Dorman 904-065 Diesel Exhaust Fluid Filler Neck Instruction Manual

1. Product Overview

The Dorman 904-065 Diesel Exhaust Fluid (DEF) Filler Neck is a direct replacement component designed to match the fit and function of the original filler neck on specified Ford vehicles. This part ensures the reliable and secure transfer of DEF from the fill point to the DEF tank, addressing issues such as leaks or failures in the original component.

Figure 1: Dorman 904-065 Diesel Exhaust Fluid Filler Neck. This image shows the complete assembly of the DEF filler neck, including the main tube and associated hoses and connectors.

2. Compatibility

This Dorman 904-065 DEF Filler Neck is compatible with the following Ford F-Series Super Duty models:

• Ford F-350 Super Duty: 2011, 2012, 2013, 2014, 2015, 2016
• Ford F-450 Super Duty: 2011, 2012, 2013, 2014, 2015, 2016
• Ford F-550 Super Duty: 2011, 2012, 2013, 2014, 2015, 2016

It is recommended to verify fitment using a vehicle compatibility tool or by consulting your vehicle's service manual before installation.

3. Features

• Direct Replacement: Engineered to match the fit and function of the original equipment (OE) part.
• Reliable Solution: Designed to replace leaking or failed original filler necks, ensuring proper DEF transfer.
• Durable Construction: Manufactured and tested to meet strict specifications for long-lasting service.
• Quality Assurance: Backed by Dorman's extensive automotive experience and product expertise.

4. Installation Instructions

Installation of the Dorman 904-065 DEF Filler Neck requires mechanical knowledge and appropriate tools. If you are not confident in performing this installation, it is recommended to seek assistance from a qualified automotive technician.

4.1. Safety Precautions

• Always wear appropriate personal protective equipment (PPE), including safety glasses and gloves.
• Ensure the vehicle is parked on a level surface and the engine is off and cooled down.
• Disconnect the vehicle's battery before beginning work to prevent electrical hazards.
• DEF can be corrosive; avoid contact with skin and eyes. In case of contact, rinse thoroughly with water.

4.2. Required Tools

Specific tools may vary depending on the vehicle model. Common tools include:

• Socket set and ratchet
• Screwdrivers
• Pliers
• Drain pan (for any residual DEF)

4.3. Removal of Old Filler Neck

1. Locate the DEF filler neck assembly on your vehicle. Refer to your vehicle's service manual for exact location.
2. Carefully disconnect any electrical connectors or sensors attached to the filler neck.
3. Using appropriate tools, loosen and remove the clamps or fasteners securing the filler neck to the DEF tank and the vehicle body.
4. Gently detach the hoses connected to the filler neck. Be prepared for minor DEF spillage and use a drain pan if necessary.
5. Remove the old filler neck assembly from the vehicle.

Figure 2: Dorman 904-065 DEF Filler Neck, showing the full length and connections. This image provides a comprehensive view of the filler neck's design, including the main tube and smaller auxiliary lines.

4.4. Installation of New Filler Neck

1. Inspect the new Dorman 904-065 DEF Filler Neck for any damage before installation.
2. Position the new filler neck into the vehicle, ensuring all mounting points align correctly.
3. Connect the hoses to the new filler neck, securing them with the appropriate clamps or fasteners. Ensure a tight, leak-free connection.
4. Attach any electrical connectors or sensors that were removed during the old filler neck's removal.
5. Secure the filler neck to the vehicle body and DEF tank using the original or new fasteners.
6. Reconnect the vehicle's battery.
7. Perform a visual inspection to ensure all connections are secure and there are no visible leaks.

Figure 3: Close-up view of the primary connection point on the Dorman 904-065 DEF Filler Neck. This image highlights the robust design of the main inlet, including the mounting tabs.

Figure 4: Detailed view of a hose connection point on the Dorman 904-065 DEF Filler Neck. This image shows the quick-connect fitting with its green release tab, designed for secure attachment.

5. Operating the DEF System

Once the Dorman 904-065 DEF Filler Neck is installed, the DEF system operates as designed by the vehicle manufacturer. The filler neck provides the conduit for adding Diesel Exhaust Fluid to the vehicle's DEF tank.

5.1. Adding DEF

• Ensure the vehicle is off and on a level surface.
• Open the DEF tank cap.
• Carefully pour DEF into the filler neck. Avoid overfilling.
• Replace the DEF tank cap securely.

Always use DEF that meets the ISO 22241 standard. Refer to your vehicle's owner's manual for specific DEF requirements and fill procedures.

6. Maintenance

The Dorman 904-065 DEF Filler Neck is designed for durability and minimal maintenance. However, periodic inspection is recommended:

• Visual Inspection: Regularly check the filler neck and its connections for any signs of cracks, damage, or leaks.
• Cleanliness: Keep the area around the filler neck clean to prevent contaminants from entering the DEF tank.
• Cap Security: Ensure the DEF tank cap is always securely tightened to prevent evaporation or contamination of the DEF.

7. Troubleshooting

If you experience issues after installing the DEF filler neck, consider the following:

For persistent issues, consult your vehicle's service manual or a certified mechanic.

8. Specifications

9. Warranty and Support

Dorman products are designed and manufactured to high-quality standards. For specific warranty information, please refer to the documentation included with your purchase or visit the official Dorman website. Dorman stands by its products with over a century of automotive experience and a team of product experts in the United States.

For technical assistance or customer support, please contact Dorman directly through their official channels. You can often find contact information on their website or product packaging.

Dorman Official Website: www.dormanproducts.com