Ford F-150 Pickups Repair Manual 2004-2010

1. Disconnect the cable from the negative battery terminal (see Chapter 5, Section 1)
   
   
2. Remove the engine cooling fan (see Chapter 3).
   
   
3. Remove drivebelt (see Chapter 1).
   
   
4. Unbolt and remove the crankshaft pulley. Remove the bolt from the front of the crankshaft, then use a puller to detach the crankshaft pulley. Caution: Don't use a puller with jaws that grip the outer edge of the damper.
   
   The puller must be the type that utilizes bolts to apply force to the damper hub only. Clean the crankshaft nose and the seal contact surface on the pulley with lacquer thinner or acetone. Leave the Woodruff key in place in the crankshaft keyway.
   
   Note: lock the crankshaft pulley in place with a special strap-wrench designed for this purpose.

FLYWHEEL/DRIVEPLATE: REMOVAL AND INSTALLATION
(Refer to illustrations 16.3, 16.4a and 16.4b)

1. Raise the vehicle and support it securely on jackstands, then refer to Chapter 7 and remove the transmission. If it's leaking, now would be a very good time to replace the front pump seal/O-ring (automatic transmission only).
   
   
2. Remove the pressure plate and clutch disc (see Chapter 8) (manual transmission equipped vechiles). Now is a good time to check/replace the clutch components and pilot bearing.
   
   
3. Look for factory paint marks that indicate flywheel-to-crankshaft alignment. If they aren't there, use a center-punch or paint to make alignment marks on the flywheel/driveplate and crankshaft to ensure correct alignment during reinstallation (see illustration).

• Tune-up and routine maintenance
• 4.2L V6 engine
• 4.6L and 5.4L V8 engines
• General engine overhaul procedures
• Cooling heating and air conditioning systems
• Fuel and exhaust systems
• Engine electrical systems
• Emissions and engine control systems
• 5-speed manual transmission
• 4- and 6-speed automatic transmission
• Transfer case
• Clutch and driveline
• Brakes
• Suspension and steering systems
• Body
• Chassis electrical system
• Wiring diagrams