch internal spline friction 55 7B442 Plates direct clutch external spline steel 56 7B066 Plate direct clutch pressure S-S Ring direct clutch plate retaining (selective fit) 58 7C096 Washer intermediate brake thrust No. 7T 59 7F374 Bearing assembly intermediate clutch No. 8B 60 7D019 Seals forward clutch cylinder (2 required) 61 7A360 Cylinder assembly forward clutch 62 7A262 Piston assembly forward clutch 63 7B070 Spring forward clutch piston return 64 7H360 Piston assembly forward clutch balance 65 7H365 Ring forward clutch balance piston retaining 66 7B070 Spring forward clutch cushion 67 7B164 Plates forward clutch internal spline friction 68 7B442 Plates forward clutch external spline steel 69 7B066 Forward clutch pressure plate 70 7D483 Ring forward clutch plate retaining (selective fit) 71 7D090 Washer forward clutch hub thrust No. 9T 72 7G375 Ring retaining (forward ring gear) 73 7D234 Bearing and race assembly sun gear thrust No. 10B, 12B, 15B 74 7B067 Hub and bushing assembly forward ring gear 75 7D392 Gear forward ring 76 7A166 Bearing and race assembly forward carrier No. 11B 77 7A398 Planet assembly forward 78 7L339 Lube dam forward carrier 79 7D062 Shell and sun gear assembly 80 7D483 Ring reverse clutch plate retaining 81 7D006 Planet assembly reverse (with clutch plates) 82 7A153 Gear output shaft ring 83 7D164 Hub output shaft ring gear 84 7G375 Ring retaining (reverse ring gear) 85 7G178 Bearing and race assembly No. 16B 86 7D483 Ring reverse clutch spring retaining 87 7D406 Retainer and spring assembly reverse clutch 88 7D402 Piston reverse clutch 89 7D019 Seals Teflon 90 7R411 Seal assembly intermediate brake drum 91 7A020 Indicator transmission fluid level 92 7A228 Tube assembly transmission fluid fill S-S O-ring 94 7A160 Tube transmission fluid inlet short Case assembly Vent assembly case 97 7D273 Cooler line case fittings 98 W S300-S300 O-rings cooler connector 99 7Z101 O-ring sensor 100

71 7M101 Sensor Turbine Shaft Speed (TSS) 101 N S439-S439 Bolts M6 x 1 x J122 Valve air bleed check Snubber output shaft 104 7E380 Plug case oil filler 105 7B368 Bearing assembly parking gear needle thrust (slip yoke) No. 17B 106 7A233 Gears output shaft park S-S Plug cups Shaft output (slip yoke) Gaskets extension housing 110 7A039 Extension assembly slip yoke 111 7Z101 O-rings Output Shaft Speed (OSS) sensor 112 7H103 Sensors output shaft 113 N S437-S437 Stud M6 x 1 1-M10 x extension housing 114 N S437-S437 Bolts M10 x 1.5 x 93.5 extension housing 115 N S437-S437 Bolts M10 x 1.5 x 40 extension housing 116 7A034 Extension housing bushing 117 7A292 Seal output shaft spline Seal assembly extension housing Rear Wheel Drive (RWD) 119 7B368 Washer park gear thrust fixed yoke No. 17 T Shaft output fixed yoke 121 7A039 Extension assembly fixed yoke Seal assembly extension housing Four-Wheel Drive (4WD) Retainer assembly transmission output shaft 124 4K177 Flange drive shaft 4WD 125 W S426-S426 Bolt M12 x 55 overdrive flange 126 N S-S Screw and washer M8 x 1.25 x 23.5 hex (2 required) 127 7D419 Plate park rod guide 128 7D070 Spring park pawl return 129 7D071 Pin 0.5 x 1.91 dowel ground hardened 130 7A441 Pawl park 131 N S191-S191 Screw M8 x 1.25 x 25 pan head 132 7G101 Abutment park pawl S2-S2 Spring nut 134 7B148 Tag transmission service identification 135 7A232 Rod assembly park pawl actuating 136 7A256 Lever assembly manual control (model dependent) 137 7H557 Transmission Range (TR) detent assembly 138 N S100-S100 Bolts M6 x 1.0 x 15.2 hex flange head transmission range 139 7G100 Pin shaft retaining 140 7B498 Seal manual lever 141 7B210 Roll pin manual control lever to case S2-S2 Plug line pressure 143 7Z302 Seal transmission fluid filter 144 7G186 Filter and seal assembly 145 7A191 Gasket transmission fluid pan 146 7A194 Transmission fluid pan 147 7L027 Ceramic magnet fluid pan Plug transmission fluid pan drain 149 N S437-S437 Bolt transmission fluid pan 150 7Z276 O-ring transmission vehicle harness connector 151 7C155 Gasket control valve body 152 Ditch plate 153 7H200 Gasket filter plate 154 Manifold body 155 7E335 W-clip pressure switch plug 156 7E440 Plug direct clutch 157 7H141 Sensor Transmission Fluid Temperature (TFT) 158 7H038 Gasket backing plate 159 Backing plate 160 7D389 Valve manual 161 W S300-S300 Bolt M6 x 1 x 30 hex head (5 required) 162 W Bolt M6 x 15.2 solenoid backing plate-to-ditch plate (5 required) 163 W Bolt M6 x 27.5 solenoid manifold-to-ditch plate (3 required) 164 N S-S Bolt M6 x 1.0 x 42.5 hex flange head (3 required) 165 W Bolt M6 x 55 solenoid manifold-to-ditch plate (1 required) 166 W S300-S300 Bolt M6 x 68 hex flange (13 required) 167 7G383 Variable Force Solenoid (VFS) line pressure 168

72 7J136 VFS directly proportional (4 required) 169 7J136 VFS inversely proportional (2 required) 170 7J137 VFS E-clip (7 required) 171 7G276 Wiring harness 172 Bolt T25 holds wire harness to manifold (2 required) 173 Overdrive clutch assembly 174 Coast clutch assembly 175 Intermediate clutch assembly 176 Direct clutch assembly 177 Forward clutch and planetary assembly 178 Reverse clutch and planetary assembly 179 7A039 Extension housing RWD (slip yoke) 180 7A039 Extension housing 4WD (fixed yoke) NOTE: Soak all friction clutch plates in transmission fluid. NOTE: Prior to installation, lightly lubricate all O-ring seals with transmission fluid. NOTE: Lightly lubricate all thrust washers with petroleum jelly to hold them in place during assembly. All transmissions 1. Mount the transmission case into a suitable stand. 2. If removed, use the Fluid Filler Tube Installer to install the short transmission fluid inlet tube. 3. If removed, use the Output Shaft Seal/Housing Installer to install a new Teflon seal retainer. Install 2 new Teflon seals. 4. NOTE: Coat the reverse clutch piston seals with petroleum jelly. Install the reverse clutch piston in the case until it is fully seated in the case. 5. Install the reverse clutch return spring assembly. 6. NOTICE: Do not over compress the return spring or damage to the spring will occur. Using the Clutch Spring Compressor Aligner and the Clutch Spring Compressor, install the reverse clutch return spring snap ring.

73 Transmissions equipped with a slip yoke 7. NOTE: The use of petroleum jelly will hold the No. 17 thrust bearing in place during assembly. Install the No. 17 park gear thrust bearing. Transmissions equipped with a fixed flange 8. NOTE: The use of petroleum jelly will hold the No. 17 thrust washer in place during assembly. Install the No. 17 park gear thrust washer. All transmissions 9. NOTICE: Be careful when installing the output shaft not to damage the seals or a transmission leak could occur. Install the output shaft. 10. NOTICE: The Torx screw has a threadlocking compound. If the screw is removed, it must be discarded and a new screw installed. If removed, install the park pawl abutment with a new Torx screw. Tighten to 25 Nm (18 lb-ft). 11. Install the park pawl. 1. Install the park pawl shaft. 2. Install the park pawl. 3. Install the park pawl return spring.

74 12. NOTE: Make sure the dimple on the park guide support plate is facing inward. Install the park rod guide plate. 1. Install the park rod guide plate. 2. Install the bolts. Tighten to 25 Nm (18 lb-ft). 13. Install a new orifice lube plug in the rear of the case. Using a 12 mm (0.472 in) socket, tap the orifice lube plug into the back of the transmission. Check to make sure that the orifice lube plug is fully seated into the back of the transmission. 14. Install a new extension housing gasket. 15. NOTE: Fixed flange transmission shown, slip yoke transmission similar. Install the extension housing and 9 extension housing bolts. Tighten to 47 Nm (35 lb-ft). 16. Using the Shift Shaft Fluid Seal Installer, install a new manual control lever seal. 17. Install the Transmission Range (TR) sensor, park rod assembly and loosely install the bolts.

75 18. Install the manual control lever. 19. Install the roll pin into the case. 20. Install a new roll pin. Leave 2 mm (0.08 in) of the pin exposed. 21. Tighten the TR sensor bolts. Tighten to 10 Nm (89 lb-in). Transmissions equipped with a fixed flange 22. Using the Transmission Extension Housing Seal Installer, install a new extension housing seal. 23. Inspect the new output shaft nut O-ring for cuts. A new nut must be installed. 24. Using the Output Shaft Locknut Socket, install a new output shaft retaining nut.

76 Tighten to 200 Nm (148 lb-ft). 25. Install the output flange and a new bolt. Tighten to 130 Nm (96 lb-ft). Transmissions equipped with a slip yoke 26. Install a new extension housing seal using the Output Shaft Seal Installer. All transmissions 27. Install the No. 16 bearing and race. 28. Assemble the rocker clutch and ring gear assembly. 1. Install the No. 15 hub bearing onto the ring gear hub. 2. Install the rocker clutch, low/reverse clutch pack and carrier and hub assembly into the output hub and ring gear assembly. 29. NOTE: Place the transmission in the horizontal position. Install the rocker clutch and ring gear assembly into the transmission case.

77 30. NOTICE: Do not apply air pressure to move the low/reverse piston without first installing the friction plates and the snap ring, or damage to the snap ring will occur. Install a new flat snap ring and make sure that the snap ring is fully seated in the case snap ring groove. Install a new flat snap ring so the tang ends are in the gaps to the right and to the left of the case spline as shown. Check the function of the reverse clutch by applying air to the correct passage (through the case valve body worm trail) for the reverse clutch. 31. Using the Adapter and the Transmission Forward Clutch Assembly Installer, install the forward geartrain as an assembly. 32. Install the intermediate clutch pressure plate. Position the intermediate clutch pressure plate in the case with the 3 tabs facing downward. 33. Install the intermediate clutch plates, starting with a friction plate. 34. Install the center support with the transmission in a vertical position to avoid damage to the center support Teflon seals.

78 35. Loosely install the center support feed bolts. 1. Loosely install the Torx head forward clutch feed bolt into the case toward the rear of the case. 2. Loosely install the hex-head intermediate clutch feed bolt into the case toward the front of the case. 36. Using the Retaining Ring Pliers, install the center support snap ring. The snap ring should be installed with the flat edge facing downward. The gap in the snap ring should be facing in the 6 o'clock position. Tap the snap ring securely into the case. 37. Tighten the center support feed bolts. Tighten to 33 Nm (24 lb-ft). 38. Install the No. 5 thrust bearing onto the center support. 39. Install the center shaft and ring gear. 40. Install the No. 4 thrust bearing onto the center shaft. 41. Using the Clutch Loading Fixture, install the coast clutch assembly and overdrive carrier.

79 42. Install the overdrive clutch assembly snap ring with the gap in the 6 o'clock position. 43. Install the overdrive pressure plate with the notches facing up. 44. Install the overdrive clutch. Start with a friction plate, alternating with a steel plate. 45. Install a new pump gasket. 46. Install the No. 2 thrust bearing. 47. Install the input shaft into the case. 48. NOTE: Transmission Fluid Pump Aligner pins are used in case holes located at the 5 o'clock and 11 o'clock positions. Install the Transmission Fluid Pump Aligner into the case in order to install the pump.

80 49. Check to make sure that the No. 1 thrust washer is installed on the pump stator, and make sure that the No. 2A bearing is installed onto the pump support. 50. NOTE: Pump-to-case alignment pins are used in case holes located at the 11 o'clock and 5 o'clock positions. Using the Transmission Fluid Pump Aligner, install the pump assembly with the transmission in a vertical position to avoid damage to the pump stator support Teflon seals. 51. Install new pump body-to-case retaining bolts. Tighten to 27 Nm (20 lb-ft). 52. Install a new main control body gasket. 53. Using the Transmission Air Test Plate along with the Transmission Test Plate Screw Set, check the function of each clutch. Apply kpa (20 psi) of air to each port. Item 1 Coast clutch 2 Intermediate clutch 3 Reverse clutch 4 Forward clutch 5 Direct clutch 6 Overdrive clutch Description 54. Using the Valve Body Aligner, install the solenoid body and loosely install the bolts. While installing the solenoid body, align the manual valve.

81 55. Remove the Valve Body Aligner and install the 2 remaining bolts. Tighten all the bolts in the sequence shown. Tighten to 13 Nm (115 lb-in). 56. Connect the TR sensor connector. 57. NOTE: Prior to installing the transmission fluid filter, make sure that the old seal is not stuck in the case. Install a new transmission fluid filter. 58. NOTE: Reuse the transmission fluid pan gasket unless it is damaged. Install the transmission fluid pan gasket to the transmission fluid pan. Make sure the magnet is positioned over the dimple in the transmission fluid pan.

82 59. NOTE: Tighten all the transmission fluid pan bolts in a crisscross pattern. Install the transmission fluid pan. Tighten to 20 Nm (177 lb-in). 60. Install the Turbine Shaft Speed (TSS) and the intermediate shaft speed sensor. 1. Lubricate the O-ring and install the TSS sensor. 2. Install the speed sensor bolt. Tighten to 9 Nm (80 lb-in). 61. Install the Output Shaft Speed (OSS). 1. Lubricate the O-ring and install the OSS sensor. 2. Install the OSS sensor bolt. Tighten to 9 Nm (80 lb-in). 62. If a new case was installed, wipe the cooler tube case fittings dry. Install new O-rings onto the transmission fluid cooler tube case fittings, apply threadlock and sealer onto the threads and install into the new case. Tighten to 52 Nm (38 lb-ft). 63. NOTICE: Do not damage the pump gear stator support seal when installing the torque converter. NOTICE: Make sure the converter hub is fully engaged in the pump support and the gear rotates freely. Do not damage the hub seal. NOTICE: If the torque converter slides out, the hub seal may be damaged. Lubricate the converter hub with automatic transmission fluid. 64. NOTICE: Use care when installing the torque converter to avoid damage to the pump stator support seal. NOTE: Check the converter crankshaft pilot for nicks or damaged surfaces that can cause interference when installing the transmission to the engine. Check the converter impeller hub for nicks or sharp edges that can damage the pump seal. Using the Torque Converter Handles, install the torque converter. Push and rotate the converter onto the pump assembly until it bottoms out. 65. Check the seating of the torque converter. 1. Place the straightedge across the converter housing. 2. Make sure there is a gap between the converter pilot face and the straightedge. 3. Remove the Torque Converter Handles.

83 66. Use the Torque Converter Retainer to hold the torque converter in place when installing the transmission. Copyright 2015 Ford Motor Company

84 Automatic Transaxle/Transmission TorqShift 2015 E-Series DESCRIPTION AND OPERATION Procedure revision date: 08/11/2014 Automatic Transmission Sectional View Main Components and Functions Torque converter 2 7A103 Pump assembly 3 Overdrive (O/D) clutch assembly 4 Coast clutch assembly 5 7M101 Turbine Shaft Speed (TSS) intermediate shaft speed sensor 6 7B446 O/D planet assembly 7 Intermediate clutch assembly 8 7C108 Direct clutch assembly 9 7A511 Forward clutch assembly 10 7A398 Forward planet assembly 11 Reverse clutch assembly 12 7D006 Reverse planet assembly 13 7H103 Output Shaft Speed (OSS) sensor Output shaft assembly 15 7A089 Low/reverse rocker One-Way Clutch (OWC) 16 7A658 Center shaft assembly 17 7A089 Coast mechanical diode OWC Input shaft Copyright 2015 Ford Motor Company

85 Automatic Transaxle/Transmission TorqShift 2015 E-Series DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES Procedure revision date: 08/11/2014 Solenoid Body Assembly Material Item Motorcraft MERCON LV Automatic Transmission Fluid XT-10-QLVC (US); CXT-10-LV12 (Canada) Upper, Lower, Accumulator and Solenoid Body, Disassembled View Specification MERCON LV 1 7C155 Solenoid body-to-case gasket 2 Ditch plate 3 7H038 Backing plate gasket 4 Backing plate 5 W Backing plate-to-manifold bolt 6 W S300-S300 Backing plate-to-case bolt 7 N S-S Solenoid-to-case bolt 8 Manifold body 9 7D376 Manual valve 10 7J136 Low reverse clutch Shift Solenoid Pressure Control E (SSPCE) 11 7J136 Direct clutch Shift Solenoid Pressure Control D (SSPCD) 12 7J136 Intermediate clutch Shift Solenoid Pressure Control C (SSPCC) 13 7J136 Coast clutch Shift Solenoid Pressure Control A (SSPCA) 14 W S300-S300 Solenoid-to-case bolt 15 7J136 Overdrive (O/D) clutch Shift Solenoid Pressure Control B (SSPCB) 16 Line pressure relief valve 17 7J136 Torque Converter Clutch (TCC) solenoid 18 7G383 Line Pressure Control Solenoid A (PCA) 19 7E335 Pressure switch retaining W-clip 20 Wiring harness retaining bolt 21 7G276 Wiring harness 22 7H141 Transmission Fluid Temperature (TFT) sensor 23 7E440 Direct clutch bore plug 24 7Z276 Bulkhead connector O-ring seal 25 W Manifold-to-ditch plate bolt 26 W Manifold-to-ditch plate bolt

86 27 7J137 Shift solenoid retaining E-clip 28 Line Pressure Control (LPC) pressure relief valve 29 7H200 Filter plate gasket Disassembly 1. Remove the manual valve. 2. Remove and discard the solenoid body connector O-ring seal. 3. Remove the main control valve body electrical harness. Remove the 2 bolts. Disconnect the electrical connectors. Lift the tab and twist and push the transmission internal harness connector through the solenoid body. Remove the solenoid body electrical harness. 4. NOTE: Mark the location of each solenoid for correct installation. Remove the shift solenoid retaining E-clips and remove the solenoids. 5. Remove the Transmission Fluid Temperature (TFT) sensor by lifting the tab and rotating counterclockwise. 6. Note the location and length of each bolt. Remove the 4 bolts and remove the top half of the main control valve body. 7. NOTE: The backing plate gasket should not be cleaned or reused.

87 Remove and discard the backing plate gasket. 8. Remove the bolts, backing plate and discard the gasket. Clean and inspect the components. Assembly 1. Install a new backing plate gasket, the backing plate and bolts. Tighten to 13 Nm (115 lb-in). 2. Install a new filter screen gasket. 3. NOTE: Tighten the bolts in a crisscross pattern to prevent the gasket from becoming distorted. Assemble the top and bottom halves of the solenoid body. Tighten to 13 Nm (115 lb-in). 4. Install the TFT sensor. 5. Install the shift solenoids and the shift solenoid retaining E-clips.

88 6. Install a new O-ring seal on the solenoid body electrical connector in the uppermost groove. Lubricate the O-ring seal with transmission fluid. 7. Install the solenoid body harness and connect the connectors. 8. Install the manual valve. Copyright 2015 Ford Motor Company

89 Transaxle/Transmission Cooling 2015 E-Series REMOVAL AND INSTALLATION Procedure revision date: 08/11/2014 Transmission Fluid Cooler Tubes Special Tool(s) Disconnect Tool, Transmission Cooler Line Material Item Motorcraft MERCON LV Automatic Transmission Fluid XT-10-QLVC (US); CXT-10-LV12 (Canada) Transmission Fluid Cooler Tubes Specification MERCON LV 1 7C1C7 Clamps 2 7Z465 Transmission fluid cooler tube secondary latch Transmission fluid cooler hose Transmission fluid cooler hose 5 7R081 Transmission fluid cooler tube assembly 6 Transmission fluid cooler tube fittings Removal 1. With the vehicle in NEUTRAL, position it on a hoist. Refer to Section Disconnect the battery ground cable. Refer to Section If equipped, remove the pushpin retainers and the splash shield.

90 4. Remove the pushpin retainers and the lower air deflector. 5. Remove the transmission fluid cooler tubes from the transmission case. 6. Remove the transmission fluid cooler tube secondary latch from the transmission fluid cooler hose. 7. Using the Transmission Cooler Line Disconnect Tool, disconnect the transmission fluid cooler hose. 8. Disconnect the fluid cooler hose from the radiator. 9. Remove the nut for the transmission cooler tubes and starter motor electrical harness front bracket, and move the bracket aside. 10. If equipped, remove the transmission cooler tubes from the bracket.

91 11. Remove the starter motor solenoid terminal cover. 12. Disconnect the starter motor electrical connections. 13. Disconnect the starter motor electrical harness pushpin and move the harness to the front of the vehicle. 14. Remove the transmission fluid cooler tubes from the vehicle. Installation 1. Install the transmission fluid cooler tubes into the vehicle. 2. Reposition the starter motor electrical harness to the rear of the vehicle and connect the pushpin. 3. Connect the starter motor electrical connections. Tighten the ground cable to 20 Nm (177 lb-in). Tighten the battery cable to 12 Nm (106 lb-in). Tighten solenoid wire to 6 Nm (53 lb-in). 4. Install the starter motor solenoid terminal cover.

92 5. If equipped, install the transmission fluid cooler tubes into the bracket. 6. Install the transmission fluid cooler tubes bracket-to-engine stud nut. Tighten to 12 Nm (106 lb-in). 7. Connect the transmission fluid cooler hose. 8. Install the transmission fluid cooler tube secondary latch onto the transmission fluid cooler hose. 9. Install the transmission fluid cooler hose onto the radiator fitting. 10. Install the transmission fluid cooler tube fittings. Tighten to 40 Nm (30 lb-ft). 11. Install the lower air deflector and the pushpin retainers.

93 12. If equipped, install the splash shield and the pushpin retainers. 13. Connect the battery ground cable. Refer to Section NOTICE: The use of any transmission fluid other than recommended can cause transmission damage. Fill the transmission with the specified transmission fluid type and quantity. Refer to Transmission Fluid Drain and Refill in Section Check for leaks. Copyright 2015 Ford Motor Company

94 Transaxle/Transmission Cooling 2015 E-Series DESCRIPTION AND OPERATION Procedure revision date: 08/11/2014 Transmission Cooling The transmission fluid cooling system, without an auxiliary transmission fluid cooler, consists of: an in-tank fluid cooler inlet tube. a non-repairable in-tank transmission fluid cooler. an in-tank fluid cooler return tube. The transmission fluid cooling system, with an auxiliary transmission fluid cooler, consists of: an in-tank fluid cooler inlet tube. a non-repairable in-tank transmission fluid cooler. fluid cooler hoses. hose clamps. an auxiliary transmission fluid cooler. a fluid cooler return tube. The transmission fluid flows from the transmission to the in-tank transmission fluid cooler, to the auxiliary transmission fluid cooler (if equipped) and returns to the transmission. For the Transmission Fluid Cooler Backflushing and Cleaning procedure, refer to Section Transmission Cooling Components 1 7H420 Transmission fluid cooler tube inlet fitting 2 7H420 Transmission fluid cooler tube outlet fitting 3 N Transmission Auxiliary transmission fluid cooler outlet hose 5 7A095 Auxiliary transmission fluid cooler Auxiliary transmission fluid cooler inlet hose 7 7J081 Transmission fluid cooler tube secondary latch 8 8C2P-7C107-AA-7C107-AA Clamps 9 8C2P-7C107-AA-7C107-AA Clamps Copyright 2015 Ford Motor Company

95 Automatic Transaxle/Transmission External Controls 2015 E-Series REMOVAL AND INSTALLATION Procedure revision date: 08/11/2014 Selector Lever Selector Lever 1 7C24 Ignition lock cylinder Screw (3 required) Upper steering column shroud 4 7G357 Selector lever pin Selector lever Removal and Installation 1. Disconnect the battery. Refer to Section Remove the 2 screws and DLC. 3. Pull to release the retaining clips and remove the steering column opening lower finish panel. 4. If equipped with tilt column, position the steering wheel in the full DOWN position. 5. Remove the ignition switch lock cylinder. 1. Position the lock cylinder to RUN. 2. Using a suitable tool, push upward on the cylinder release tab through the hole in the lower shroud while pulling the cylinder outward.

96 6. Remove the 3 screws and remove the lower steering column shroud. 7. Remove the upper steering column shroud. 8. Disconnect the TCS connector. 9. NOTE: Install a new selector lever pin whenever it is removed. Remove the selector lever. 1. Remove the selector lever pin. 2. Remove the selector lever. 10. To install, reverse the removal procedure. Copyright 2015 Ford Motor Company

97 Automatic Transaxle/Transmission External Controls 2015 E-Series REMOVAL AND INSTALLATION Procedure revision date: 08/11/2014 Selector Lever Cable and Bracket 1 Selector lever cable eyelet (part of 7E395) 2 7H181 Selector lever cable retaining clip 3 7E395 Selector lever cable 4 Selector lever cable retainer (part of 7E395) 5 Selector lever cable eyelet (part of 7E395) S-S Selector lever cable bracket bolt S-S Selector lever cable bracket bolt 8 7B229 Selector lever cable bracket 9 W S-S Selector lever cable retaining clip bolt Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. Refer to Section Remove the 2 screws and DLC. 3. Pull to release the retaining clips and remove the steering column opening lower finish panel. 4. Remove the 4 steering column-to-cross car beam nuts and lower the steering column. To install, tighten to 15 Nm (133 lb-in). 5. NOTICE: To prevent selector lever cable damage, do not apply force to the selector lever cable assembly between the steering column shift tube bracket and the steering column bracket.

98 Disconnect the selector lever cable from the steering column. 1. Disconnect the selector lever cable from the steering column shift tube lever. 2. Carefully lift the locking tab and disconnect the selector lever cable from the steering column bracket. 6. Disconnect the cable pushpin from the stud in the bulkhead. 7. Push the rubber grommet and transmission selector lever cable through the bulkhead. 8. Remove the selector lever cable and bracket from the transmission. 1. Disconnect the selector lever cable from the manual control lever. 2. Disconnect the wire harness from the selector lever cable bracket. 3. Remove the selector lever cable bracket bolts and position the selector lever cable and bracket aside. To install, tighten to 48 Nm (35 lb-ft). 9. NOTE: When installing the selector lever cable, make sure that the selector lever cable locking tabs are locked in place. Press the selector lever cable into the selector lever cable bracket and listen for the cable to click into place. Pull back on the selector lever cable to make sure that it is locked into the selector lever cable bracket. To install, reverse the removal procedure. Adjust the selector lever cable. Refer to Selector Lever Cable Adjustment. Copyright 2015 Ford Motor Company

99 Automatic Transaxle/Transmission External Controls 2015 E-Series REMOVAL AND INSTALLATION Procedure revision date: 08/11/2014 Transmission Control (TC) Switch Transmission selector lever 2 7G550 TCS 3 7A214 TCS cover Removal and Installation 1. Disconnect the TCS connector. 2. Remove the TCS. 1. Remove the switch cover. 2. Remove the switch. 3. To install, reverse the removal procedure. Copyright 2015 Ford Motor Company

100 Exhaust System 2015 E-Series REMOVAL AND INSTALLATION Procedure revision date: 08/11/2014 Exhaust System, Van/Wagon NOTE: Vehicle body removed from art for clarity. Exhaust System Exploded View 1 5F250 Exhaust Y-pipe 2 5A281 Torca clamp Muffler and tail pipe assembly 4 W Exhaust manifold studs (2 required) 5 W Exhaust manifold studs (2 required) 6 W Exhaust manifold-to-exhaust Y-pipe nut (4 required) 7 Heated Oxygen Sensor (HO2S) electrical connectors (part of 9F472 (6.8L), 9Y460 (5.4L)) 8 Catalyst Monitor Sensor (CMS) electrical connectors (part of 9G444) Exhaust System, Stripped Chassis (5-Speed Transmission) NOTE: 5.4L shown, 6.8L similar. Vehicle body removed from art for clarity.

101 Exhaust Y-pipe 2 W Exhaust Y-pipe-to-catalytic converter nuts (3 required) 3 5D217 Exhaust Y-pipe-to-catalytic converter support bracket 4 5C226 Exhaust Y-pipe-to-converter gasket 5 5E212 Catalytic converter 6 5A281 Torca clamps Muffler and tail pipe assembly Tail pipe extension (if equipped) 9 W Exhaust manifold-to-exhaust Y-pipe studs (2 required) 10 W Exhaust manifold-to-exhaust Y-pipe studs (2 required) 11 W Exhaust manifold-to-exhaust Y-pipe nut (4 required) 12 Heated Oxygen Sensor (HO2S) electrical connectors (part of 9F472 (6.8L), 9Y460 (5.4L)) 13 Catalyst Monitor Sensor (CMS) electrical connector (part of 9G444) 14 5A212 Extension pipe (158-in wheelbase) 15 5A212 Extension pipe (176-in wheelbase) 1. For additional information, refer to the procedures in this section. Copyright 2015 Ford Motor Company

102 Fuel Tank and Lines 2015 E-Series REMOVAL AND INSTALLATION Procedure revision date: 08/11/2014 Fuel Tank and Filler Pipe Exploded View Aft-of-Axle Tank NOTE: Vehicle body removed from art for clarity. NOTE: The 151L (40 gal) aft-of-axle fuel tank shown, 208L (55 gal) aft-of-axle fuel tank and ambulance package fuel tank similar Fuel tank support strap (2 required) Fuel tank Fuel tank cradle bracket (2 required) 4 N Fuel tank cradle bracket nut (2 required) 5 N Fuel tank support strap nut (2 required) 6 N Fuel tank cradle bracket bolt (2 required) Fuel tank filler cap 8 W Fuel tank filler pipe retaining screws (3 required) 9 9B213 Fuel tank filler pipe support 10 9B178 Fuel tank filler pipe 11 W Fuel tank filler pipe hose clamp 12 W Fuel tank filler pipe vent hose clamp 13 Fuel Pump (FP) module electrical connector (part of 9H307) 14 Fuel Tank Pressure (FTP) sensor electrical connector (part of 9H307) 15 Fuel supply tube-to-fp module quick connect coupling (part of 9S296) 16 Fuel vapor tube-to-fuel vapor vent valve quick connect coupling (part of 9S296) Midship Fuel Tank NOTE: Vehicle body removed from art for clarity.

103 Item Part Number Description 1 W Fuel tank support strap nut 25 Nm (18 lb-ft) (2 required) Fuel tank Fuel tank support strap (2 required) 4 Evaporative Emission (EVAP) canister vent solenoid electrical connector (part of 9F759) 5 9G297 EVAP canister fresh air hose 6 9D683 EVAP Canister assembly-to-engine vapor hose Fuel tank filler cap 8 W Fuel tank filler pipe retaining screw (3 required) 9 W Fuel tank filler pipe bracket screw (2 required) 10 Fuel tank filler pipe vapor tube-to-fuel tank fuel vapor tube quick connect coupling (part of 9S296) 11 9B178 Fuel tank filler pipe 12 W Fuel tank filler pipe hose clamp 5 Nm (44 lb-in) 13 W Fuel Pump (FP) module cover nut 9 Nm (80 lb-in) (3 required) 14 9B007 FP module cover 15 Fuel supply tube-to-fp module quick connect coupling (part of 9L291) 16 FP module electrical connector (part of 9H307) 17 Fuel Tank Pressure (FTP) sensor electrical connector (part of 9H307) 1. For additional information, refer to the procedures in this section. Copyright 2015 Ford Motor Company

104 Acceleration Control 2015 E-Series REMOVAL AND INSTALLATION Procedure revision date: 08/11/ L Engines Accelerator Pedal 1 Accelerator Pedal Position (APP) sensor electrical connector (part of 14401) 2 W Accelerator pedal bracket bolts (2 required) 3 9F836 Accelerator pedal and position sensor assembly 6.8L Engine 1 Accelerator Pedal Position (APP) sensor electrical connector (part of 14401) 2 W Accelerator pedal bracket bolt (2 required) 3 9F836 Accelerator pedal and position sensor assembly Removal and Installation All vehicles 1. NOTE: To prevent setting DTCs, make sure the ignition switch is in the OFF position prior to disconnecting the accelerator pedal electrical connectors. NOTE: If equipped, the red clip must be pulled out before disconnecting the electrical connector. Disconnect the Accelerator Pedal Position (APP) sensor electrical connector. 5.4L engines 2. Remove the 2 bolts and the accelerator pedal. To install, tighten to 25 Nm (18 lb-ft). 6.8L engine 3. Remove the 2 bolts and slide the accelerator pedal and position sensor assembly up and off the anchor bolt. To install, tighten to 25 Nm (18 lb-ft).

105 Battery, Mounting and Cables 2015 E-Series REMOVAL AND INSTALLATION Procedure revision date: 08/11/2014 Battery and Battery Tray Exploded View, Primary Battery 2 10B684 Battery hold-down bolt - 7 Nm (62 lb-in) 3 W Battery tray bolt (4 required) - 30 Nm (22 lb-ft) Battery tray 1. For additional information, refer to the procedures in this section. Copyright 2015 Ford Motor Company

106 Battery, Mounting and Cables 2015 E-Series REMOVAL AND INSTALLATION Procedure revision date: 08/11/2014 Battery and Battery Tray Exploded View, Secondary 1 N Battery tray cover bolt (2 required) - 7 Nm (62 lb-in) 2 10B679 Battery tray cover 3 10B684 Battery hold-down clamp and bolt - 7 Nm (62 lb-in) 4 Battery terminal nut (2 required) (part of 14B060) - 9 Nm (80 lb-in) Battery 6 W Battery tray bolt (4 required) - 40 Nm (30 lb-ft) 7 Battery tray safety strap eyelet (2 required) 8 W Battery tray safety strap bolt (2 required) - 30 Nm (22 lb-ft) Battery tray 1. For additional information, refer to the procedures in this section. Copyright 2015 Ford Motor Company

107 Rear View Mirrors 2015 E-Series REMOVAL AND INSTALLATION Procedure revision date: 08/11/2014 Exterior Mirrors Exploded View Aero NOTE: LH exterior mirror shown, RH exterior mirror similar. 1 17K707 Exterior mirror glass 2 Exterior mirror screw (part of 17D696) (3 required) 3 17D696 Exterior mirror motor RH/ LH RH/ LH Exterior mirror assembly 5 N Exterior mirror nut (4 required) Trailer Tow NOTE: LH exterior mirror shown, RH exterior mirror similar. 1 N Exterior mirror nuts (4 required) 2 Exterior mirror electrical connector (part of RH/ LH) RH/ LH RH/ LH Exterior mirror assembly 4 17K707 Exterior mirror glass 5 17K707 Exterior mirror glass spotter 1. For additional information, refer to the procedures in this section. Copyright 2015 Ford Motor Company

108 Seating 2015 E-Series REMOVAL AND INSTALLATION Procedure revision date: 08/11/2014 Seat Backrest NOTE: LH shown, RH similar. Seat Exploded View, Front Backrest cover Backrest foam pad Backrest frame Armrest bolt / 644A18/ 644A18 Armrest/ armrest cover Armrest shim Adjustable lumbar assembly (if equipped) Pivot bolt 9 617C05 Recliner assembly Backrest-to-recliner bolts (2 required) Recliner bolts (2 required) Seat Cushion Driver

109 Cushion cover 2 632A22 Cushion foam pad 3 Safety belt buckle and pretensioner bolt (part of 61203) Safety belt buckle and pretensioner Inboard side shield Inboard side shield screws (3 required) Adjustable lumbar knob (if equipped) Power seat track bolt (3 required, if equipped) Pedestal Cushion frame bolts (4 required) Power seat track (if equipped) 12 N Seat track nuts (2 required if equipped with power track, 4 required for manual track) C05 Recliner assembly Recliner bolt (2 required) 15 Seat control switch screws (2 required, if equipped) 16 14A701 Seat control switch (if equipped) Outboard side shield Outboard side shield screws (3 required) Cushion frame Seat Cushion Front Passenger

110 Cushion cover Cushion foam pad Cushion frame Recliner bolt (2 required) 5 617C04 Recliner assembly Pivot bolt Inboard side shield Inboard side shield screws (2 required) Safety belt buckle and pretensioner 10 Safety belt buckle and pretensioner bolt (part of 61202) inboard/ outboard inboard/ outboard Seat track (2 required) A86 Seat track control handle Push nuts Pedestal 15 N Seat track nuts (4 required) Cushion frame bolts (4 required) Outboard side shield Outboard side shield screws (2 required) 1. For additional information, refer to the procedures in this section. Copyright 2015 Ford Motor Company

111 Glass, Frames and Mechanisms 2015 E-Series REMOVAL AND INSTALLATION Procedure revision date: 08/11/2014 Glass, Frames and Mechanisms Exploded View 1 237A05 LH/ 237A04 RH LH/ 237A04 RH Weathershield 2 N S437-S437 Nut (2 required) 3 Screw (3 required) Window regulator motor 5 W Rivets (2 required) 6 W Rivets (2 required) 7 N S439-S439 Rear glass channel bolt 8 222A01 LH/ 222A00 RH LH/ 222A00 RH Rear glass channel Inner beltline weatherstrip /21410/21410 Front door window glass 11 W Rivet (3 required) LH/ RH LH/ RH Window regulator 1. For additional information, refer to the procedures in this section. Copyright 2015 Ford Motor Company

112 Instrument Panel and Console 2015 E-Series REMOVAL AND INSTALLATION Procedure revision date: 08/11/2014 Panels and Fasteners Instrument Panel Exploded View Instrument panel cowl top screw (4 required) 2 044D82 LH upper access panel 3 N Instrument panel cowl top nut Steering column opening cover Clip retainer (4 required) Clip retainer (2 required) 7 N Data Link Connector (DLC) screw (2 required) DLC 9 Glove compartment 10 W Glove compartment screw (6 required) Electrical connector 12 Satellite radio connector (if equipped) Electrical connector Instrument panel D70 Instrument cluster finish panel Instrument cluster finish panel retainer clip (15 required) D70 Instrument cluster finish panel retainer clip (3 required) 18 N Instrument panel bolt (6 required) 19 W Instrument panel bolt 20 N Steering column pinch bolt 21 N Steering column nuts (4 required) Vacuum and Electrical Connector View

113 1 Instrument cluster finish panel electrical connectors (part of 14401) 2 Climate control vacuum connector 3 Instrument cluster finish panel electrical connector (part of 14401) (if equipped) 1. For additional information, refer to the procedures in this section. Copyright 2015 Ford Motor Company