Safety Warning

DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.

SYS.OK|MANUAL.DB● LIVE

HOMESERVICE MANUALSFORD2004ECONOLINE E150, VAN CARGO, 4.6 WREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 309 (AUTOMATIC TRANSMISSION)DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIESCHAIN COVERASSEMBLY

2004 Ford Econoline E150, Van Cargo, 4.6 W

Chain Cover: Assembly

2004 Ford Econoline E150, Van Cargo, 4.6 WSECTION Assembly

WARNING: This page is about a different car, the 2004 Mercury Monterey and 2004 Ford Freestar. However, it is still accessible from the selected car via links, so may be relevant.

Measure the distance that the center bi-metal element pin protrudes from the chain cover.

Fig 1: Measuring Distance Between Center Bi-Metal Element Pin And Chain Cover
Courtesy of FORD MOTOR CO.
Using the special tool, install the bi-metal element.
1. Position the bi-metal strip onto the end of the pin.
2. Install the special tool under the bi-metal element.
3. Tap the retaining collar onto the pin until it seats against the special tool edge.
Fig 2: Installing Bi-Metal Element (1 Of 2)
Courtesy of FORD MOTOR CO.
Using the special tool install the bi-metal element.
1. Position the bi-metal strip onto the end of the pin.
2. Install the special tool under the bi-metal element.
3. Tap the retaining collar onto the pin until it seats against the special tool edge.
  
  Fig 3: Installing Bi-Metal Element (2 Of 2)
  Courtesy of FORD MOTOR CO.
Remove the slotted end of the bi-metal element and install the thermostat plate over the end and middle pins.

Fig 4: Installing Thermostat Plate
Courtesy of FORD MOTOR CO.
Install the slotted end of the bi-metal element under the retaining ring.

Fig 5: Installing Slotted End Of Bi-Metal Element
Courtesy of FORD MOTOR CO.

CAUTION: Do not allow the pistons to cock in their bores or damage to the seals may result.

RENDER: 1.0x

NO RELATED

Recommended Tools & Savings

Use the Manual With the Right Hardware

Pair factory procedures with proven DIY tools so the instructions are easier to execute.

Affiliate disclosure: We may earn a commission at no extra cost to you.

Shop Manual-Ready Tools Free Quote Check Quote Shield Pro

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.