Bulletproofing my 6 Liter - Page 7 - Ford Powerstroke Diesel Forum
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post #61 of 242 Old 01-03-2013, 12:23 PM Thread Starter
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A little mini update for you guys.

During lunch today I FINALLY got my fan and shroud off! I ended up hitting it with my purse.

But really, I went to harbor freight and picked up a 36" jimmy bar (has a hook on one end and a point on the other.) I put the pointed end into the black pulley hole and laid that down on the passenger side fender to hold it. Then I hooked my 2ft pipe wrench with a 4ft cheater bar on it up to the nut and pulled and out she came.

Now I'm out to try to figure out how to remove the A/C system, wish me luck..

2004 6.0L F-250 XLT - ECSB
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post #62 of 242 Old 01-03-2013, 12:26 PM
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The hvac box is easy, pull the rh fender liner, and 4 or 5 11mm nuts on the inside of the cab and the whole thing comes out.

03 cclb dually,6.0,arp studs,bpd oil cooler,bpd 6 phase ficm,bpd water pump,bpd all aluminum cac,all aluminum radiator,amsoil bypass oil filter,ipr high flow coolant filter,egr delete,livewire ts tuned by Vivian & tony,php ficm tuner,dc power 300-spx,Detroit trutrac,6" dual side pipes,07 front end,custom front bumper,shaved badges,led button roof lights,08+ mirrors,12 tailgate,13 rear bumper,13 tail lights,dropped I beams,custom rear 4 link w/bags,k5la train horn,24" alcoa's.

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post #63 of 242 Old 01-03-2013, 12:33 PM
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There a couple nuts you don't have to remove. You can see the holes in this pic, there's one or two more behind the oil fill tube.


03 cclb dually,6.0,arp studs,bpd oil cooler,bpd 6 phase ficm,bpd water pump,bpd all aluminum cac,all aluminum radiator,amsoil bypass oil filter,ipr high flow coolant filter,egr delete,livewire ts tuned by Vivian & tony,php ficm tuner,dc power 300-spx,Detroit trutrac,6" dual side pipes,07 front end,custom front bumper,shaved badges,led button roof lights,08+ mirrors,12 tailgate,13 rear bumper,13 tail lights,dropped I beams,custom rear 4 link w/bags,k5la train horn,24" alcoa's.

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post #64 of 242 Old 01-03-2013, 12:43 PM
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The hvac box is easy, pull the rh fender liner, and 4 or 5 11mm nuts on the inside of the cab and the whole thing comes out.
You don't have to pull the fender liner out and there are 6 11mm nuts on the inside of the cab. Just make sure to disconnect the vacuum lines inside the cab before you pull it out and make sure to pull everything out in front of the evaporator core in the engine compartment and it will come right out.

l BRYAN l


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post #65 of 242 Old 01-03-2013, 12:59 PM
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No you don't "have" to pull the liner. But trust me its way easier to get the box in and out with the liner at least dropped down on to the tire.

I didn't do the liner when I removed my hvac box and faught it....dropped the liner to go back in, and it fell in! With no trouble.

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post #66 of 242 Old 01-03-2013, 01:03 PM
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No you don't "have" to pull the liner. But trust me its way easier to get the box in and out with the liner at least dropped down on to the tire.

I didn't do the liner when I removed my hvac box and faught it....dropped the liner to go back in, and it fell in! With no trouble.
I didn't have the option to drop mine without spending $20 on a damn #2 square drive bit. So I didn't drop it at all and to be honest I didn't have any problems getting it in or out, but then again I never tried it with the liner dropped so I wouldn't be able to compare the two.

l BRYAN l


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post #67 of 242 Old 01-03-2013, 01:23 PM
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I couldn't get the whole fender liner removed but I was able to push the front end down enough to give it some play and didn't have too much of a problem getting the box out. I wish I knew about the 5 nuts on the interior before I started. It came right out after that. I had to search for a while for the top nut towards the center of the vehicle. It was behind that fluffy white insulation which is so annoying when trying to see anything past it.


I guess I got lucky with my fan. I used channel locks and a screw driver with some grunting and it came loose. Once I broke it free I was able to unscrew it by hand the rest of the way. I did see marks from an air hammer once I pulled it out. I ended up putting it back on with a pipe wrench and a screw driver.

Oh, and I thought I didn't have much room. Damn! My garage is 26' deep minus the shelving. It left me with about 4'-5' in front on the Ex to stack parts.


If you haven't already done so, I sprayed the hell out of my intake manifold with engine degreaser (one full can)-inside and out- and let it sit for a few hours. I hit it again with another can and took it to the pressure washer. I got ALOT of crap out of it that way. Not as good as a dunk tank, but it came out pretty good.


Looking good so far.
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post #68 of 242 Old 01-03-2013, 03:37 PM
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I couldn't get the whole fender liner removed but I was able to push the front end down enough to give it some play and didn't have too much of a problem getting the box out. I wish I knew about the 5 nuts on the interior before I started. It came right out after that. I had to search for a while for the top nut towards the center of the vehicle. It was behind that fluffy white insulation which is so annoying when trying to see anything past it
I'm pretty sure it's those two nuts behind the insulation that DON'T have to come out, I remember because I went thru all the trouble of getting them out just to find out after the box was out they didnt have to be removed.

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post #69 of 242 Old 01-03-2013, 04:22 PM
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I'm pretty sure it's those two nuts behind the insulation that DON'T have to come out, I remember because I went thru all the trouble of getting them out just to find out after the box was out they didnt have to be removed.
Are you F'ING kidding me??

l BRYAN l


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post #70 of 242 Old 01-03-2013, 04:32 PM Thread Starter
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I'm pretty sure it's those two nuts behind the insulation that DON'T have to come out, I remember because I went thru all the trouble of getting them out just to find out after the box was out they didnt have to be removed.
Seriously? Those were the two biggest pains in the butt. The hardest one for me was the top one all the way to the right. Half mine weren't even tight on the studs.

2004 6.0L F-250 XLT - ECSB
CTS SCT
Deleted
Studded
5" Exhaust
175cc Injectors


1995 7.3L 5-Speed F-350 XL Dump
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