Ford Expedition / Ford F-150 / Ford F-250 Pick-Ups / Lincoln Navigator 1997 thru 2002, repair e-manual (in Russian)

Content

Welcome to your new FORD car

Introduction

• Purpose of the guide
• Introduction to modifications of F-150, F-250, Expedition and Navigator
• Vehicle identification numbers
• Purchase of spare parts
• Methods of service, tools and work equipment
• Lifting the jack and towing a car
• Starting an engine from an auxiliary battery
• Conversion factors
• Translation of decimal and fractional values ​​in inches to values ​​in millimeters
• Service fluids and lubricants
• Safety first!
• Troubleshooting

Instruction manual

• Introduction
• Instrument panel shield
• Head unit
• Manual heating and air conditioning system
• Electronic automatic climate control system (EATC)
• Lighting
• Controlling equipment from the driver's seat
• Locks and car security system
• Seats and devices of passive safety of the driver and passengers

Daily care and maintenance

• Service schedule
• Introduction
• General recommendations for car care
• Checking the level of fluids and lubricants
• Check of a condition and pressure of inflation of tires
• Checking the fluid level in the hydraulic system of the power steering
• Checking the transmission fluid level in the automatic transmission
• Replacement of engine oil and oil filter
• Lubrication of suspension components
• Checking the technical condition, maintenance and charging of the battery
• Checking the condition and replacing the wiper blades
• Rearrangement of tires
• Inspection of the technical condition of the exhaust system
• Checking the condition of the seat belts
• Check for hoses leakage and replacement
• Checking the condition of the cooling system
• Checking the technical condition of the fuel system
• Replacing the fuel filter
• Check of a condition of components of a steering and a suspension bracket
• Checking the condition of the braking system
• Checking the level of the transmission fluid in the manual transmission
• Checking the level of the transmission fluid in the transfer case
• Checking the level of the transmission fluid in the differential
• Checking the condition and replacing the air filter
• Maintenance of the cooling system (coolant draining, flushing and filling the system)
• Replacing transmission fluid and filter in automatic transmission
• Checking the condition, lubrication and adjustment of the front wheel bearing (models with a two-wheel drive)
• Brake fluid replacement
• Checking the condition and replacing the drive belt
• Checking the condition of the crankcase ventilation (PCV) valve
• Check of a condition and replacement of spark plugs
• Check of a condition and replacement of components of system of ignition
• Changing the oil of a manual gearbox
• Replacement of transmission oil in transfer case (4WD versions)
• Replacing differential oil

V6 engines

• General information
• Carrying out repairs without removing the engine from the car
• The top dead center (TDC) of the piston of the first cylinder is the location
• Valve mechanism covers - removing and installing
• Rockers and pushers of valves - removal, inspection and installation
• Springs, biscuits and oil seals of valves - replacement
• Intake manifold - removal and installation
• Exhaust manifold - removal and installation
• Cylinder head - removal and installation
• Drive chain casing - removing and installing
• Drive chain and sprockets - inspection, removal and installation
• Tip of valve tappets - removal, inspection and installation
• Camshafts and their bearings - removal, inspection and installation
• Pallet - removal and installation
• Oil pump - removal and installation
• Crankshaft oil seals - replacement
• Handwheel / drive plate - removal and installation
• Engine supports - checking and replacing

V8 Engines

• General information
• Carrying out repairs without removing the engine from the car
• The top dead center (TDC) of the piston of the first cylinder is the location
• Valve mechanism covers - removing and installing
• Rockers and pushers of valves - removal, inspection and installation
• Springs, biscuits and oil seals of valves - replacement
• Intake manifold - removal and installation
• Exhaust manifold - removal and installation
• Cylinder head - removal and installation
• Drive chain casing - Removing and installing
• Drive chain and sprockets - inspection, removal and installation
• Tip of valve tappets - removal, inspection and installation
• Camshafts and their bearings - removal, inspection and installation
• Pallet - removal and installation
• Oil pump - removal and installation
• Crankshaft oil seals - replacement
• Handwheel / drive plate - removal and installation
• Engine supports - checking and replacing

V8 engines

• General information
• Carrying out repairs without removing the engine from the car
• The top dead center (TDC) of the piston of the first cylinder is the location
• Valve mechanism covers - Removing and installing
• Crankshaft pulley - removing and installing
• Drive chain casing - removing and installing
• Drive chain, tensioning mechanism and sprockets - removal, inspection and installation
• Rocker arms and valve clearance adjusters - removal, inspection and installation
• Camshaft (s) - removal, inspection and installation
• Springs, biscuits and oil seals of valves - removal and installation
• Intake manifold - removal and installation
• Exhaust manifold - removal and installation
• Cylinder head - removal and installation
• Pallet - removal and installation
• Oil pump - removal and installation
• Handwheel / drive plate - removal and installation
• Crankshaft oil seals - replacement
• Engine supports - checking and replacing

Major engine repairs

• General information
• Major engine repairs - general information
• Compression check in engine cylinders
• Diagnosis with measurement of the degree of vacuum
• Engine removal - methods and precautions
• Engine - removal and installation
• Alternative methods of engine restoration
• Engine overhauling - sequence of disassembly
• Cylinder head - disassembly
• Cylinder head - cleaning and inspection
• Valve - service
• Cylinder head - disassembly
• Pistons / connecting rods - removal
• Crankshaft - removal
• Cylinder block - cleaning
• Cylinder block - inspection
• Honing cylinders
• Pistons / connecting rods - inspection
• Crankshaft - inspection
• Radial and connecting rod bearings - inspection
• Engine overhaul - assembly sequence
• Piston rings - installation
• Crankshaft - installation and inspection of the oil clearance of the main bearings
• Pistons / connecting rods - installation and check of the oil clearance of connecting rod bearings
• The first start-up and engine break-in after major overhaul

Cooling, heating and air conditioning systems

• General information
• Antifreeze - general information
• Thermostat - check and replace
• Cooling fan and its coupling - check, remove and install
• Radiator and expansion tank - removal and installation
• Coolant temperature sensor - check and replace
• Oil cooler - removal and installation
• Cooling pump check
• Cooling pump - removing and installing
• The fan of heating and air conditioning systems, as well as its electrical circuit - check
• Ventilator of heating and air conditioning - removal and installation
• Control panel for heating and air conditioning - removal and installation
• Heater - removal and installation
• Air conditioning and heating systems - inspection and maintenance
• The filter - the dehumidifier of an air conditioning system - removal and installation
• Air conditioning compressor - removal and installation
• Condenser for air conditioning - removal and installation
• Evaporator of air conditioning system - removal and installation

Fuel and exhaust systems

• General information
• Pressure relief in the fuel system
• Fuel pump / fuel pressure check
• Fuel lines and their connectors - general information
• Fuel tank - removal and installation
• Fuel tank - cleaning and recovery
• Fuel pump - removal and installation
• Fuel level sensor - check and replace
• Air filter housing - removing and installing
• Accelerator cable - removal, installation and adjustment
• Fuel injection system - general information
• Fuel injection system - inspection
• Electronic fuel injection (SEFI) - checking the condition of components and replacing them
• Idle air valve (IAC) - checking, removing and adjusting
• Intake manifold
• Maintenance of the exhaust system - general information

Electric engine systems

• General information
• Battery - removing and installing
• Battery - emergency start from an external source
• Battery wires - check and replace
• Ignition system - general information
• Ignition system - check
• Ignition coil - check and replace
• Ignition timing - check
• Charge system - general information and precautions
• Charge system - check
• Generator - removal and installation
• Generator components - replacement
• Launch system - general information and precautions
• The starter and its electrical circuit - check without removal
• Starter - removal and installation
• Starter solenoid valve - replacement

Engine control and exhaust control systems

• General information
• On-board diagnostic system (OBD) and DTCs
• Engine control module (PCM) - replacement
• Information Sensors
• Exhaust gas recirculation (EGR) system
• Fuel vapor recovery system (EVAP)
• Crankcase ventilation system (PCV)
• Catalytic converter

Manual transmission

• General information
• Gear lever - removal and installation
• Oil seals - replacement
• Transmission supports - check and replace
• Manual gearbox - removing and installing
• Repair manual transmission general information

Automatic transmission

• General information
• Diagnosis - general information
• Gear lever - removal and installation
• Adjusting the selector cable
• Gearbox control switch - description, check and replacement
• Cable of the switching mechanism - removal, installation and adjustment
• Transmission mode (TR) sensor - description, adjustment and replacement
• Box locking system in the "PARK" position - description, check and replacement of drives
• Automatic gearbox - removal and installation

Transfer case

• General information
• Switch lever (models with manual switching mode) - removal and installation
• All wheel drive indicator sensor (models with manual switching mode) - replacement
• Selector position sensor (models with electronic switching) - replacement
• The electric motor of a gear change (models with electronic switching) - replacement
• Oil seal - replacement
• Transfer case - removal and installation

Coupling and gimbal transmission

• General information
• Clutch - description and verification
• Master clutch cylinder - removal, inspection and installation
• Clutch release bearing - removal, inspection and installation
• Clutch slave cylinder - removal, inspection and installation
• Components of the clutch - removal, inspection and installation
• Guide bearing - inspection and replacement
• Hydraulic clutch system - pumping
• Clutch pedal position sensor - check and replace
• Cardan shafts and their joints - general information
• Preventive inspection cardan transmission
• Drive shaft - removal and installation
• Cardan shaft joints - replacement
• Covers of crosses of universal joints and central bearing (transfers with two compound propeller shafts) inspection and replacement
• Bridges - description and verification
• Axle shafts - removal and installation
• Seal shafts (rear) - replacement
• Semi-axle bearings (rear) - replacement
• The shaft seal of the differential gear shaft is a replacement
• Bridge (rear) - removal and installation
• Drive axle (all-wheel drive models) - removal and installation
• Replacement of covers of the leading bridge (all-wheel drive models)
• Vacuum switching system (all-wheel drive models) - description, testing and replacement of components
• Axle (front) (all-wheel drive models) - removal and installation

Brake system

• General information
• Anti-lock system - general information
• Disc brake pads - replacement
• Disc brake support - removal, repair and installation
• Brake disc - inspection, removal and installation
• Brake shoe pads - replacement
• Service brake cylinder - removal, repair and installation
• Master cylinder - removal, repair and installation
• Hoses and pipes of brake system - check of a condition and replacement
• Hydraulic braking system - pumping
• Stop light sensor - operation and replacement test
• Vacuum brake booster - status check, removal and installation
• Parking brake cables - replacement
• Brake shoes (models with rear disc brakes) - replacement

Suspension and steering systems

• General information
• Shock absorber (front) - removal and installation
• Stabilizer of lateral stability (front) - removal and installation
• Ball bearings - checking the condition and replacing
• Top suspension arms - removal and installation
• Lower levers of suspension - removal and installation
• Springs of the suspension (models with a two-wheel drive) - removal and installation
• Rotary fists (models with a drive on two wheels) - removal and installation
• Bearing and hub (all-wheel drive models) - replacement
• Rotary fists (all-wheel drive models) - removal and installation
• Torsion bar (all-wheel drive models) - removal and installation
• The system of the control of a road gleam is the general information
• Shock absorbers (rear) - removal and installation
• Springs / pneumatic springs - removal and installation
• Lateral pull - removal and installation
• Stabilizer of lateral stability (rear) - removal and installation
• Suspension levers - removal and installation
• Cylindrical springs / pneumatic springs (rear) - removal and installation
• Steering wheel - removal and installation
• Steering gear - inspection, removal and installation
• Steering gear - removal and installation
• Power steering pump - removal and installation
• Hydraulic power steering system - pumping
• Wheels and tires - general information
• Front wheel alignment angles - general information

Body

• General information
• Body - service
• Vinyl cladding - maintenance
• Upholstery and carpets - maintenance
• Body repair - minor damage
• Body repair - serious damage
• Loops and locks - maintenance
• Wind and fixed glass - replacement
• Hood and tailgate cover racks - removing and installing
• Hood cover - removal, installation and adjustment
• Latch and wire hood cover - removal and installation
• Radiator grille - removal and installation
• Bumpers - removal and installation
• Front fenders - removal and installation
• Facing panels of doors - removal and installation
• Doors - removal, installation and adjustment
• Latches, lock cylinders and door handles - removal and installation
• Glasses of door windows - removal and installation
• Lifters - removal and installation
• Side mirrors - removal and installation
• Board - removal, installation and adjustment
• Rear hinged door - removal, installation and adjustment
• Latch, handle and lock cylinder of the rear hinged door - removal and installation
• Central console (Expedition and Navigator) - uninstall and install
• Framing the instrument panel - removal and installation
• Facing the front of the instrument panel - removal and installation
• Steering column cover - removing and installing
• Front dashboard - removal and installation
• Cladding of air intakes - removal and installation
• Seats - removal and installation

Electric equipment of the body

• General information
• Detection of faults in electrical circuits - general information
• Fuses - general information
• Fusible inserts - general information
• Reverse current relay - general information
• Relay - general information and testing
• Flashing light / turn signal light
• Alarms - check and replace
• Switches on the steering column - check and replace
• Ignition switch - check and replace
• Ignition lock cylinder - removal and installation
• Headlight switch - check and replace
• Dashboard indicators - check
• Instrument panel - removal and installation
• Car radio and speakers - removing and installing
• Antenna - removal and installation
• Headlights - replacement
• Headlights - adjustment
• Replacing bulbs
• Daylighting (DRL) lighting - general information
• Windshield wiper motor - check and replace
• Signal - check and replace
• Rear window heater - inspection and repair
• Cruise control system - description and verification
• Power windows - description and verification
• Automatic door locks and "HANDS FREE" system - description and verification
• Mirrors of lateral view with the electric drive - the description and check
• Safety airbags - general information
• Electroschemes

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