Exterior

Doors

REMOVAL & INSTALLATION

Remove the door hinge-to-body bolts
  1. Disconnect the negative battery cable.
  2. Remove any trim necessary to access the electrical connector inside the front door.
  3. Detach the electrical connector inside the door and pull the wire harness out of the front door.
  4. Matchmark the hinge-to-body and hinge-to-door locations.
  5. Support the door either on jackstands or have somebody hold it for you.
  6. Remove the lower hinge-to-door bolts.
  7. Remove the upper hinge-to-door bolts and lift the door off the hinges.
  8. If the hinges are being replaced, remove them from the door pillar.

To install:

  1. Install the door and hinges with the bolts finger tight.
  2. Adjust the door and tighten the hinge bolts to 19-25 ft. lbs. (26-35 Nm).
  3. Install the wire harness into the door opening.
  4. Attach the electrical connector inside the front door.
  5. Install any trim removed from the door.
  6. Connect the negative battery cable.

ADJUSTMENT

1997-98 F-250HD, F-350 and F-Super Duty

Door hinge adjustment

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Rear door hinge adjustment, F-350 Crew Cab

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Loosen the hinge-to-door bolts for lateral adjustment only. Loosen the hinge-to-body bolts for both lateral and vertical adjustment.

  1. Determine which hinge bolts are to be loosened and back them out just enough to allow movement.
  2. To move the door safely, use a padded prybar. When the door is in the proper position, tighten the bolts to 19-25 ft. lbs. (26-35 Nm) and check the door operation. There should be no binding or interference when the door is closed and opened.
  3. Door closing adjustment can also be affected by the position of the lock striker plate. Loosen the striker plate bolts and move the striker plate just enough to permit proper closing and locking of the door.

F-150, F-250, Expedition and Navigator

HORIZONTAL AND VERTICAL ADJUSTMENT
  1. Loosen the front door hinge to front door bolts.
  2. Adjust the front door alignment.
  3. Tighten the front door hinge to front door bolts to 19-25 ft. lbs. (26-35 Nm).
FRONT DOOR FORE AND AFT ADJUSTMENT

Check the rear door hinge adjustment before adjusting the front door hinge.

  1. Remove the front fender.
  2. Loosen the front door hinge to body bolts.
  3. Adjust the front door alignment to specification.
  4. Tighten the front door hinge to body bolts.
  5. Install the front fender.

1999-00 F-Super Duty Models

DOOR ADJUSTMENT

The following procedure is for performing fore, aft, up, down and tilt adjustments.

  1. Remove the door striker.
  2. Loosen the bolts only enough to allow for slight door movement.
  3. Carefully close and adjust the door until flush with the adjacent body panels.
  4. Carefully open the door and tighten the bolts.
  5. Re-install and adjust the door striker.
  6. Check the door for proper operation and alignment.
STRIKER ADJUSTMENT
Loosen the striker mounting bolt

Mark the position of the striker before loosening.

  1. Loosen the striker retaining bolts.
  2. Adjust the door striker and tighten the striker retaining bolts.

Hood

REMOVAL & INSTALLATION

Detach the connector for the underhood lamp and ...
... disengage the underhood lamp harness retaining clips and remove the harness from the hood
Disconnect the washer fluid hose from the washer jet nipple and ...
... disengage the hose retaining clips and remove the hose from the hood
Release the hood lift-to-body retaining clips and remove the hood lifts from the pivot ball
Matchmark the hood-to-hinge position
While an assistant supports the hood, remove the hinge bolts from one side of the hood
A good way to keep track of the hood hinge-to-hood bolts is to install the bolts into the hood while storing the hood

You'll need an assistant for this job.

  1. Open the hood.
  2. Disconnect the negative battery cable.
  3. Detach any electrical connectors, washer fluid lines, or any other components necessary for hood removal.
  4. On all models except for 1997-98 F-250HD, F-350 and F-Super Duty:
    1. Support the hood with a bar, long sturdy handle or have an assistant hold it.
    2. Release the hood lift-to-body retaining clips and remove the hood lifts from the pivot ball.
  5. Matchmark the hood-to-hinge position.
  6. While an assistant supports the hood, remove the hinge bolts from one side of the hood.
  7. Repeat the procedure for the other side.
  8. Carefully lift and remove the hood taking care not to scratch the paint.
  9. Place the hood in a safe place and place rags around the painted surfaces that will make contact with the ground or other surface on which it is placed.

To install:

  1. The installation is the reverse of the removal. Tighten the hinge bolts to19-25 ft. lbs. (26-35 Nm).

ALIGNMENT

  1. Open the hood.
  2. Loosen the hinge-to-hood bolts just enough to allow movement of the hood.
  3. Move the hood as required to obtain the proper fit and alignment between the hood and the top of the cowl panel.
  4. Tighten the hood-to-hinge bolts to 19-25 ft. lbs. (26-35 Nm).
  5. Lubricate the latch and hinges and check the hood fit several times.

Tailgate

REMOVAL & INSTALLATION

Grasp the tailgate support cable and ...
... lift the cable from the pillar T-head pivot
1997-98 F-250HD, F-350 and F-Super Duty tailgate

Click to enlarge

  1. Remove the tailgate support or strap or cable at the pillar T-head pivot.
  2. Lift off the tailgate at the right hinge.
  3. Pull off the left hinge.
  4. Installation is the reverse of removal.

ALIGNMENT

Loosen the striker bolts and move the strikers until the tailgate is aligned. Tighten the striker bolts.

Liftgate

REMOVAL & INSTALLATION

Remove the liftgate hinge-to-body bolts
  1. Disconnect the negative battery cable.
  2. Remove the trim and detach the harness connector for the liftgate.
  3. Have an assistant support the liftgate.
  4. Remove the liftgate hinge-to-body bolts.
  5. Remove the liftgate from the vehicle.
  6. The installation is the reverse of the removal.
  7. Tighten the liftgate hinge-to-body bolts to 91-123 inch lbs. (10-14 Nm).

ALIGNMENT

  1. Loosen the liftgate hinge to liftgate bolts.
  2. Adjust the liftgate alignment.
  3. Tighten the liftgate hinge to liftgate bolts.
  4. Tighten the liftgate hinge-to-liftgate bolts to 91-123 inch lbs. (10-14 Nm).

Grille

REMOVAL & INSTALLATION

1997-98 F-250HD, F-350 and F-Super Duty

Grille installation—1997-98 F-250HD, F-350 and F-Super Duty

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  1. Open the hood.
  2. Remove the screws securing the top of the grille to the front valance panel.
  3. Remove the screws securing the top of the grille to the radiator grille opening panel reinforcement.
  4. Remove the grille.
  5. The installation is the reverse of the removal.

F-150, F-250 and Expedition

Remove the eight stone guard pin-type retainers (four on each side)
Remove the ten radiator grille screws
  1. Raise and support the hood.
  2. Remove the service jack handle.
  3. Remove the retaining screws and remove front upper air deflector.
  4. Remove the headlamps.
  5. Remove the combination lamps.
  6. Remove the eight stone guard pin-type retainers (four on each side).
  7. Remove the ten radiator grille screws.
  8. Release the clips from the radiator grille opening panel reinforcement.
  9. Remove the radiator grille.
  10. The installation is the reverse of the removal.

Navigator

The grille on the Navigator is part of the hood assembly. Refer to hood removal and installation in this section.

1999-00 F-Super Duty Models

Remove the grille retaining screws
Release the lower retainers and remove the grille assembly
  1. Remove the grille retaining screws.
  2. Release the lower retainers.
  3. Remove the radiator grille.

To install:

  1. Position the radiator grille in the grille opening.
  2. Secure the radiator grille retainers by pushing into place.
  3. Install the retaining screws.

Outside Mirrors

REMOVAL & INSTALLATION

1997-98 F-250HD, F-350 and F-Super Duty

DUAL POSITION RECREATION SWING-OUT MIRROR
Dual position recreation swing-out mirror mounting

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  1. Remove the four mirror retaining screws .
  2. Remove the mirror from the door.
  3. The installation is the reverse of the removal.
WESTER TYPE SWING-AWAY MIRROR
Western type swing-away mirror mounting

Click to enlarge

  1. Remove the four mirror retaining screws .
  2. Remove the mirror from the door.
  3. The installation is the reverse of the removal.
POWER MIRROR
Power mirror mounting—1997-98 F-250HD, F-350 and F-Super Duty

Click to enlarge

  1. Disconnect the negative battery cable.
  2. Remove the front door trim panel.
  3. Remove the front door watershield.
  4. Detach the power mirror electrical connector.
  5. Remove the two screws retaining the mirror to the outside of the door.
  6. Remove the one screw retaining the mirror to the inside of the door.
  7. Remove the mirror from the door.
  8. The installation is the reverse of the removal.

Except 1997-98 F-250HD, F-350 and F-Super Duty

Remove the mirror sail cover to gain access to the mirror retaining nuts
Remove the outside rear view mirror nuts and ...
... remove the outside rear view mirror
  1. Disconnect the negative battery cable.
  2. Remove the front door trim panel.
  3. Remove the mirror sail cover to gain access to the mirror retaining nuts.
  4. If equipped with power mirrors, detach the power mirror electrical connector.
  5. Disconnect the power mirror wiring clip.
  6. Remove the outside rear view mirror nuts.
  7. Remove the outside rear view mirror and feed the power mirror wiring through the opening in the front door.
  8. The installation is the reverse of the removal.

Antenna

REPLACEMENT

1997-98 F-250HD, F-350 And F-Super Duty Models

Antenna mounting—1997-98 F-250HD, F-350 and F-Super Duty

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  1. Remove the radio from the instrument panel and detach the antenna cable from the radio.
  2. Remove the antenna cable from retaining clips along the bottom of the instrument panel.
  3. Remove the antenna mast from the base by unscrewing it.
  4. Unsnap the cap from the antenna base and remove the cap.
  5. Remove the 4 screws and lift off the antenna.
  6. Detach the antenna cable from the antenna base.
  7. Remove the antenna base from the vehicle.
  8. Installation is the reverse of removal.

F-150, F-250, Expedition and Navigator

  1. Remove the antenna mast from the base by unscrewing it.
  2. Remove the 3 screws and lift off the antenna.
  3. Detach the antenna cable from the antenna base.
  4. Remove the antenna base from the vehicle.
  5. Installation is the reverse of removal.

1999-00 F-Super Duty Models

Remove the passenger side cowl top vent panel cover
Remove the 3 screws and lift off the antenna
Detach the antenna cable from the antenna base
  1. Remove the passenger side cowl top vent panel cover.
  2. Remove the antenna mast from the base by unscrewing it.
  3. Remove the 3 screws and lift off the antenna.
  4. Detach the antenna cable from the antenna base.
  5. Remove the antenna base from the vehicle.
  6. Installation is the reverse of removal.

Fenders

REMOVAL & INSTALLATION

1997-98 F-250HD, F-350 and F-Super Duty Models

Right front fender installation—1997-98 F-250HD, F-350 and F-Super Duty Models

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Right front fender apron installation—1997-98 F-250HD, F-350 and F-Super Duty Models

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  1. Clean all fender fasteners and liberally apply penetrating oil.
  2. Remove the headlamp assemblies.
  3. Remove the fender-to-radiator support screws.
  4. Remove the screw attaching the fender to the lower corner of the cab.
  5. Remove the screw inside the cab attaching the lower end of the fender to the cowl.
  6. Remove the screws attaching the top edge of the fender to the cowl extension.
  7. Remove the screws that attach the fender to the apron, around the wheel opening.
  8. Remove the top fender-to-apron bolts.
  9. On the right side, remove the battery and the battery tray.
  10. On the driver's side, remove the auxiliary battery and/or tool box (both are options).
  11. On the right side, detach the main wiring harness from the fender.
  12. On the driver's side, detach the hood latch cable from the fender.
  13. Remove the hood prop spring from the fender.
  14. Remove the fender.

To install:

  1. Apply sealer to the upper edge of the apron.
  2. Position the fender on the truck and loosely install all screws nuts and bolts.
  3. Go around the fender and check its fit. Position the fender for even fit with all adjoining panels and tighten all the fasteners.
  4. Install all parts removed previously.

F-150, F-250 and Expedition

  1. Remove the radiator grille opening panel reinforcement.
  2. If equipped, remove the front wheel opening moulding.
  3. Remove the front fender splash shield.
  4. Remove the cowl grille.
  5. On the passenger side front fender:
    1. Remove the antenna mast.
    2. Remove the antenna base by gently inserting a thin straight-edged screwdriver underneath the cap and carefully following inside the perimeter until both snaps are free.
    3. Remove the screws and lift the antenna base.
    4. Disconnect the radio antenna lead-in cable and remove the antenna base.
  6. Remove the fender stuffer.
  7. Remove the stone guard.
  8. Remove the front fender retaining bolts.
  9. Remove the fender from the body.
  10. The installation is the reverse of the removal.

Navigator

  1. Remove the cowl top vent panels.
  2. Remove the jack handle.
  3. Remove the air deflector.
  4. Remove the headlamp mounting clips and remove the headlamp.
  5. Detach the electrical connectors.
  6. Remove the radiator opening cover.
  7. Remove the driver's side radiator grille opening panel reinforcement bolts.
  8. Remove the center radiator grille opening panel reinforcement bolts.
  9. Remove the passenger side radiator grille opening panel reinforcement bolts.
  10. Remove the radiator grille opening panel reinforcement-to-front fender bolt.
  11. On the passenger side front fender, remove the antenna mast.
  12. On passenger side front fender, remove the antenna base by gently inserting a thin straight-edged screwdriver underneath the cap and carefully following inside the perimeter until both snaps are free.
  13. Remove the screws and lift the antenna base.
  14. Disconnect the radio antenna lead-in cable and remove the antenna base.
  15. Remove the lower rear screw from the front wheel opening moulding.
  16. Remove the lower rear pushpin from the front wheel opening moulding.
  17. Remove the front fender splash shield.
  18. Remove the front fender splash shield
  19. Remove the front bumper cover to front fender nuts.
  20. Remove the concealed radiator grille opening panel reinforcement nut.
  21. Carefully position the radiator grille opening panel slightly forward.
  22. Remove the inner fender stuffer.
  23. Remove the front fender retaining bolts.
  24. Remove the fender from the body.
  25. The installation is the reverse of the removal.
  26. Tighten the fender retaining bolts to 94-120 inch lbs. (11-14 Nm).

1999-00 F-Super Duty Models

Remove the screws at the lower edge of the front fender securing the splash shield
Remove the bolts securing the lower rear of the front fender
Remove the fender-to-radiator grille opening support retaining bolts
Remove the fender-to-radiator support retaining screws
Open the door, then remove the fender retaining bolts
Remove the upper fender retaining bolts
Remove the hood support bolt
  1. Support the hood using a prop rod.
  2. Disconnect the hood lifts.
  3. Remove the headlights and turn signals.
  4. Remove the screws at the lower edge of the front fender securing the splash shield.
  5. If equipped, remove the running board.
  6. Remove the pushpins at the rear lower edge of the front fender.
  7. Remove the bolts securing the lower rear of the front fender.
  8. Remove the fender-to-radiator grille opening support retaining bolts.
  9. Remove the fender-to-radiator support retaining screws.
  10. Open the door, then remove the fender retaining bolts.
  11. Remove the upper fender retaining bolts.
  12. Remove the hood support bolt.
  13. Remove the front fender.
  14. The installation is the reverse of the removal.

Body Mount Bushings

REPLACEMENT

Typical body mount location for the F-150, 250, 350 and F-Super Duty chassis/cab

Click to enlarge

The body mount bushings are replaced on an individual basis. The easiest way to replace the bushings is to support the frame under the mount using a jackstand or other suitable device. Remove the mount through-bolt and remove the bolt. Raise the frame sufficiently enough to access and remove the bushings. Replace the bushings, lower the frame and install and tighten the through-bolt. Remove the jackstands or other support device.

Chilton® Automotive Information Systems. © 2004 Thomson Delmar Learning.