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Home >> Ford Truck >> 2010 >> F 550 2WD Super Duty V10-6.8L >> Repair and Diagnosis >> Body and Frame >> Service and Repair >> Removal and Replacement >> Body

Body




Body - 6.8L





Removal and Installation

NOTE: Crew Cab shown, all others similar.











All vehicles

NOTE: A 2-post hoist must be used to lift the body from the chassis.

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Vehicle Jacking and Lifting.

2. Drain the engine coolant. For additional information, refer to Cooling System &/or Engine Block Heater.

3. Disconnect the battery cables from the battery. For additional information, refer to Battery.

4. Separate the leads from the positive battery cable.





5. Remove the battery.

6. Remove the hose from the degas bottle and unclip from the retainers. Position the hose aside.





Manual transmission

7. Lift upward on the gear shift boot to access the gear shift bolt.





8. Remove the gear shift bolt.
- To install, tighten to 30 Nm (22 lb-ft).





All vehicles

9. Remove the Air Cleaner (ACL) and inlet pipe assembly. For additional information, refer to Fuel Delivery and Air Induction.

10. Remove the retaining clip and disconnect the fill hose from the degas bottle and remove the degas bottle.





11. Remove the bolts and position the ACL box aside.
- To install, tighten to 16 Nm (142 lb-in).





12. Remove the retaining clip and disconnect the upper radiator hose from the radiator.





13. Remove the 2 wiring harnesses from the top of the battery tray.





14. Remove the vacuum line from the battery tray, if equipped.





15. Remove the battery cable from the retainer on the side of the battery tray.





16. Remove the bolts from the battery tray.
- To install, tighten to 16 Nm (142 lb-in).





17. Remove the battery tray for access to the washer fluid bottle.
- Disconnect the washer fluid bottle electrical connector.

- Disconnect the washer fluid bottle hose.





18. Disconnect the engine wiring harness located below the PCM.





19. NOTE: The connector must be removed to access the A/C fitting. Install the connector after the A/C system has been charged.

Disconnect the electrical connector and clip from the PCM.





20. Recover the refrigerant. For additional information, refer to Heating and Air Conditioning.

21. Remove the bolt and the left upper ground wires from the right front of dash.





22. Disconnect the connector from the PCM.





23. Disconnect the 2 electrical connectors and unclip from the retainer.
- Position the harness aside.





24. Disconnect the electrical connector from the right side of the engine.





25. Disconnect the generator electrical connector from the right side of the engine.





26. Remove the bolt and the ground wire from the right fender.
- To install, tighten to 12 Nm (106 lb-in).





Four-Wheel Drive (4WD) vehicles

27. Disconnect the electrical connector from the Four-Wheel Drive (4WD) vacuum switch.





28. Disconnect the two 4WD vacuum hoses and position aside.





All vehicles

29. Disconnect the front heater hose from the right side of the engine.





30. Disconnect the rear heater hose from the right side of the engine.





31. Disconnect the electrical connector from the A/C pressure switch.





32. Unclip the wiring harness retainer from the manifold assembly at the A/C compressor.

33. Disconnect the 2 compressor manifold tube assemblies from the A/C compressor.





34. Using a suitable suction device, drain the power steering fluid reservoir.

35. Disconnect the hose from the rear of the power steering fluid reservoir.





36. Disconnect the lower hose from the power steering auxiliary cooler line and position aside.





37. Unclip the wiring harness from the top of the power steering fluid reservoir.





38. Remove the 2 electrical connectors from the bracket on the left side of the engine compartment and disconnect the electrical connectors.





39. Disconnect the canister purge valve electrical connector and remove from the bracket.
- Position the canister aside.





40. Disconnect the fog lamp electrical connector from the front of the radiator support and position aside, if equipped.





41. NOTE: Make sure the vehicle wheels are straight.

Place the vehicle in PARK and remove the key.

42. NOTICE: Do not allow the steering column shaft to rotate while the intermediate shaft is disconnected or damage to the clockspring can result. If there is evidence that the shaft has rotated, the clockspring must be removed and recentered. For additional information, refer to Restraint Systems.

Remove the intermediate steering shaft bolt and separate the shafts. Discard the bolt.
- To install, tighten to 48 Nm (35 lb-ft).





43. Disconnect the 3 electrical connectors from the brake master cylinder, if equipped.





44. Remove the 2 nuts and the brake master cylinder from the vacuum boost and position aside.
- To install, tighten to 30 Nm (22 lb-ft).





45. Remove the hydraulic brake lines from the retainer.





46. Disconnect the brake booster vacuum supply hose.





47. Remove the 3 radiator lower splash shield-to-bumper pushpins.





48. Raise the vehicle.

Manual transmission

49. Remove the clutch slave cylinder from the rear of the bell housing by turning counterclockwise.





Four-Wheel Drive (4WD) vehicles

50. Disconnect the rod from the transfer case shift handle, if equipped.





All vehicles

51. Release the parking brake tension and disconnect the brake cable at the intermediate connection and remove from the retainer on the frame. For additional information, refer to Parking Brake System.

52. Remove the body/chassis ground on the right frame rail, behind the front wheel.
- To install, tighten to 25 Nm (18 lb-ft).





53. Remove the safety clips from the transmission cooler lines.





54. Using the Transmission Cooler Line Disconnect Tool, disconnect the transmission lines from the transmission cooler hoses and remove from the retainer on the frame.





55. Open the lower radiator shroud.

56. Remove the retaining clip and separate the lower radiator hose and disconnect the lower radiator hose from the retainers on the frame.





57. If equipped, remove the running boards.

58. NOTE: Make sure to use only hand tools when removing the body mounting bolts.

NOTE: Make sure the insulator is removed with the body bolt.

NOTE: If the body mount bolts spin and cannot be removed, refer to Body Retainer Cage Nuts Body Retainer Cage Nuts.

Remove the body mounting bolts starting with the rear bolts.
- Discard the body bolts.

- To install, tighten to 103 Nm (76 lb-ft).





59. Lower the vehicle.

60. Place several fender covers between the cab and the pickup bed.

61. NOTE: Marking the position of the tires will aid in aligning the cab to the chassis.

Mark the position of the tires on the floor.

62. NOTE: A 2-post hoist must be used to lift the body from the chassis.

Position equally side-to-side the hoist lift pads below the pinch welds at the furthest most possible front and rear positions.

63. WARNING: Securely strap the cab to the lift using an appropriate tool. If the cab is not correctly secured, it could shift or fall. Failure to follow this instruction may result in serious personal injury.

Using the Universal Cab Hold-Down Strap, secure the vehicle to the hoist.





64. NOTICE: An assistant will be necessary to make sure all connections are disconnected and nothing interferes with the raising of the body while it is lifted. Failure to follow this instruction may result in damage to the components.

With the aid of an assistant, lift the body from the chassis.

65. To install, reverse the removal procedure.
- Align the tires to the marks on the floor.

- Top off the fluids.

- Install new body bolts.

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