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HOMESERVICE MANUALSFORD2004ECONOLINE E150, VAN CARGO, 4.6 WREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 285 (CLIMATE CONTROL SYSTEM)REMOVAL AND INSTALLATIONAIR DISTRIBUTION DUCTS
2004 Ford Econoline E150, Van Cargo, 4.6 W

Air Distribution Ducts

2004 Ford Econoline E150, Van Cargo, 4.6 WSECTION Air Distribution Ducts
WARNING: This page is about a different car, the 2004 Lincoln LS. However, it is still accessible from the selected car via links, so may be relevant.
  1. If removing the front floor ducts, remove the instrument panel lower insulators.
  2. If removing the rear seat floor ducts, remove the front seats. For additional information, refer to SEATING .
  3. If removing the rear seat floor ducts, remove the lower cowl trim panels and front door sill plates to position the carpet away from the ducts.
  4. If removing the fresh air inlet duct, remove the cowl panel grille. For additional information refer to EXTERIOR TRIM .
  5. To remove individual components, only carry out the following steps. See COMPONENTS REMOVING STEPS .
    COMPONENTS REMOVING STEPS

    Component Steps
    LH floor duct 1-3
    RH floor duct 4-6
    Defroster duct 7, 11-12
    Demister ducts 7, 11-12, 16-17, 20-21
    Panel ducts 7-26
    Floor console ducts 27-33
    Rear seat floor ducts 34-36
    Fresh air inlet duct 38-44
  6. Illustration 1 of 3. Remove the components in the order indicated in the following illustration and table. See Fig 1.
    Fig 1: Identifying Removing Sequence Of Air Distribution Ducts
    G03202359Courtesy of FORD MOTOR CO.
  7. Illustration 2 of 3. Remove the components in the order indicated in the following illustration and table. See Fig 2.
    Fig 2: Identifying Removing Sequence Of Air Distribution Ducts
    G03202360Courtesy of FORD MOTOR CO.
  8. Illustration 3 of 3. Remove the components in the order indicated in the following illustration and table. See Fig 3.
    Fig 3: Identifying Removing Sequence Of Air Distribution Ducts
    G03202361Courtesy of FORD MOTOR CO.
  9. To install, reverse the removal procedure.

Item 7: Instrument Panel Removal Note 

  1. Remove the instrument panel. For additional information, refer to INTERIOR TRIM .

Item 8-9: LH and RH Instrument Panel Register Removal Note 

  1. Remove the instrument panel register. For additional information, refer to INSTRUMENT PANEL REGISTERS .

Item 10: Plenum Chamber Removal Note 

  1. Remove the plenum chamber. For additional information, refer to PLENUM CHAMBER, ASSEMBLY AND COMPONENTS .

Item 27: Floor Console Removal Note 

  1. Remove the floor console. For additional information, refer to INTERIOR TRIM .

Item 30: Transmission Selector Assembly Removal Note 

  1. Remove the transmission selector assembly. For additional information, refer to AUTOMATIC TRANSMISSION - 5R55S .
RENDER: 1.0x

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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • • You smell fuel, burning insulation, or see smoke.
  • • Brakes feel soft, pull hard to one side, or make grinding noises.
  • • The engine overheats, stalls repeatedly, or misfires under load.
  • • You are missing required tools, torque specs, or safe lifting equipment.
  • • You are not confident in the next step or safety outcome.