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NOTE: If a heater core leak is suspected, the heater core must be pressure leak tested before it is removed from the vehicle. For additional information, refer to Section 412-00. 1. Drain the radiator. For additional information, refer to Section 303-03A. 2. Remove the instrument panel. For additional information, refer to Section 501-12. 3. Disconnect the heater core hose couplings. For additional information, refer to Section 412-00. 4. Remove the A/C plenum demister adapter. 1. Remove the screw. 2. Remove the A/C plenum demister adapter. 5. Remove the screws and position aside the relay bracket. 6. Disconnect the vacuum line. 7. Remove the plenum chamber top. 1. Remove the 15 screws. 2. Remove the plenum chamber top. 8. Remove the blend door assembly from the case. 9. Remove the heater core. 10. To install, reverse the removal procedure. Lubricate the coolant hoses with coolant hose lubricant or plain water only, if needed.

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Removal 1. CAUTION: Electronic modules are sensitive to electrical charges. If exposed to these charges, damage may result. Disconnect the battery ground cable (14301). 2. Remove the cover from the instrument panel fuse junction panel. 3. Remove the lower instrument panel steering column cover (044F08). 1. Remove the lower instrument panel steering column cover bolts. 2. Remove the lower instrument panel steering column cover. 4. Remove the (A) bulkhead electrical connectors from the (B) instrument panel fuse junction panel. 5. Remove the (A) instrument panel fuse junction panel bolts and remove the (B) interior fuse junction panel nuts. 6. Disconnect the (A) generic electronic module/central timer module (GEM/CTM) electrical connectors from the (B) GEM/CTM. 7. Remove the GEM/CTM screws and the GEM/CTM. Installation NOTE: When the battery (10655) is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. 1. To install, reverse the removal procedure. Check for proper operation.

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FORD: LINCOLN: This article supersedes TSB 06-11-3 to update the vehicle model years. ISSUE: Some 2004-2007 F-150 and 2006-2007 Mark LT vehicles may exhibit shudder/vibration on moderate to hard acceleration. ACTION: Adjust the rear axle pinion angle. Order and install the appropriate shim kit for 4X2 / 4X4 Light Duty or 4X2 / 4X4 Heavy Duty vehicle. Refer to the Driveline Angle Corrections chart in this TSB. Refer to the installation Instruction Sheet included in the kit. NOTE: FOR 2-PIECE DRIVE SHAFT EQUIPPED VEHICLES IT MAY BE NECESSARY TO ORDER THE FOLLOWING ADDITIONAL PARTS: EOTZ-4A209-A – Center Support Shim (Up to 3 maximum) W711116-S439 – Center Support Mount Bolts NOTE: HEAVY DUTY REAR AXLES HAVE 7 LUG NUTS. 2004-2007 F-150

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The axle housing assembly consists of a cast-aluminum center section, a removable cast-aluminum axle housing tube (3B210), and a differential housing cover (3N136). Both the axle housing tube and the differential housing cover use silicone sealant as a gasket. The hypoid-design gearset consists of an 8.8-inch ring gear (3A397) and a pinion gear (3N175). Two opposed tapered roller bearings support the drive pinion in the axle housing. A drive pinion collapsible spacer (4662), located on the pinion shaft, maintains pinion bearing preload. The pinion nut adjusts the preload. Differential bearing shims (4A451), located between the differential bearing cups (4221) and the axle housing, adjust the differential bearing preload and the ring gear backlash. The differential case (4205) is a one-piece design with two openings to allow for assembly of the internal components and lubricant flow. Two opposed tapered roller bearings (differential bearings [4221]) support the differential case in the axle housing. Removable differential bearing caps (4224) retain the differential assembly in the axle housing. Inside the differential case, the differential pinion shaft (4211) supports two differential pinion gears (4215). The pinion gears engage the differential side gears (4236), to which the left axle shaft (3A381) and the axle cluster gear shaft (7L253) are splined. The differential pinion shaft bolt retains the differential pinion shaft in the differential case. An embossed metal tag, bolted to the rear face of the RH axle tube, contains front axle identification information. CAUTION: Actuate the front drive axle with the wheels in a straight ahead position, and at light throttle only. A front axle actuator motor assembly (7G360), controlled by an instrument panel-mounted switch, actuates the front drive axle.

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All Vehicles 1. Remove the RH lower instrument panel insulator. 2. If equipped, remove the dealer installed air filter and brackets. 3. Remove the passenger side scuff plate. 4. Remove the passenger side kick panel. 1. Position aside the weatherstrip. 2. Remove the passenger side kick panel. 5. Disconnect and detach the electrical connector. 6. Position back the carpet. EATC Vehicles 7. Disconnect the aspirator tube and remove the screw. 8. Remove the aspirator tube extension. 1. Remove the screws. 2. Remove the aspirator tube extension. All Vehicles 9. Disconnect the electrical connector. 10. Remove the screws and remove the blower motor. 11. Remove the wheel from the blower motor. 1. Remove the clip. 2. Remove the blower wheel. 12. To install, reverse the removal procedure.