Ford F-150 Pickup REPAIR MANUAL -- HOW TO FIX YOUR CAR OR TRUCK

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Ford F-150 Pickup CAR/TRUCK REPAIR PROCEDURES AND DIAGRAMS - WHAT Ford REPAIR SHOPS DON'T WANT YOU TO KNOW

Learn how to repair a car or truck, install or remove parts, wire an engine, reset warning lights, replace fuel filter, fix auto body and more. Get Automotix DIY!

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Get Full Access Automotix DIY provides automotive consumers and do it yourselfers; the most comprehensive repair information about Ford F-150 Pickup car and truck repair procedures including Ford engine diagrams, wiring diagrams, repair work estimating measures, technical service bulletins, auto body work guidance, starter & alternator replacement procedures, serpentine belt replacement procedures, radiator & hose replacement procedures, tune-up & drivability specifications, quick lube illustrations, preventive maintenance guide, engine light reset instructions, parts removal and install procedures, fuel filter replacement directions, component location diagrams, air filter locations & replacement instructions, a/c system specifications, and general auto service procedures. You don't have to be a car mechanic or technician to know how to fix your Ford F-150 Pickup automobile. Try the Automotix DIY solution today!
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Using the Automotix DIY repair procedures will save you hundreds and even thousands of dollars! In addition, it will save you hours of touring the city searching for Ford mechanics you can trust. The Automotix DIY solution is particularly affordable. A full access to the entire DIY repair procedures and diagrams for your Ford F-150 Pickup vehicle will cost less than a single gallon of gas. Here are some of the DIY repair tips and procedures you will find here:

A/C & HEATER SERVICE PROCEDURES FOR Ford F-150 Pickup AUTOMOBILES

Air Conditioner and Heater Service Includes module configuration procedures, general service, maintenance, automatic temperature control, compressor services, electric cooling fans, vacuum diagrams, specifications, and manual air conditioning and heater diagnostics and replacement procedures for domestic and imported Ford F-150 Pickup cars and light trucks from 1990+

Component Replacement & Adjustment -> Light Duty Trucks & Vans -> ELECTRIC ACTUATORS, REPLACE -> Outside/Recirculation Air Door Actuator -> Panel/Floor/Defrost Door Actuator -> Temperature Blend/Panel Bypass Door Actuator -> VILLAGER
Vehicle: 1994 Ford F-150 Pickup 5.8 V8 GAS

VILLAGER

Outside/Recirculation Air Door Actuator
  • Remove glove compartment and illumination lamp.
  • Remove right knee reinforcement plates and inner and outer ducts.
  • Remove PCM and Transaxle Control module and position aside.
  • Remove four actuator attaching bolts, then disconnect actuator electrical connector.
  • Remove actuator attaching screws and the actuator.
  • Reverse procedure to install.
Panel/Floor/Defrost Door Actuator
  • Remove three actuator attaching bolts.
  • Disconnect electri...

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BRAKE SERVICE PROCEDURES FOR Ford F-150 Pickup AUTOMOBILES

Includes anti-lock brakes, disc, drum, power and hydraulic brake services diagnostics and procedures for domestic and imported Ford F-150 Pickup cars and light trucks from 1990+.

Disc Brakes -> Rotor Replacement -> 1999-2001 -> 2002-03 -> Aviator -> E-Series -> Escape -> Excursion, F-Super Duty & Motorhome -> Expedition & Navigator -> Explorer & Mountaineer -> Explorer Sport/Sport Trac -> F-250 & F-350 2WD -> F-250 & F-350 4WD, F-450 & F-550 -> F-Series -> Front -> Installation -> Motorhome -> Ranger -> Rear -> Removal -> Windstar & Villager
Vehicle: 2002 Ford F-150 Pickup 5.4 V8 BI-FUEL

Aviator

Front
  • Raise and support vehicle.
  • Remove front tire and wheel assemblies.
  • Remove front brake components in sequence, Fig. .
  • Reverse procedure to install.
Rear

Refer to Fig. , and remove rear brake components in sequence listed.

Escape

  • Remove disc brake caliper and anchor plate as outlined in "Caliper Service".
  • Remove rotor
  • Reverse Procedure to install. Tighten all nuts and bolts to specification.

E-Series

Front

Refer to Figs. through , and remove components in sequence listed.

Rear
Removal
  • Remove disc brake caliper, refer to "Caliper Service."
  • Remove axle shafts as outlined in "Rear Axle & S... "

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FUEL FILTER REPLACEMENT PROCEDURES FOR Ford F-150 Pickup AUTOMOBILES

Fuel filter replacement procedures with corresponding images for most domestic and imported Ford F-150 Pickup cars and light trucks sold in the U.S. for 1980+.

Ford Motor Co. Light Trucks, SUVs & Vans -> Fuel Pressure Relief -> Gasoline Fuel Injected Engines Except Escape, Freestar, Mariner, Monterey, Villager, 2005-06 Aviator, Explorer & Mountaineer, 2005-06 Expedition & Navigator & 2004-06 F150 & Mark LT
Vehicle: 1993 Ford F-150 Pickup Super CAB 5.8 V8 GAS

The fuel system remains under high pressure even when the engine is not running. This residual pressure must be relieved before servicing the fuel system. To avoid injury or fire, release pressure from the fuel system before disconnecting any fuel line.

The fuel system pressure must be relieved prior to disconnecting fuel lines to prevent accidental spray of fuel.

After the battery ...

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DRIVELINE, U-JOINT & CV AXLES REPLACEMENT PROCEDURES FOR Ford F-150 Pickup AUTOMOBILES

Includes CV axle, universal joint, and driveline replacement, for domestic and imported Ford F-150 Pickup cars and light trucks from 1990+.

DRIVESHAFT U-JOINT, Replace -> Assemble -> Disassemble -> Double Cardan -> Single Cardan, Flange Yoke -> Single Cardan, Slip Yoke
Vehicle: 2004 Ford F-150 Pickup Lightning 5.4 V8 GAS

Single Cardan, Slip Yoke

Disassemble

Do not, under any circumstance, clamp the shaft in the jaws of a vise or similar holding fixture. Denting or localizing fracture can result, causing shaft failure during vehicle operation. Place the shaft on a suitable workbench. Do not damage the tube. If components are not marked and installed incorrectly, driveline imbalance can occur.

  • Index-mark the shaft components.
  • Remove and discard all four snap rings.
  • Clamp bearing cup removal tool No. 205-086 or equivalent in a vise.
  • If necessary, use a pair of pliers to remove a bearing cup t...

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STARTER & ALTERNATOR REPLACEMENT PROCEDURES FOR Ford F-150 Pickup AUTOMOBILES

Includes starter and alternator replacement procedures for domestic and imported Ford F-150 Pickup cars and light trucks from 1990+.

Starter, Replace
Vehicle: 1997 Ford F-150 Pickup Super CAB 4.6 V8 GAS

  • Remove battery ground cable.
  • On models equipped with air suspension, turn air suspension switch to off position.
  • On all models, raise and support vehicle.
  • Remove starter solenoid terminal cover.
  • Disconnect starter motor electrical connections.
  • Remove starter motor ground cable and nut.
  • R...

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CABIN AIR FILTER LOCATIONS & REPLACEMENT PROCEDURES FOR Ford F-150 Pickup AUTOMOBILES

Cabin air filter locations and replacement procedures with corresponding images for most domestic and imported Ford F-150 Pickup cars and light trucks sold in the U.S. as equipped to the current model year.

Cabin Air Filter Service -> Ford Motor Co. -> 1997-2007 Expedition, F-150, Navigator, 2002 Blackwood & 2006-07 Mark LT
Vehicle: 2003 Ford F-150 Pickup 4.6 V8 GAS

On these models, the cabin air filter is an option.

Under normal operating conditions the cabin air filter should be replaced every 15,000 miles. In dusty areas change the cabin air filter more often.

  • From under passenger side of the instrument panel behind the glove compartment, remove the cabin air filter cover to the bottom of the heater plenu...

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MAINTENANCE LAMP RESET PROCEDURES FOR Ford F-150 Pickup AUTOMOBILES

Maintenance lamp reset procedures with corresponding images for most domestic and imported Ford F-150 Pickup cars and light trucks sold in the U.S. from 1990+.

Ford Motor Co. Trucks -> Electronic Throttle Control ->
Vehicle: 2004 Ford F-150 Pickup Heritage 5.4 V8 BI-FUEL

Electronic throttle displays when the system has malfunctioned and the engine has defaulted to a limp-home operation. On vehicles equipped with ...

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RADIATOR & HOSE REPLACEMENT PROCEDURES FOR Ford F-150 Pickup AUTOMOBILES

Includes radiator, cooling and heater hose replacement procedures for domestic and imported Ford F-150 Pickup cars and light trucks from 1990+

Radiator, Replace
Vehicle: 2001 Ford F-150 Pickup 4.2 V6 GAS

  • Drain cooling system.
  • Remove front air deflector if necessary.
  • Using a suitable fan clutch holding tool and fan clutch wrench tool remove fan blade and lefthand thread clutch.
  • Disconnect and plug transmission fluid cooler ...

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SERPENTINE BELT SERVICE PROCEDURES FOR Ford F-150 Pickup AUTOMOBILES

Serpentine belt replacement procedures with corresponding images for most domestic and imported Ford F-150 Pickup cars and light trucks sold in the U.S. from 1990+.

Serpentine Drive Belt, Replace -> Automatic Tension -> Manual Tension
Vehicle: 1992 Ford F-150 Pickup 5.8 V8 GAS

Automatic Tension

  • Install suitable 5/16 inch closed end wrench on tensioner pulley bolt, then lift tensioner arm away from belt. Do not use socket and ratchet.
  • Remove belt, slowly release tensioner. Do not allow tensioner to snap back, as damage may result.
  • Reverse procedure to install.

Manual Tension

  • Loosen accessory adjustment bolt and pivot bolt.
  • Remove belt.
  • Reverse procedure to install, adjust belt tension as follows:
    • Lo...

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COMPONENT LOCATION DIAGRAMS FOR Ford F-150 Pickup AUTOMOBILES

Component location diagrams for most Ford F-150 Pickup cars and light trucks sold in the U.S. from 1990+.

I/P Components & Connectors Diagram for 1998 Ford F-150 Pickup Super CAB 4.6 V8 GASI/P Components & Connectors Diagram for 1998 Ford F-150 Pickup Super CAB 4.6 V8 GAS

Components on diagram:
  • Transmission Control Switch
  • Main Light Switch
  • Shift Lock Actuator
  • Clutch Pedal Position Switch
  • 4 Wheel Drive Mode Switch
  •  Diagram for 1994 Ford F-150 Pickup Lightning 5.8 V8 GAS Diagram for 1994 Ford F-150 Pickup Lightning 5.8 V8 GAS

    Components on diagram:
  • A/C Clutch Field Coil
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    WIRING DIAGRAMS FOR Ford F-150 Pickup AUTOMOBILES

    OEM drawn wiring diagrams for most Ford F-150 Pickup cars and light trucks sold in the U.S.

    1994 Ford F-150 Pickup Super CAB 5.0 V8 GAS Wiring Diagram1994 Ford F-150 Pickup Super CAB 5.0 V8 GAS Wiring Diagram

    Components on diagram:
  • Trailer Relay Box
  • Trailer Backup Lamps Relay
  • Trailer/Marker Lamps Relay
  • PCM Power Relay
  • Brake Fluid Level Switch
  • 2002 Ford F-150 Pickup  4.6 V8 GAS Wiring Diagram2002 Ford F-150 Pickup 4.6 V8 GAS Wiring Diagram

    Components on diagram:
  • Interior Lamp
  • LH Side Rail Lamp
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    TECHNICAL SERVICE BULLETINS FOR Ford F-150 Pickup AUTOMOBILES

    OEM TSB listings for most Ford F-150 Pickup cars and light trucks sold in the U.S. from 1985+.

    Document: INADVERTENT DISABLING OF BRAKE SHIFT INTERLOCK
    Vehicle: 2002 Ford F-150 Pickup Lightning 5.4 V8 GAS

    Auto Systems:
  • Brakes, Power Brakes, Traction Control
  • Document: WIRING HARNESS - TERMINAL REPAIR KIT - REV4
    Vehicle: 1996 Ford F-150 Pickup 5.8 V8 GAS

    Auto Systems:
  • Chassis Electrical, Wiring, Fuses & Breakers, Wipers, Motors
  • CLICK HERE TO GET FULL ACCESS TO Ford F-150 Pickup TECHNICAL SERVICE BULLETINS!

    COMPONENT/PARTS SPECIFICATIONS FOR Ford F-150 Pickup AUTOMOBILES

    BRAKE SPECIFICATIONS: Brake drum, rotor, caliper, and related specifications for most Ford F-150 Pickup cars and light trucks sold in the U.S. and Canada from 1970+.

    • Brake caliper mounting bolt torque
    • Brake drum runout, machining, & discard specs
    • Minimum brake lining thickness.
    • Brake rotor runout, parallelism, machining, discard, & finish specs

    A/C SYSTEM SPECIFICATIONS: Air conditioning refrigerant capacity and type as well as lubricant capacity for most Ford F-150 Pickup cars and light trucks sold in the U.S. and Canada from 1980+.

    • Refrigerant capacity & type, compressor oil viscosity, total system oil capacity & compressor clutch gap

    COOLING SYSTEM BLEED: Cooling system bleeder valve identification, bleeder type and bleed procedures for most domestic and imported cars and light trucks sold in the U.S. and Canada from 1986+.

    PREVENTIVE MAINTENANCE: Preventive maintenance recommendations and required services for most domestic and imported cars and light trucks sold in the U.S. and Canada from 1980+. Includes severe and routine service schedules

    QUICK-LUBE and ILLUSTRATIONS: Fluid recommendations, capacities, drain plug torques, tire data, and severe service recommended preventive maintenance schedules. Information covers most Ford F-150 Pickup cars and light trucks sold in the U.S. and Canada from 1980+. Engine and chassis service images.

    • Automatic transmission/transaxles capacities, lubricant recommendations
    • Differential/final drive capacities, lube recommendations, grades, & viscosities
    • Final drive fill & drain plug torques
    • Number of lubrication fittings & plugs
    • Power steering, brake, & clutch fluid recommendations
    • Manual transmission/transaxle capacities, lube recommendations, grades, & viscosities
    • Number of lubrication fittings & plugs
    • Power steering, brake, & clutch fluid recommendations
    • Engine oil capacities, API grade recommendations, SAE viscosity recommendations, drain plug torque
    • Severe service maintenance & interval recommendations
    • Tire sizes, wheel nut/bolt torque, pressures & rim sizes
    • Transfer case capacities, lube recommendations, grades, & viscosities

    TUNE-UP & DRIVEABILITY SPECIFICATIONS: Most tune-up specifications for most Ford F-150 Pickup cars and light trucks sold in the U.S. and Canada from 1980+

    • Airflow sensor electrical specifications
    • Tensioning specifications for systems with automatic tensioners
    • Barometric pressure sensor specs
    • Battery group number and cranking performance
    • Crankshaft & camshaft position sensor resistance
    • Engine compression pressures
    • Coolant temperature sensor specs
    • Computer advance.
    • Diesel fuel temperature sensor resistance.
    • Distributor advance specifications
    • Ignition pickup coil resistance
    • Exhaust gas recirculation temperature sensor resistance
    • Engine fastener torque values
    • Firing order diagrams
    • Fuel system pressures
    • Generator (alternator) specs
    • Intake air temperature sensor specs
    • Ignition coil specifications
    • Fuel injector resistance
    • Engine idle speeds
    • Knock sensor resistance
    • Manifold absolute pressure sensor specs
    • Mixture control solenoid resistance
    • Voltage regulator specs
    • Spark plug applications & gaps
    • Starter motor electrical specs.
    • Tensioning specifications for systems without automatic tensioners
    • Throttle body temperature sensor resistance
    • Ignition timing in degrees at rpm
    • Transmission oil temperature sensor resistance
    • Throttle position sensor specs
    • Vacuum sensor valve specs

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