2003 ICP Replacement (How to)
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2003 ICP Replacement (How to)
2003 ICP sensor replacement
This weekend I replaced my ICP sensor. I did not use a hoist or raise my stock truck off the ground. It was not easy but it was better than paying the dealer. Total time 4hrs.
1. Remove tranny fill tube attach bolt (10mm w/ extension and swivel) from right side under hood. Push tube out of tranny from underneath.
2. Remove drive shaft from front differential and let hang.
3. Tie back the gear shift cable (automatic).
4. Remove heat shield. Remove 10mm bolt from passenger side and one from drivers side. Also remove 13mm bolt from drivers side and slide heat shield onto bell housing.
5. Slide insulating sleeve off the ICP sensor
6. Remove electrical connector from ICP sensor. Lift tab with finger and slide off being careful not to remove connector seal.
7. With 1 1/16" deep well socket remove ICP sensor. I could not get a ratchet & socket up there so I drilled a 3/8" hole in the drive end of the socket and slid a 1/4" extension trough it (like "T" handle)
8. Clean area on block where sensor attaches.
9. Apply dielectric grease to the sensor's electrical end and little oil to the sensors o-ring and install.
10. Clean electrical connector on harness. I could not get access to my connector from the top so I cleaned it from the bottom with carb cleaner. I could not get the can close enough to clean the connector so I cut the red plastic nozzle extension in half and put 2.5' of chainsaw gas line between them. This allowed me to clean the connector and left the can on the ground.
This weekend I replaced my ICP sensor. I did not use a hoist or raise my stock truck off the ground. It was not easy but it was better than paying the dealer. Total time 4hrs.
1. Remove tranny fill tube attach bolt (10mm w/ extension and swivel) from right side under hood. Push tube out of tranny from underneath.
2. Remove drive shaft from front differential and let hang.
3. Tie back the gear shift cable (automatic).
4. Remove heat shield. Remove 10mm bolt from passenger side and one from drivers side. Also remove 13mm bolt from drivers side and slide heat shield onto bell housing.
5. Slide insulating sleeve off the ICP sensor
6. Remove electrical connector from ICP sensor. Lift tab with finger and slide off being careful not to remove connector seal.
7. With 1 1/16" deep well socket remove ICP sensor. I could not get a ratchet & socket up there so I drilled a 3/8" hole in the drive end of the socket and slid a 1/4" extension trough it (like "T" handle)
8. Clean area on block where sensor attaches.
9. Apply dielectric grease to the sensor's electrical end and little oil to the sensors o-ring and install.
10. Clean electrical connector on harness. I could not get access to my connector from the top so I cleaned it from the bottom with carb cleaner. I could not get the can close enough to clean the connector so I cut the red plastic nozzle extension in half and put 2.5' of chainsaw gas line between them. This allowed me to clean the connector and left the can on the ground.
Post Fiend
Joined: Jul 2005
Posts: 6,127
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9. Apply dielectric grease to the sensor's electrical end and little oil to the sensors o-ring and install.
10. Clean electrical connector on harness. I could not get access to my connector from the top so I cleaned it from the bottom with carb cleaner. I could not get the can close enough to clean the connector so I cut the red plastic nozzle extension in half and put 2.5' of chainsaw gas line between them. This allowed me to clean the connector and left the can on the ground.
Well done.
Instead of carb cleaner, I would have use the specialized circuit / connector cleaner developed for the electronics industry.
See this link for circuit cleaning from a guy that tried and tested nearly everything.
Contact Cleaners
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2003, 60, 60l, connection, dielectric, excursion, ford, grease, icp, powerstroke, remove, replacement, replacing, replacment, sensor
