Repair And Fix it

Remove the air conditioner from the vehicle to access the cylinder heads on top of the engine block. This generally requires a professional mechanic with special equipment to avoid releasing rigerant gas into the atmosphere.

Disconnect the cable from the negative battery terminal with a socket wrench to ensure the engine does not start accidentally. Remove the covers for the cylinder heads.

Remove the intake manifold from the engine block with a socket wrench. Disconnect the timing chains from their sprockets. Remove the exhaust manifolds from the engine.

Disconnect the two retaining bolts for the heater hose with a socket wrench. Squeeze the clamp together, and slide it down the hose to release the hose. Detach the heater hose from the engine block. Remove all additional electrical connectors and hoses needed to access the cylinder heads in your F250.

Remove the mounting bolts for the cylinder heads with a socket wrench, and lift the cylinder heads from the engine block. Remove and discard the cylinder head gasket from the engine block. Clean all traces of the gasket from the engine block with a gasket scraper.

Turn off the F-350s engine. Gather your tools and replacement throttle position sensor.

Open the F-350s hood to view the 5.8L engine. Move to the passenger side of the engine compartment. Look in the center, behind the intake manifold, right next to the area the large black air hose comes from. Youll see the throttle position sensor mounted next to the air hose. The sensor looks similar to a capital "T." The top part of it is wide. The bottom part (the connector) is thin. It is a black plastic piece.

Push the tab on the TPS electrical connection and unplug it from the sensor. The connection is attached to the thin part of the throttle position sensor.

Remove the two screws with a Phillips screwdriver. Carefully pull the TPS away from its mount.

Insert and seat the new throttle position sensor in its mount. Insert and tighten the two screws. Plug in the electrical connection. Shut the hood.

Park the truck on level ground. Set the parking brake and chock the rear wheels. Place the transmission in the Neutral position. Raise the front of the truck with a jack and support it using jack stands.

Locate the sensor on the driver side of the transmission behind the shift control cable and the manual control lever shaft. Lift the locking tab on the electrical connector and unplug the connector from the sensor.

Remove the shift control cable retainer from the control lever. Slide the control cable off the pin on the control lever.

Hold the shift control lever in position and remove the control lever shaft nut using a ratchet and socket. Remove the shift lever from the lever shaft and discard the old nut.

Remove the sensor retaining bolts using a ratchet and socket. Remove the old sensor.

Install the new sensor and start the sensor retaining bolts. Do not tighten the retaining bolts at this time.

Position the sensor alignment tool above the control lever shaft with the single prong up and the double prongs down. Insert the double prongs into the two detents in the sensor collar around the control lever shaft. Rotate the collar using the alignment tool until the upper single prong fits into the detent at roughly the 10 oclock position on the upper edge of the sensor case. Remove the alignment tool.

Tighten the sensor retaining bolts to 62 to 89 inch-pounds using an inch-pound torque wrench and socket.

Install the manual control lever shaft and a new control lever shaft nut (included with new sensor). Hold the control lever in position and tighten the nut to 22 to 26 foot-pounds using a foot-pound torque wrench.

Place the shift lever in the passenger cab in the Overdrive position. Install the shift lever control cable and retainer on the shift lever.

Snap the sensor electrical connector on the sensor terminal.

Lower the truck to the ground and place the shift lever in the Park position. Remove the wheel chocks and check for proper reverse light operation before driving the truck.

Pop open the hood of the vehicle and prop it up with the rod. Locate the battery in the engine compartment.

Find the negative battery terminal and the clamp with a nut attached to it. Loosen the nut with a wrench and remove the clamp from the negative battery terminal. Make sure it doesnt touch anything, especially the positive battery terminal.

Wait 20 minutes to allow the electricity to drain out of the OBD computer and to allow it to reset itself.

Reconnect the negative battery clamp and tighten the nut with the wrench. Lower the hood.

Use the key to start the engine. Verify that all service and warning lights have shut off.

Remove the power window control retainer screw from the window control and door lock switch housing, using a Phillips screwdriver. Carefully separate the window control housing from the door trim panel enough to gain access to the underside of the housing. Do not pull the housing any farther than necessary or you risk damaging the electrical connections at the control.

Remove the three screws holding the window control and door lock switch, and the wiring in place under the control housing. Pull the housing off the controls. Feed the wiring and controls back through the control opening in the door trim panel.

Locate the door trim pushpin on the trailing edge of the door trim panel toward the bottom. Carefully pry out the center button of the pushpin a short distance using a small flat-head screwdriver to disengage the pin, then pull the pin body out of the panel.

Remove the screw located within the armrest pull using a Phillips screwdriver. Remove the screw from the top forward area of the trim panel using a Phillips screwdriver.

Remove the upper door trim panel from the door. Remove the five screws from the bottom of the lower door trim panel and map compartment using a Phillips screwdriver. Remove the lower trim panel from the door if the truck has the two-piece Lo-Series trim panel.

Remove the four screws from the bottom of the trim panel using a Phillips screwdriver. Remove the panel from the door if the truck has the one-piece Hi-Series trim panel.

Carefully peel the plastic water shield off the inner door panel. Place the water shield aside, adhesive-side up, in a safe place where the adhesive will not become contaminated with dust or grit.

Disconnect the window motor power supply wire from the wiring harness within the door.

Locate the drill dimples in the inner door panel over the two unexposed motor drive retaining screws. Check behind the dimples and make certain there are no wires in line with the dimples. Drill a hole through each of the drill dimples using a 1/2-inch drill bit and drill motor. Remove the motor retaining screws through the two drilled holes and the other existing hole over the motor drive unit using a ratchet, extension and socket.

Push the motor drive unit away from the inner door panel to disengage it from the window regulator arm. Push the window to the full up position and prop it in place using a short wooden dowel. Remove the old motor from the door.

Install the new motor in the door and engage it with the window regulator. Tighten the motor retaining screws to 50 to 85 inch-pounds using an inch-pound torque wrench, extension and socket.

Apply two, 1-inch square pieces of pressure-sensitive waterproof tape over the drilled holes in the inner door panel.

Connect the window motor power supply wire to the wiring harness. Remove the window prop dowel. Actuate the window motor using the window control, and check for full window operation.

Inspect the door drain holes located at the bottom of the door; make certain they are open and free of debris.

Install the plastic water shield on the inner door panel. Make certain the adhesive holds the shield firmly in place around the access hole in the inner door panel.

Install the lower door trim panel and panel screws on two-piece Lo-Series door trim panels. Feed the power window control and door lock switch through its hole in the upper door trim panel, and engage the upper panel with the lower panel. Install the upper door trim panel screws.

Feed the power window control and door lock switch through its hole in the one-piece Hi-Series door trim panel, then install the door trim panel screws.

Insert the door trim pushpin body in its hole in the panel. Push the center button of the pushpin in to expand the pin and engage it in the inner door panel.

Install the window control and door lock switch in its housing and install the three control-to-housing screws using a Phillips screwdriver. Install the housing on the door trim panel and install the housing retaining screw.

Plug the OBDII code retriever into the socket on the underside of the dashboard to the left of the steering wheel.

Put the key into the ignition and turn it to the "II" position, but dont crank the engine. This will power on most code retrievers. Enter in your vehicles model, make and engine size when instructed to by the code retriever.

Select the command "Read Codes" or something similar. Wait while the OBDII code retriever interfaces with the computer and retrieves the codes. Write down the codes on a piece of paper. Look up the codes in the manual to get the exact diagnosis.

Unplug the code retriever. Take the codes to your mechanic or repair and service the vehicle yourself.