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2004 Ford E-450 Econoline 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!Select Section
- Component Locations
- Wiring Diagrams
- Technical Service Bulletins
- Specifications
- A/C & Heater Service
- Brake Service
- Fuel Filter Replacement
- Driveline, U-Joint & CV Axles Replacement
- Starter & Alternator Replacement
- Maintenance Lamp Reset
- Radiator & Hose Replacement
- Serpentine Belt Service
Automotix DIY provides automotive consumers and do it yourselfers; the most comprehensive repair information about 2004 Ford E-450 Econoline 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 E-450 Econoline automobile. Try the Automotix DIY solution today!
A/C & HEATER SERVICE PROCEDURES FOR 2004 Ford E-450 Econoline AUTOMOBILES
Compressor Service -> Compressor Clutch Service -> Clutch Field Coil, Replace -> Clutch Hub & Pulley, Replace -> FS-10, SC90V & SC105V -> Installation -> Removal -> SC115
Vehicle: 2004 Ford E-450 Econoline 5.4 V8 GAS
Clutch Hub & Pulley, Replace
Removal
FS-10, SC90V & SC105V
- Holding clutch plate with a suitable spanner wrench, Figs. and , remove clutch hub retaining nut or bolt, Figs. through .
- On models where clutch plate is retained with a nut, remove clutch hub and shims from compressor shaft using hub remover tool No. T94P-19703-AH, or equivalent, Fig. .
- On models where clutch plate is retained by a bolt, lift assembly and shims from compressor. If required, thread a suitable bolt into clutch plate hub to break hub free of shaft, F...
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BRAKE SERVICE PROCEDURES FOR 2004 Ford E-450 Econoline AUTOMOBILES
Disc Brakes -> Inspection -> Brake Bleed -> Brake Disc Service -> Brake Linings -> Brake Roughness -> Caliper Inspection -> General Precautions
Vehicle: 2004 Ford E-450 Econoline 5.4 V8 GAS
Brake Linings
Remove both front wheels and inspect the brake discs, calipers and linings. (Wheel bearings should be inspected at this time and repacked if required).
Do not get any oil or grease on the linings. It is recommended that both front wheel sets be replaced whenever a respective shoe and lining is worn or damaged. Inspect and, if required, replace rear brake linings also.
If the caliper is cracked or fluid leakage through the casting is evident, it must be replaced as a unit.
Brake Roughness
The most common cause of brake chatter on disc brakes is a variation in thickness of the...
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FUEL FILTER REPLACEMENT PROCEDURES FOR 2004 Ford E-450 Econoline AUTOMOBILES
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: 2004 Ford E-450 Econoline 5.4 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 2004 Ford E-450 Econoline AUTOMOBILES
DRIVESHAFT U-JOINT, Replace -> Assemble -> Disassemble -> Single Cardan, Flange Yoke -> Single Cardan, Slip Yoke
Vehicle: 2004 Ford E-450 Econoline 6.0 V8 DIESEL
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 2004 Ford E-450 Econoline AUTOMOBILES
Alternator, Replace -> Dual Alternator -> Single Alternator
Vehicle: 2004 Ford E-450 Econoline 6.0 V8 DIESEL
Single Alternator
- Disconnect both battery ground cables.
- Remove bolt and position manifold absolute pressure sensor aside.
- Remove bolt and position ground strap aside.
- Remove bracket bolts and position power steering fluid reservoir aside.
- Remove bolts and position cowl wire harness aside.
- Remove intercooler tube bracket.
- Remove left stud nut.
- Remove bracket screws.
- Remove right stud nut.
- Loosen clamps and remove intercooler tube.
- Rotate accessory drive belt tensioner clockwise and remove alternator drive belt.
- Remove transmission dipstick tube bracket nut from alternator and position b...
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MAINTENANCE LAMP RESET PROCEDURES FOR 2004 Ford E-450 Econoline AUTOMOBILES
Ford Motor Co. Trucks -> Electronic Throttle Control ->
Vehicle: 2004 Ford E-450 Econoline 6.8 V10 GAS
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 2004 Ford E-450 Econoline AUTOMOBILES
Radiator, Replace
Vehicle: 2004 Ford E-450 Econoline 6.8 V10 GAS
- Drain cooling system into a suitable container.
- Remove air cleaner assembly, then plastic rivet retainers and air deflector.
- Remove upper and lower radiator hoses from radiator.
- Disconnect overflow hose from radiator.
- Remove fan and fan clutch from water pump pulley.
- Remove radiator upper fan shroud a...
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SERPENTINE BELT SERVICE PROCEDURES FOR 2004 Ford E-450 Econoline AUTOMOBILES
Serpentine Drive Belt, Replace
Vehicle: 2004 Ford E-450 Econoline 6.0 V8 DIESEL
- Remove cooling fan, blade, clutch and shroud.
- Rotate drive ...
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COMPONENT LOCATION DIAGRAMS FOR 2004 Ford E-450 Econoline AUTOMOBILES
Component location diagrams for most 2004 Ford E-450 Econoline cars and light trucks sold in the U.S. from 1990+.
 Transmission Components Diagram for 2004 Ford E-450 Econoline 5.4 V8 GASComponents on diagram: |
 Body Components Diagram for 2004 Ford E-450 Econoline 5.4 V8 GASComponents on diagram: |
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WIRING DIAGRAMS FOR 2004 Ford E-450 Econoline AUTOMOBILES
OEM drawn wiring diagrams for most 2004 Ford E-450 Econoline cars and light trucks sold in the U.S.
 2004 Ford E-450 Econoline 6.8 V10 GAS Wiring DiagramComponents on diagram: |
 2004 Ford E-450 Econoline 6.8 V10 GAS Wiring DiagramComponents on diagram: |
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TECHNICAL SERVICE BULLETINS FOR 2004 Ford E-450 Econoline AUTOMOBILES
OEM TSB listings for most 2004 Ford E-450 Econoline cars and light trucks sold in the U.S. from 1985+.
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Document: COOLANT LOSS - 6.0L Vehicle: 2004 Ford E-450 Econoline 6.0 V8 DIESEL Symptoms: |
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Document: DRIVEABILITY - NO START, HARD START, RUNS ROUGH - FUEL INJECTION CONTROL MODULE DIAGNOSIS Vehicle: 2004 Ford E-450 Econoline 5.4 V8 GAS Symptoms: |
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COMPONENT/PARTS SPECIFICATIONS FOR 2004 Ford E-450 Econoline AUTOMOBILES
BRAKE SPECIFICATIONS: Brake drum, rotor, caliper, and related specifications for most 2004 Ford E-450 Econoline 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 2004 Ford E-450 Econoline 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 2004 Ford E-450 Econoline 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 2004 Ford E-450 Econoline 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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