How to Remove a 1992 F-150 Front Fender

The 1992 model year brought about a more aerodynamic look for the ultra-popular F-150, as Ford installed front lights and a bumper the angle rearward. The remainder of the F-150s body was strikingly similar to the previous generation. The 1992 F-150s front fender attaches to the trucks skin and frame via a series of bolt and screws and requires removing the newly restyled front lights to remove it. Reinstalling the fender requires an assistants aid, so you may install the bolts while keeping the fender correctly aligned.

Instructions

Lift the hood and support it with a prop rod.

Remove the two screws on top of the turn signal assembly using a Phillips screwdriver. Remove the two turn signal assembly-retaining nuts using a ratchet and socket. Pull the turn signal assembly from the front of the truck until you can access the bulb sockets on its backside.

Label the sockets plugged into the back of the turn signal assembly in a manner that will aid you in installing them correctly using masking tape and a marker. Twist the three light sockets counterclockwise to unlock then and pull the sockets and bulbs from the turn signal assembly. Remove the turn signal assembly from the F-150.

Unplug the wiring harness from the headlight bulb assembly. Pull the two retaining clips securing the headlight to the front of the truck upward to remove them. These retainers are U-shaped and attach to the rods protruding from the rear of the headlight bulb assembly.

Loosen the headlight adjuster screw with a Phillips screwdriver until you can remove it. Pull the headlight bulb assembly from the truck.

Remove the screws securing the front of the fender to the upper and lower radiator supports, using a ratchet and socket.

Lay on your back under the rearmost corner of the fender and find the bolt securing the fender to the F-150s cab. Remove this bolt with a ratchet and socket.

Open the door and find the bolt on the bottom of the doorjamb that secures the cab to the fender. Remove this bolt with a ratchet and socket.

Remove the two bolts that secure the top rear of the fender to the upper cowl using a ratchet and socket, then remove the five screws securing the wheel well liner to the underside of the fender.

Unfasten the two bolts securing the battery tray to the fender, if applicable, using a ratchet and socket.

Pull the hood latch cable from its mounts on the drivers side fender or the wiring harness from its mounts on the passengers side fender. Release the fender completely by removing the hood prop spring-to-fender screw using a ratchet and socket.

Pull the fender from the F-150.

Apply a bead of silicone sealant to the wheel well liners upper mating surface. Sit the fender into place on the side of the truck. Align the wheel well liners mounting holes with the mounting holes on the fender. Hand-thread the liner-to-fender bolts.

Hand-thread, but do not tighten, the remaining bolts in the following order: cab-to-fender, fender-to-cab, fender-to-radiator supports, fender-to-upper cowl and battery tray-to-fender. Adjust the fender, as needed, to line up the body lines, and have an assistant hold the fender in place.

Tighten the wheel well liner-to-fender bolts to between 9 and 20 inch-pounds with an inch-pound torque wrench and socket.

Torque the following bolts to their torque specifications using a toque wrench and socket: cab-to-fender to between 17 and 23 foot-pounds; fender-to-cab to between 9 and 13 foot-pounds; fender-to-upper radiator support to between 17 and 23 foot-pounds; fender-to-lower radiator support to between 6 and 10 foot-pounds; fender-to-upper cowl to between 17 and 23 foot-pounds; and battery tray-to-fender to between 17 and 15 foot-pounds.

Tell your assistant to release his grip of the fender. Guide the hood prop spring back onto its mount on the fended and snug its screw with a ratchet and socket. Press the hood latch cable or wiring harness into its retaining clips along the fender.

Guide the headlight bulb assembly onto the front of the truck. Guide the adjuster screw into place and align it with the adjuster nut. Thread the adjuster screw into the nut just a few turns. Press the headlight bulb assemblys retaining clips onto the pins on the rear of the headlight bulb assembly.

Plug the wiring harness into the headlight bulb assembly.

Reinstall the three bulbs and sockets into the rear of the turn signal assembly, using the labels as your guide. Turn each socket clockwise to lock it into place.

Slide the turn signal assembly into place on the front of the truck. Tighten its retaining screws to between 13 and 20 inch-pounds, using an inch-pound torque wrench and Phillips-bit socket. Tighten the turn signal assemblys retaining nuts to between 36 and 61 inch-pounds.