Ford - F 150 2wd Pickup - Workshop Manual - 1986 - 1986

Factory Workshop Manual Make Ford Model F 150 2wd Pickup Engine and year V8-351 5.8L (1986) Please navigate through the PDF using the options provided by OnlyManuals.com on the sidebar. This manual was submitted by Anonymous Date 1st January 2018 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by System > A L L Diagnostic Trouble Codes Engine Controls > System Information > System Diagnosis > Transmisson Codes A L L Diagnostic Trouble Codes - Engine Controls: Testing and Inspection Transmisson Codes For Transmission related codes, proceed to Computers and Control Systems. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by System > A L L Diagnostic Trouble Codes Trans and Drivetrain > System Information > System Diagnosis A L L Diagnostic Trouble Codes - Trans and Drivetrain: Testing and Inspection For Transmission related codes, proceed to Computers and Control Systems. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Locations Cruise Control Module: Locations Underneath LH Side Of I/P Behind I/P, To Right Of Steering Column Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Locations > Page 16 Cruise Control Module: Testing and Inspection Use only a multi-meter of 5000 ohm/volt rating or higher when performing amplifier test. ``On'' Circuit Test 1. Turn ignition ``On.'' 2. Connect a voltmeter between light blue wire w/black hash and ground on models exc. 1983-87 Ranger, 1984-87 Bronco II and 1986-87 Aerostar or white wire w/purple stripe and ground on 1983-87 Ranger, 1984-87 Bronco II and 1986-87 Aerostar. 3. Battery voltage should be indicated when ``On'' switch on steering column is depressed and held. If battery voltage is not indicated, check horn relay and perform control switch test. 4. Release ``On'' button. Voltmeter should indicate 7.8 volts indicating ``On'' circuit is engaged. If voltage does not remain, check amplifier ground, fuses or circuit breakers or replace amplifier with known good amplifier and repeat test. 5. Replace as necessary. ``Off'' Circuit Test 1. Turn ignition ``On.'' 2. Connect a voltmeter between light blue wire w/black hash and ground. 3. Depress ``Off'' button. Voltage should drop to zero indicating ``On'' circuit is de-energized. 4. If voltage does not drop to zero, perform ``Control Switch Test.'' ``Set-Accelerate'' Circuit Test 1. Turn ignition ``On.'' 2. Connect a voltmeter between light blue wire w/black hash and ground. 3. Depress ``On'' switch, then hold ``Set-Accel'' button on steering wheel. Voltmeter should indicate 4.5 volts. Rotate steering wheel back and forth and check for voltmeter fluctuations. If reading varies more than .5 volts, perform ``Control Switch Test.'' ``Coast'' Circuit Test 1. Turn ignition ``On.'' 2. Connect a voltmeter between light blue wire w/black hash and ground. 3. Depress ``On'' switch, then depress and hold ``Coast'' button on steering wheel. Voltmeter should indicate 1.5 volts. Rotate steering wheel back and forth and check for voltage fluctuations. If reading varies more than .5 volts, perform ``Control Switch Test.'' ``Resume'' Circuit Test 1. Turn ignition ``On.'' 2. Connect a voltmeter between light blue wire w/black hash and ground. 3. Depress and hold ``Resume'' button. Voltmeter should indicate 6.5 volts. If all circuits are functioning properly, perform ``Servo Assembly Test'' using a known good amplifier. Do not replace amplifier before performing servo test. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Fuel Distance/Mileage Module > Component Information > Locations Right Hand Side of Instrument Panel Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Control Module > Component Information > Diagrams > Diagram Information and Instructions Headlamp Control Module: Diagram Information and Instructions Symbol Identification Wire Color Code Identification Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 26 NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 27 Fig. 38 Headlamp Wiring Circuit Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations Horn Relay: Locations Horn Relay Location Under LH Side Of I/P. Under LH Side Of I/P, With Speed Control Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 31 Underneath LH Side Of I/P Below LH Side Of I/P Horn Relay With Speed Control Bronco F-150 thru F-350, E-150 thru E-350 and Super F Series The horn relay is use on vehicles equipped with speed control and is located under the left side of the instrument panel, left of the steering column and is mounted on the outboard attaching screw of the speed control amplifier module. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 32 Horn Relay: Testing and Inspection Fig. 3 Speed control wiring diagram. 1981---83 E-100-350 & 1984-87 E-150-350 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 33 Fig. 4 Speed control wiring diagram. 1981 F-100-350 & Bronco Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 34 Fig. 5 Speed control wiring diagram. 1982---83 F-100-350, 1984---87 F-150-350 & 1982---87 Bronco 1981-87 Models Exc. 1983-87 Ranger, 1984-87 Bronco II & 1986-87 Aerostar 1. Locate horn relay wire connector marked X and Y, Figs. 3, 4 and 5. 2. Using connector X, locate wire 460, then using a suitable voltmeter, check for battery voltage at male side of connector. 3. Using connector Y, locate wire 1, then using a suitable voltmeter, check for battery voltage at female side of connector. Depress horn, voltmeter should read zero and horn should sound. If battery voltage remains, circuit is open. Connectors should remain connected during testing. 4. Check horn relay by momentarily grounding circuit 1 to chassis. This bypasses horn switch and horn should sound. If horn does not sound, check for battery voltage at connector X wire 6 during relay operation. If voltage is present at circuit 6 during relay operation, an open circuit is indicated between horn and connector X. 5. If relay does not operate with battery voltage present at circuit 460 and circuit 1 is grounded, replace relay. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Marker Lamp Relay > Component Information > Locations Marker Lamp Relay: Locations LH Side Of Dash Panel Attached To Dash Panel, Below Junction Block Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Locations Trailer Lighting Relay: Locations Attached To Dash Panel, Below Junction Block Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Trailer Lighting Module > Component Information > Locations Trailer Lighting Module: Locations Attached To Brake Pedal Assembly Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Electronic Throttle Control Module > Component Information > Locations Electronic Throttle Control Module: Locations Under LH Side Of I/P Under LH Side Of I/P Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Electronic Throttle Control Module > Component Information > Locations > Page 49 Electronic Throttle Control Module: Testing and Inspection Ford provides trouble code/symptom driven diagnostics for this component. For complete diagnosis and pinpoint testing, refer to Computers and Control Systems, Testing and Inspection. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Body/Frame - Arc Welding Precautions Engine Control Module: Technical Service Bulletins Body/Frame - Arc Welding Precautions Article No. 90-11-6 EEC IV-ELECTRONIC CONTROL MODULES AND PROCESSORS-POSSIBLE DAMAGE FROM ARC WELDING FORD: 1985-90 CROWN VICTORIA, ESCORT, MUSTANG, TEMPO, THUNDERBIRD 1986-90 TAURUS LINCOLN-MERCURY: 1985-86 CAPRI 1985-90 CONTINENTAL, COUGAR, GRAND MARQUIS, MARK VII, TOPAZ, TOWN CAR 1986-90 SABLE MERKUR: 1985-89 XR4Ti 1988-90 SCORPIO LIGHT TRUCK: 1985-90 BRONCO II, BRONCO, ECONOLINE, F-150, F-250, F-350, RANGER 1986-90 AEROSTAR 1989-90 F SUPER DUTY 1991 EXPLORER ISSUE: Electronic control modules, including EEC processors, may be damaged if the negative battery ground cable is not disconnected before arc welding is done to the vehicle, This occurs because the arc welding process can produce high electrical currents in the body of a vehicle when the negative battery ground cable is left connected. ACTION: If arc welding procedures are to be performed, be sure to disconnect the battery ground cable, CAUTION: DISCONNECT THE NEGATIVE BATTERY GROUND CABLE BEFORE USING ANY ELECTRIC WELDING EQUIPMENT OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 2800, 680000 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 54 Right Hand Instrument Panel Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions Engine Control Module: Diagram Information and Instructions Symbol Identification Wire Color Code Identification Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 57 NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Page 58 Engine Control Module: Description and Operation The center of the EEC IV system is a microprocessor called the Electronic Control Assembly (ECA). The ECA, receives data from a number of sensors and other electronic components (switches, relays, etc.). The ECA contains a specific calibration for optimizing emissions, fuel economy, and driveability. Based on information received and programmed into its memory, the ECA generates output signals to control various relays, solenoids, and other actuators. The ECA in the EEC IV system is a microprocessor like the one in the other EEC systems. One significant difference is that this ECA has the calibration module located inside the ECA assembly, unlike the EEC III system. The ECA is found in different locations, depending on the model. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Page 59 Engine Control Module: Testing and Inspection Ford provides trouble code/symptom driven diagnostics for this component. For complete diagnosis and pinpoint testing, refer to Computers and Control Systems, Testing and Inspection. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Component Locations Main Relay (Computer/Fuel System): Component Locations Fuel Pump Relay Engine Compartment Components. LH Side Of Engine Compartment, On Relay Bracket. Fuel pump relay is next to the EEC Relay. Applicable to: 4.9L/6-300 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Component Locations > Page 64 Engine Compartment Components. LH Side Of Engine Compartment, On Relay Bracket. Fuel pump relay is next to the EEC Relay. Applicable to: 5.0L/V8-302 & 5.8L/V8-350 Engine Compartment Components. LH Side Of Engine Compartment, On Relay Bracket. Fuel pump relay is next to the EEC Relay. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Component Locations > Page 65 Applicable to: 7.5L/V8-460 EEC Power Relay Under Dash Panel Next To, Or On ECA Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Component Locations > Page 66 Right Hand Instrument Panel Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 67 Main Relay (Computer/Fuel System): Description and Operation There are two types of relays: the power relay and the time delay power relay. The time delay relay has a delay of 5 to 10 seconds and is used with an actuator assembly throttle control. Both relay types consist of a movable contact in the normally open position. All power relays (except time delay) have the same design with a different bracket attachment. Function EEC power relays are in parallel with the ignition switch and provide power to the EEC module. Power relays also provide reverse battery protection and increased load handling to improve ignition switch reliability. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 68 Main Relay (Computer/Fuel System): Testing and Inspection Ford provides trouble code/symptom driven diagnostics for this component. For complete diagnosis and pinpoint testing, refer to Computers and Control Systems, Testing and Inspection. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Emission Control Systems > EGR Control Module > Component Information > Locations EGR Control Module: Locations Back View Of I/P On I/P, To Left Of Steering Column Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Technical Service Bulletins > Customer Interest for Fuel Pump Relay: > 90183 > Aug > 90 > Fuel Pump - Buzzing/Humming After Engine Shut Down Fuel Pump Relay: Customer Interest Fuel Pump - Buzzing/Humming After Engine Shut Down ^ NO START - 1.9L, 2.3L, 3.0L, 3.8L, 4.9L, 5.0L, 5.8L, 7.5L - LOW STATE OF BATTERY CHARGE ^ BATTERY - DISCHARGED - 1.9L, 2.3L, 3.0L, 3.8L, 4.9L, 5.0L, 5.8L, 7.5L ^ FUEL PUMP - NOISY - 1.9L, 2.3L, 3.0L, 3.8L, 4.9L, 5.0L, 5.8L, 7.5L ^ NOISE - "BUZZING" OR "HUMMING" FROM FUEL PUMP AFTER ENGINE IS TURNED OFF Article No. 90-18-3 FORD: 1983-90 CROWN VICTORIA, ESCORT, EXP, MUSTANG, TEMPO, THUNDERBIRD 1986 LTD 1986-90 TAURUS LINCOLN-MERCURY: 1983-87 LYNX 1983-90 CONTINENTAL, COUGAR, GRAND MARQUIS, MARK VII, TOPAZ, TOWN CAR 1985-86 CAPRI, MARQUIS 1986-90 SABLE LIGHT TRUCK: 1983-90 BRONCO II, BRONCO, ECONOLINE, F-150, F-250, F-350, RANGER 1988-90 F SUPER DUTY ISSUE: A "buzzing" or "humming" noise from the fuel pump may occur after the engine has been shut off. There may also be a no start condition or a discharged battery. These conditions are caused by a sticking fuel pump relay. ACTION: Install a new fuel pump relay. Refer to the following procedure for service details. 1. Check the fuel pump relay circuit for proper operation. Refer to the appropriate EVTM for troubleshooting details. 2. Install a new fuel pump relay, if the old one is defective. 3. Check the vehicle for proper operation. PART NUMBER PART NAME F19Z-9345-A Fuel Pump Relay Assy. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION DESCRIPTION TIME 901803A 1985-86 LTD/Marquis 0.6 Hr. (includes pinpoint test) 901803A 1990 Town Car (includes 0.4 Hr. pinpoint test) 901803A All Other Cars (includes 0.5 Hr. pinpoint test) 901803A All Trucks (includes pinpoint 0.5 Hr. test) DEALER CODING BASIC PART NO. CONDITION CODE 9345 09 OASIS CODES: 404000, 603300, 203000, 203100, 702000 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Pump Relay: > 90183 > Aug > 90 > Fuel Pump - Buzzing/Humming After Engine Shut Down Fuel Pump Relay: All Technical Service Bulletins Fuel Pump - Buzzing/Humming After Engine Shut Down ^ NO START - 1.9L, 2.3L, 3.0L, 3.8L, 4.9L, 5.0L, 5.8L, 7.5L - LOW STATE OF BATTERY CHARGE ^ BATTERY - DISCHARGED - 1.9L, 2.3L, 3.0L, 3.8L, 4.9L, 5.0L, 5.8L, 7.5L ^ FUEL PUMP - NOISY - 1.9L, 2.3L, 3.0L, 3.8L, 4.9L, 5.0L, 5.8L, 7.5L ^ NOISE - "BUZZING" OR "HUMMING" FROM FUEL PUMP AFTER ENGINE IS TURNED OFF Article No. 90-18-3 FORD: 1983-90 CROWN VICTORIA, ESCORT, EXP, MUSTANG, TEMPO, THUNDERBIRD 1986 LTD 1986-90 TAURUS LINCOLN-MERCURY: 1983-87 LYNX 1983-90 CONTINENTAL, COUGAR, GRAND MARQUIS, MARK VII, TOPAZ, TOWN CAR 1985-86 CAPRI, MARQUIS 1986-90 SABLE LIGHT TRUCK: 1983-90 BRONCO II, BRONCO, ECONOLINE, F-150, F-250, F-350, RANGER 1988-90 F SUPER DUTY ISSUE: A "buzzing" or "humming" noise from the fuel pump may occur after the engine has been shut off. There may also be a no start condition or a discharged battery. These conditions are caused by a sticking fuel pump relay. ACTION: Install a new fuel pump relay. Refer to the following procedure for service details. 1. Check the fuel pump relay circuit for proper operation. Refer to the appropriate EVTM for troubleshooting details. 2. Install a new fuel pump relay, if the old one is defective. 3. Check the vehicle for proper operation. PART NUMBER PART NAME F19Z-9345-A Fuel Pump Relay Assy. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION DESCRIPTION TIME 901803A 1985-86 LTD/Marquis 0.6 Hr. (includes pinpoint test) 901803A 1990 Town Car (includes 0.4 Hr. pinpoint test) 901803A All Other Cars (includes 0.5 Hr. pinpoint test) 901803A All Trucks (includes pinpoint 0.5 Hr. test) DEALER CODING BASIC PART NO. CONDITION CODE 9345 09 OASIS CODES: 404000, 603300, 203000, 203100, 702000 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Technical Service Bulletins > Page 87 Fuel Pump Relay: Locations The EEC Power Relay is mounted to the Electronic Control Assembly in the rear center of the instrument panel. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions Fuel Pump Relay: Diagram Information and Instructions Symbol Identification Wire Color Code Identification Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 90 NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Shut-off Solenoid Relay > Component Information > Locations Fuel Shut-off Solenoid Relay: Locations LH Side Of Dash Panel In Engine Compartment, On LH Side Of Dash Panel Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Component Locations Main Relay (Computer/Fuel System): Component Locations Fuel Pump Relay Engine Compartment Components. LH Side Of Engine Compartment, On Relay Bracket. Fuel pump relay is next to the EEC Relay. Applicable to: 4.9L/6-300 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Component Locations > Page 98 Engine Compartment Components. LH Side Of Engine Compartment, On Relay Bracket. Fuel pump relay is next to the EEC Relay. Applicable to: 5.0L/V8-302 & 5.8L/V8-350 Engine Compartment Components. LH Side Of Engine Compartment, On Relay Bracket. Fuel pump relay is next to the EEC Relay. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Component Locations > Page 99 Applicable to: 7.5L/V8-460 EEC Power Relay Under Dash Panel Next To, Or On ECA Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Component Locations > Page 100 Right Hand Instrument Panel Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 101 Main Relay (Computer/Fuel System): Description and Operation There are two types of relays: the power relay and the time delay power relay. The time delay relay has a delay of 5 to 10 seconds and is used with an actuator assembly throttle control. Both relay types consist of a movable contact in the normally open position. All power relays (except time delay) have the same design with a different bracket attachment. Function EEC power relays are in parallel with the ignition switch and provide power to the EEC module. Power relays also provide reverse battery protection and increased load handling to improve ignition switch reliability. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 102 Main Relay (Computer/Fuel System): Testing and Inspection Ford provides trouble code/symptom driven diagnostics for this component. For complete diagnosis and pinpoint testing, refer to Computers and Control Systems, Testing and Inspection. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 87720 > Apr > 87 > Tape Player - Ignition Noise Through Speakers Ignition Control Module: Customer Interest Tape Player - Ignition Noise Through Speakers RADIO - IGNITION NOISE THROUGH FACTORY Article No. TAPE PLAYER - 4.9L - WITH TSB MODIFICATION87-3-20 87-7-20 LIGHT TRUCK: 1984-86 F SERIES, BRONCO ISSUE: Ignition noise through the radio speakers when operating the radio in the tape player mode may result if a new multispark ignition module was installed to correct a rough idle condition per TSB 87-3-20. ACTION: To correct this, modify the multi-spark ignition module wire harness as outlined in the following service procedure. 1. Shorten the heavy gauge BLACK wire on the module to 14 inches (357 mm). Crimp on a new solderless lug and hook up wire directly to negative terminal of battery. 2. Perform TSB 86-24-26 to eliminate the radio noise. OTHER APPLICABLE ARTICLES: 86-24-26, 87-3-20 WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual OPERATION: SP870720A TIME: 0.3 Hr. DLR. CODING: Basic Part No. 12A199 Code: 85 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 87610 > Mar > 87 > Engine - Stalling and/or A No Start Condition Ignition Control Module: Customer Interest Engine - Stalling and/or A No Start Condition ^ STALL - THICK FILM IGNITION (TFI) MODULE - Article No. EEC IV VEHICLES 87-6-10 ^ STALL/NO START - THICK FILM IGNITION (TFI) MODULE - EEC IV VEHICLES FORD 1984-87 ALL LINCOLN-MERCURY 1984-87 ALL MERKUR 1985-87 XR4Ti LIGHT TRUCK 1984-87 ALL ISSUE: Stalling and/or a no-start condition on vehicles with EEC IV and certain TFI modules may be caused by moisture or salt splash entering at the upper right hand mounting hole of the TFI module housing. This condition will result in a service code 14. ACTION: To correct this, use the following diagnostic and service procedure to seal the hole and prevent further concerns. NOTE: The distributor does not have to be removed to perform this repair. 1. Check to see if the TFI-IV module part number suffix is A2A and the date code is 6K08 or prior, (mounting hole was sealed after 6K08). If the suffix is not A2A, use normal diagnostic procedures and do not perform Steps 2 and 3. 2. Thoroughly clean and dry upper right hand mounting hole of the TFI module with a clean paper towel. 3. Fill the cleaned hole with silicone grease (D7AZ-19A331-A). 4. Clear service code 14 from memory. PART NUMBER PART NAME CLASS D7AZ-19A331-A Silicone Grease AM OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual OPERATION: SP870610A TIME: 1.0 Hr. DLR. CODING: Basic Part No. 12A297 - Code: 09 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 86220 > Jan > 86 > Ignition System - Weak/No Spark Ignition Control Module: Customer Interest Ignition System - Weak/No Spark Article No. 86-2-20 IGNITION SYSTEM - TFI - WEAK OR NO SPARK - DIAGNOSTIC TIP FORD 1982-86 ESCORT, EXP; 1983-86 THUNDERBIRD, LTD, CROWN VICTORIA, MUSTANG; 1984-86 TEMPO; 1986 TAURUS LINCOLN-MERCURY 1982-83 LN7; 1982-86 LYNX; 1983-86 COUGAR, MERCURY, GRAND MARQUIS, CONTINENTAL, MARK VII, LINCOLN; 1984-86 TOPAZ; 1986 SABLE LIGHT TRUCK 1983-86 EAND F-SERIES, RANGER, BRONCO; 1984-86 BRONCO II; 1986 AEROSTAR CALIBRATIONS: All with TFI Systems If the TFI module fails and causes a short to ground, the primary winding of the ignition coil can be damaged. The TFI diagnostic procedure published in the Shop Manual will not identify this condition. When servicing a weak or no spark condition, perform the following: 1. Check for spark using the procedures found in the Manual Information, Computerized Engine, Quick Test Section, Test 1. 2. If there is no spark, test the coil primary resistance using Rotunda digital volt-ohmmeter 007-00001, as shown. 3. If the coil primary resistance is O.K., continue with the diagnostic procedure in Test 1. 4. If the coil primary resistance is not O.K., replace the coil and recheck for weak or no spark. If the spark is now O.K., the problem is resolved. 5. If the spark is still NOT O.K., continue with normal diagnostic procedure in Test 1. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Wiring Harness TFI-IV Part 2 Test 5 TEST EQUIPMENT: VOM, STRAIGHT PIN TEST PROCEDURE 1. Separate wiring harness connector from ignition module. Inspect for dirt, corrosion, and damage. NOTE: PUSH connector tabs to separate. 2. Disconnect wire at S terminal of starter relay. 3. Attach negative (-) VOM, Rotunda Number 007-00001, lead to distributor base. 4. Measure battery voltage. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 86220 > Jan > 86 > Ignition System - Weak/No Spark > Page 120 5. Following table below, measure connector terminal voltage by attaching VOM to small straight pin inserted into connector terminal and turning ignition switch to position shown. CAUTION: Do not allow straight pin to contact electrical ground. CONNECTOR IGNITION SWITCH TERMINAL WIRE/CIRCUIT TEST POSITION #2 TO IGNITION RUN COIL (-) TERMINAL #3 RUN CIRCUIT RUN AND START #4 START CIRCUIT START 6. Turn ignition switch to Off position. 7. Remove straight pin. 8. Reconnect wire to S terminal of starter relay. TEST RESULT TEST RESOLUTION 90 percent of ^ Test result OK. battery ^ Go to Part 2, Test 6. voltage minimum Less than 90 ^ Inspect for faults in wiring percent of harness and connectors. battery ^ Refer to vehicle wiring voltage diagram for appropriate circuit. ^ Damaged or worn ignition switch, Refer to Shop Manual, Group 33. Primary Circuit Continuity TFI-IV Part 2 Test 8 TEST EQUIPMENT: VOM, STRAIGHT PIN TEST PROCEDURE 1. Separate wiring harness connector from ignition module. Inspect for dirt, corrosion, and damage. NOTE: PUSH connector tabs to separate. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 86220 > Jan > 86 > Ignition System - Weak/No Spark > Page 121 2. Attach negative (-) VOM, Rotunda Number 007-00001, lead to distributor base. 3. Measure battery voltage. 4. Attach VOM to small straight pin inserted into connector terminal No. 2. CAUTION: Do not allow straight pin to contact electrical ground. 5. Turn ignition switch to Run position and measure terminal No. 2 voltage. 6. Turn ignition switch to Off position. 7. Remove straight pin. TEST RESULT TEST RESOLUTION 90 percent of ^ Go to Part 2, Test 5. battery voltage minimum Less than 90 ^ Go to Part 2, Test 9. percent of battery voltage Ignition Coil Primary Resistance TFI-IV Part 2 Test 3 TEST EQUIPMENT: VOM TEST PROCEDURE 1. Turn ignition switch to Off. 2. Disconnect ignition coil connector. Inspect for dirt, corrosion, and damage. 3. Measure resistance from positive (+) to negative (-) terminal of ignition coil, using Rotunda digital volt-ohmmeter 007-00001. TEST RESULT TEST RESOLUTION 0.3 to 1.0 ^ Test result OK. ohm ^ Go to Test 4. Less than ^ Replace ignition coil. 0.3 ohm or greater than 1.0 ohm Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure Technical Service Bulletin # 872110 Date: 871021 TFI Module/PIP Sensor - New Diagnostic Procedure EEC IV - TFI MODULE AND PIP SENSOR - Article No. NEW DIAGNOSTIC PROCEDURE 87-21-10 FORD: 1983-88 ESCORT/EXP, MUSTANG, THUNDERBIRD, FORD 1984-88 TEMPO 1986-88 TAURUS LINCOLN-MERCURY: 1983 MARK VI 1983-86 CAPRI 1983-87 LYNX 1983-88 COUGAR, MERCURY, CONTINENTAL, LINCOLN TOWN CAR 1984-88 TOPAZ, MARK VII 1986-88 SABLE MERKUR: 1985-88 XR4Ti 1988 SCORPIO LIGHT TRUCK: 1983-88 ALL LIGHT TRUCK LINES ISSUE: A new diagnostic procedure for testing the TFI module and PIP sensor has been developed. This new procedure allows the technician to take a direct path when testing the TFI module and PIP sensor with the use of the new TFI IV diagnostic tester (Rotunda No. 105-00003). ACTION: If service is required, use the diagnostic procedures on pages 29 through 60 of this TSB. Insert these pages in the Engine/Emission Diagnosis Manual, Volume H, Section 15. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Preliminary Checkout, Equipment & Notes CHECKOUT ^ Visually inspect the engine compartment to ensure all vacuum hoses and spark plug wires are properly routed and securely connected. ^ Examine all wiring harnesses and connectors for insulation damage, burned, overheated, loose or broken conditions. ^ Check that the TFI module is securely fastened to the distributor base. ^ Be certain the battery is fully charged. ^ All accessories should be off during diagnosis. EQUIPMENT Obtain the following test equipment or an equivalent: ^ Spark Tester, Special Service Tool D81P-6666-A. See note. ^ Volt/Ohm Meter Rotunda 014-00407. ^ 12 Volt Test Light. ^ Small straight pin. ^ Remote Starter Switch. ^ TFI Ignition Tester, Rotunda 105-00002. NOTES ^ A spark plug with a broken side electrode is not sufficient to check for spark and may lead to incorrect results. ^ When instructed to inspect a wiring harness, both a visual inspection and a continuity test should be performed. ^ When making measurements on a wiring harness or connector, it is good practice to wiggle the wires while measuring. ^ References to pin-in-line connector apply to a shorting bar type connector used to set base timing. ^ This procedure is intended to identify faulty components or wiring while the fault is present. If the complaint is of an intermittent condition, refer to Intermittent Diagnosis. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 127 Functional Schematic TFI-IV The TFI-IV system electrical schematic is shown below. For detailed information, refer to the vehicle wiring diagram. Ignition Coil Secondary Voltage (Crank Mode) TFI-IV Part 2 Test 1 & 2 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 128 Ignition Coil Secondary Voltage (Run Mode) TFI-IV Part 2 Test 2 Wiring Harness Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 129 TFI-IV Part 2 Test 3 Stator - TFI Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 130 TFI-IV Part 2 Test 4 & 5 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 131 Stator - TFI-IV TFI-IV Part 2 Test 5 TFI Module TFI-IV Part 2 Test 6 Ignition Coils - Secondary & Primary Resistance Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 132 Ignition Coil Primary Resistance TFI-IV Part 2 Test 7 & 8 Ignition Coil Secondary Resistance TFI-IV Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 133 Part 2 Test 8 EEC-IV - TFI-IV TFI-IV Part 2 Test 9 Ignition Coil Supply Voltage Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 134 TFI-IV Part 2 Test 10 Wiring Harness Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 135 TFI-IV Part 2 Test 11 Preliminary Checkout, Equipment & Notes CHECKOUT ^ Visually inspect the engine compartment to ensure all vacuum hoses and spark plug wires are properly routed and securely connected. ^ Examine all wiring harnesses and connectors for insulation damage, burned, overheated, loose, or broken conditions. ^ Be certain the battery is fully charged. ^ All accessories should be off during diagnosis. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 136 EQUIPMENT Obtain the following test equipment or an equivalent: ^ Spark Tester, Special Service Tool D81P-6666-A. See note. ^ Volt/Ohm Meter Rotunda 014-00407. ^ 12 Volt Test Light. ^ Small straight pin. ^ Remote Starter Switch. ^ TFI Ignition Tester, Rotunda 105-00003. NOTES ^ A spark plug with a broken side electrode is not sufficient to check for spark and may lead to incorrect results. ^ When instructed to inspect a wiring harness, both a visual inspection and a continuity test should be performed. ^ When making measurements on a wiring harness or connector, it is good practice to wiggle the wires while measuring. ^ References to pin-in-line connector apply to shorting bar type connector used to set base timing. ^ This procedure is intended to identify faulty components or wiring while the fault is present. If the complaint is of an intermittent condition refer to Intermittent Diagnosis. Functional Schematic TFI-IV Closed Bowl Distributor The TFI-IV Closed Bowl Distributor system electrical schematic is shown below. For detailed information, refer to the vehicle wiring diagram. Ignition Coil Secondary Voltage - Crank Mode Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 137 TFI-IV Closed Bowl Distributor Part 2 Test 1 & 2 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 138 Ignition Coil Secondary Voltage - Run Mode TFI-IV Closed Bowl Distributor Part 2 Test 2 Wiring Harness Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 139 TFI-IV Closed Bowl Distributor Part 2 Test 3 Stator Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 140 TFI-IV Closed Bowl Distributor Part 2 Test 4, 5 & 6 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 141 Stator TFI-IV Closed Bowl Distributor Part 2 Test 5 Stator TFI-IV Closed Bowl Distributor Part 2 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 142 Test 6 TFI Module TFI-IV Closed Bowl Distributor Part 2 Test 7 Ignition Coil, Primary & Secondary Ignition Coil Primary Resistance TFI-IV Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 143 Closed Bowl Distributor Part 2 Test 8 Ignition Coil Secondary Resistance TFI-IV Closed Bowl Distributor Part 2 Test 9 EEC IV - Wiring Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 144 TFI-IV Closed Bowl Distributor Part 2 Test 10 Wiring Harness Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 145 TFI IV Closed Bowl Distributor Part 2 Test 11 Ignition Coil, TFI & Stator Voltage Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 146 Ignition Coil Supply Voltage TFI IV Closed Bowl Distributor Part 2 Test 12 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 147 TFI Supply Voltage TFI-IV Closed Bowl Distributor Part 2 Test 13 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 148 Stator Supply Voltage TFI IV Closed Bowl Distributor Part 2 Test 14 Wiring Harness Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 149 TFI IV Closed Bowl Distributor Part 2 Test 15 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 87720 > Apr > 87 > Tape Player - Ignition Noise Through Speakers Ignition Control Module: All Technical Service Bulletins Tape Player - Ignition Noise Through Speakers RADIO - IGNITION NOISE THROUGH FACTORY Article No. TAPE PLAYER - 4.9L - WITH TSB MODIFICATION87-3-20 87-7-20 LIGHT TRUCK: 1984-86 F SERIES, BRONCO ISSUE: Ignition noise through the radio speakers when operating the radio in the tape player mode may result if a new multispark ignition module was installed to correct a rough idle condition per TSB 87-3-20. ACTION: To correct this, modify the multi-spark ignition module wire harness as outlined in the following service procedure. 1. Shorten the heavy gauge BLACK wire on the module to 14 inches (357 mm). Crimp on a new solderless lug and hook up wire directly to negative terminal of battery. 2. Perform TSB 86-24-26 to eliminate the radio noise. OTHER APPLICABLE ARTICLES: 86-24-26, 87-3-20 WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual OPERATION: SP870720A TIME: 0.3 Hr. DLR. CODING: Basic Part No. 12A199 Code: 85 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 87610 > Mar > 87 > Engine - Stalling and/or A No Start Condition Ignition Control Module: All Technical Service Bulletins Engine - Stalling and/or A No Start Condition ^ STALL - THICK FILM IGNITION (TFI) MODULE - Article No. EEC IV VEHICLES 87-6-10 ^ STALL/NO START - THICK FILM IGNITION (TFI) MODULE - EEC IV VEHICLES FORD 1984-87 ALL LINCOLN-MERCURY 1984-87 ALL MERKUR 1985-87 XR4Ti LIGHT TRUCK 1984-87 ALL ISSUE: Stalling and/or a no-start condition on vehicles with EEC IV and certain TFI modules may be caused by moisture or salt splash entering at the upper right hand mounting hole of the TFI module housing. This condition will result in a service code 14. ACTION: To correct this, use the following diagnostic and service procedure to seal the hole and prevent further concerns. NOTE: The distributor does not have to be removed to perform this repair. 1. Check to see if the TFI-IV module part number suffix is A2A and the date code is 6K08 or prior, (mounting hole was sealed after 6K08). If the suffix is not A2A, use normal diagnostic procedures and do not perform Steps 2 and 3. 2. Thoroughly clean and dry upper right hand mounting hole of the TFI module with a clean paper towel. 3. Fill the cleaned hole with silicone grease (D7AZ-19A331-A). 4. Clear service code 14 from memory. PART NUMBER PART NAME CLASS D7AZ-19A331-A Silicone Grease AM OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual OPERATION: SP870610A TIME: 1.0 Hr. DLR. CODING: Basic Part No. 12A297 - Code: 09 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 86219 > Jan > 86 > Ignition System Resistance - Manual Revision Ignition Control Module: All Technical Service Bulletins Ignition System Resistance - Manual Revision Article No. 86-2-19 IGNITION SYSTEM - RESISTANCE TESTS - SHOP MANUAL REVISION EMISSION DIAGNOSIS MANUAL FORD 1982-86 ESCORT, EXP; 1983-86 LTD, THUNDERBIRD, CROWN VICTORIA, MUSTANG; 1984-86 TEMPO; 1986 TAURUS LINCOLN-MERCURY 1982-83 LN7; 1982-86 LYNX; 1983-86 MARQUIS, COUGAR, MERCURY, CONTINENTAL, MARK VII, LINCOLN; 1984-86 TOPAZ; 1986 SABLE LIGHT TRUCK 1983-86 EAND F-SERIES, BRONCO, RANGER; 1984-86 BRONCO II; 1986 AEROSTAR If your voltmeter has a high impedance, it will not draw enough current to show a voltage drop when testing TFI power circuits for resistive connections. To assure an accurate test, attach a test light between the circuit being tested and ground as shown. The light will draw current through the connection and allow measurement of the voltage drop so a resistive connection can be identified. IMPORTANT Do not use a test light while monitoring the PIP or SPOUT signal. The test light draws more current than the signal circuit can supply. The test light should be used only on power circuits. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 86220 > Jan > 86 > Ignition System - Weak/No Spark Ignition Control Module: All Technical Service Bulletins Ignition System - Weak/No Spark Article No. 86-2-20 IGNITION SYSTEM - TFI - WEAK OR NO SPARK - DIAGNOSTIC TIP FORD 1982-86 ESCORT, EXP; 1983-86 THUNDERBIRD, LTD, CROWN VICTORIA, MUSTANG; 1984-86 TEMPO; 1986 TAURUS LINCOLN-MERCURY 1982-83 LN7; 1982-86 LYNX; 1983-86 COUGAR, MERCURY, GRAND MARQUIS, CONTINENTAL, MARK VII, LINCOLN; 1984-86 TOPAZ; 1986 SABLE LIGHT TRUCK 1983-86 EAND F-SERIES, RANGER, BRONCO; 1984-86 BRONCO II; 1986 AEROSTAR CALIBRATIONS: All with TFI Systems If the TFI module fails and causes a short to ground, the primary winding of the ignition coil can be damaged. The TFI diagnostic procedure published in the Shop Manual will not identify this condition. When servicing a weak or no spark condition, perform the following: 1. Check for spark using the procedures found in the Manual Information, Computerized Engine, Quick Test Section, Test 1. 2. If there is no spark, test the coil primary resistance using Rotunda digital volt-ohmmeter 007-00001, as shown. 3. If the coil primary resistance is O.K., continue with the diagnostic procedure in Test 1. 4. If the coil primary resistance is not O.K., replace the coil and recheck for weak or no spark. If the spark is now O.K., the problem is resolved. 5. If the spark is still NOT O.K., continue with normal diagnostic procedure in Test 1. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Wiring Harness TFI-IV Part 2 Test 5 TEST EQUIPMENT: VOM, STRAIGHT PIN TEST PROCEDURE 1. Separate wiring harness connector from ignition module. Inspect for dirt, corrosion, and damage. NOTE: PUSH connector tabs to separate. 2. Disconnect wire at S terminal of starter relay. 3. Attach negative (-) VOM, Rotunda Number 007-00001, lead to distributor base. 4. Measure battery voltage. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 86220 > Jan > 86 > Ignition System - Weak/No Spark > Page 166 5. Following table below, measure connector terminal voltage by attaching VOM to small straight pin inserted into connector terminal and turning ignition switch to position shown. CAUTION: Do not allow straight pin to contact electrical ground. CONNECTOR IGNITION SWITCH TERMINAL WIRE/CIRCUIT TEST POSITION #2 TO IGNITION RUN COIL (-) TERMINAL #3 RUN CIRCUIT RUN AND START #4 START CIRCUIT START 6. Turn ignition switch to Off position. 7. Remove straight pin. 8. Reconnect wire to S terminal of starter relay. TEST RESULT TEST RESOLUTION 90 percent of ^ Test result OK. battery ^ Go to Part 2, Test 6. voltage minimum Less than 90 ^ Inspect for faults in wiring percent of harness and connectors. battery ^ Refer to vehicle wiring voltage diagram for appropriate circuit. ^ Damaged or worn ignition switch, Refer to Shop Manual, Group 33. Primary Circuit Continuity TFI-IV Part 2 Test 8 TEST EQUIPMENT: VOM, STRAIGHT PIN TEST PROCEDURE 1. Separate wiring harness connector from ignition module. Inspect for dirt, corrosion, and damage. NOTE: PUSH connector tabs to separate. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 86220 > Jan > 86 > Ignition System - Weak/No Spark > Page 167 2. Attach negative (-) VOM, Rotunda Number 007-00001, lead to distributor base. 3. Measure battery voltage. 4. Attach VOM to small straight pin inserted into connector terminal No. 2. CAUTION: Do not allow straight pin to contact electrical ground. 5. Turn ignition switch to Run position and measure terminal No. 2 voltage. 6. Turn ignition switch to Off position. 7. Remove straight pin. TEST RESULT TEST RESOLUTION 90 percent of ^ Go to Part 2, Test 5. battery voltage minimum Less than 90 ^ Go to Part 2, Test 9. percent of battery voltage Ignition Coil Primary Resistance TFI-IV Part 2 Test 3 TEST EQUIPMENT: VOM TEST PROCEDURE 1. Turn ignition switch to Off. 2. Disconnect ignition coil connector. Inspect for dirt, corrosion, and damage. 3. Measure resistance from positive (+) to negative (-) terminal of ignition coil, using Rotunda digital volt-ohmmeter 007-00001. TEST RESULT TEST RESOLUTION 0.3 to 1.0 ^ Test result OK. ohm ^ Go to Test 4. Less than ^ Replace ignition coil. 0.3 ohm or greater than 1.0 ohm Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure Technical Service Bulletin # 872110 Date: 871021 TFI Module/PIP Sensor - New Diagnostic Procedure EEC IV - TFI MODULE AND PIP SENSOR - Article No. NEW DIAGNOSTIC PROCEDURE 87-21-10 FORD: 1983-88 ESCORT/EXP, MUSTANG, THUNDERBIRD, FORD 1984-88 TEMPO 1986-88 TAURUS LINCOLN-MERCURY: 1983 MARK VI 1983-86 CAPRI 1983-87 LYNX 1983-88 COUGAR, MERCURY, CONTINENTAL, LINCOLN TOWN CAR 1984-88 TOPAZ, MARK VII 1986-88 SABLE MERKUR: 1985-88 XR4Ti 1988 SCORPIO LIGHT TRUCK: 1983-88 ALL LIGHT TRUCK LINES ISSUE: A new diagnostic procedure for testing the TFI module and PIP sensor has been developed. This new procedure allows the technician to take a direct path when testing the TFI module and PIP sensor with the use of the new TFI IV diagnostic tester (Rotunda No. 105-00003). ACTION: If service is required, use the diagnostic procedures on pages 29 through 60 of this TSB. Insert these pages in the Engine/Emission Diagnosis Manual, Volume H, Section 15. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Preliminary Checkout, Equipment & Notes CHECKOUT ^ Visually inspect the engine compartment to ensure all vacuum hoses and spark plug wires are properly routed and securely connected. ^ Examine all wiring harnesses and connectors for insulation damage, burned, overheated, loose or broken conditions. ^ Check that the TFI module is securely fastened to the distributor base. ^ Be certain the battery is fully charged. ^ All accessories should be off during diagnosis. EQUIPMENT Obtain the following test equipment or an equivalent: ^ Spark Tester, Special Service Tool D81P-6666-A. See note. ^ Volt/Ohm Meter Rotunda 014-00407. ^ 12 Volt Test Light. ^ Small straight pin. ^ Remote Starter Switch. ^ TFI Ignition Tester, Rotunda 105-00002. NOTES ^ A spark plug with a broken side electrode is not sufficient to check for spark and may lead to incorrect results. ^ When instructed to inspect a wiring harness, both a visual inspection and a continuity test should be performed. ^ When making measurements on a wiring harness or connector, it is good practice to wiggle the wires while measuring. ^ References to pin-in-line connector apply to a shorting bar type connector used to set base timing. ^ This procedure is intended to identify faulty components or wiring while the fault is present. If the complaint is of an intermittent condition, refer to Intermittent Diagnosis. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 173 Functional Schematic TFI-IV The TFI-IV system electrical schematic is shown below. For detailed information, refer to the vehicle wiring diagram. Ignition Coil Secondary Voltage (Crank Mode) TFI-IV Part 2 Test 1 & 2 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 174 Ignition Coil Secondary Voltage (Run Mode) TFI-IV Part 2 Test 2 Wiring Harness Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 175 TFI-IV Part 2 Test 3 Stator - TFI Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 176 TFI-IV Part 2 Test 4 & 5 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 177 Stator - TFI-IV TFI-IV Part 2 Test 5 TFI Module TFI-IV Part 2 Test 6 Ignition Coils - Secondary & Primary Resistance Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 178 Ignition Coil Primary Resistance TFI-IV Part 2 Test 7 & 8 Ignition Coil Secondary Resistance TFI-IV Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 179 Part 2 Test 8 EEC-IV - TFI-IV TFI-IV Part 2 Test 9 Ignition Coil Supply Voltage Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 180 TFI-IV Part 2 Test 10 Wiring Harness Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 181 TFI-IV Part 2 Test 11 Preliminary Checkout, Equipment & Notes CHECKOUT ^ Visually inspect the engine compartment to ensure all vacuum hoses and spark plug wires are properly routed and securely connected. ^ Examine all wiring harnesses and connectors for insulation damage, burned, overheated, loose, or broken conditions. ^ Be certain the battery is fully charged. ^ All accessories should be off during diagnosis. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 182 EQUIPMENT Obtain the following test equipment or an equivalent: ^ Spark Tester, Special Service Tool D81P-6666-A. See note. ^ Volt/Ohm Meter Rotunda 014-00407. ^ 12 Volt Test Light. ^ Small straight pin. ^ Remote Starter Switch. ^ TFI Ignition Tester, Rotunda 105-00003. NOTES ^ A spark plug with a broken side electrode is not sufficient to check for spark and may lead to incorrect results. ^ When instructed to inspect a wiring harness, both a visual inspection and a continuity test should be performed. ^ When making measurements on a wiring harness or connector, it is good practice to wiggle the wires while measuring. ^ References to pin-in-line connector apply to shorting bar type connector used to set base timing. ^ This procedure is intended to identify faulty components or wiring while the fault is present. If the complaint is of an intermittent condition refer to Intermittent Diagnosis. Functional Schematic TFI-IV Closed Bowl Distributor The TFI-IV Closed Bowl Distributor system electrical schematic is shown below. For detailed information, refer to the vehicle wiring diagram. Ignition Coil Secondary Voltage - Crank Mode Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 183 TFI-IV Closed Bowl Distributor Part 2 Test 1 & 2 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 184 Ignition Coil Secondary Voltage - Run Mode TFI-IV Closed Bowl Distributor Part 2 Test 2 Wiring Harness Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 185 TFI-IV Closed Bowl Distributor Part 2 Test 3 Stator Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 186 TFI-IV Closed Bowl Distributor Part 2 Test 4, 5 & 6 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 187 Stator TFI-IV Closed Bowl Distributor Part 2 Test 5 Stator TFI-IV Closed Bowl Distributor Part 2 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 188 Test 6 TFI Module TFI-IV Closed Bowl Distributor Part 2 Test 7 Ignition Coil, Primary & Secondary Ignition Coil Primary Resistance TFI-IV Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 189 Closed Bowl Distributor Part 2 Test 8 Ignition Coil Secondary Resistance TFI-IV Closed Bowl Distributor Part 2 Test 9 EEC IV - Wiring Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 190 TFI-IV Closed Bowl Distributor Part 2 Test 10 Wiring Harness Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 191 TFI IV Closed Bowl Distributor Part 2 Test 11 Ignition Coil, TFI & Stator Voltage Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 192 Ignition Coil Supply Voltage TFI IV Closed Bowl Distributor Part 2 Test 12 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 193 TFI Supply Voltage TFI-IV Closed Bowl Distributor Part 2 Test 13 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 194 Stator Supply Voltage TFI IV Closed Bowl Distributor Part 2 Test 14 Wiring Harness Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 195 TFI IV Closed Bowl Distributor Part 2 Test 15 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 86219 > Jan > 86 > Ignition System Resistance - Manual Revision Ignition Control Module: All Technical Service Bulletins Ignition System Resistance - Manual Revision Article No. 86-2-19 IGNITION SYSTEM - RESISTANCE TESTS - SHOP MANUAL REVISION EMISSION DIAGNOSIS MANUAL FORD 1982-86 ESCORT, EXP; 1983-86 LTD, THUNDERBIRD, CROWN VICTORIA, MUSTANG; 1984-86 TEMPO; 1986 TAURUS LINCOLN-MERCURY 1982-83 LN7; 1982-86 LYNX; 1983-86 MARQUIS, COUGAR, MERCURY, CONTINENTAL, MARK VII, LINCOLN; 1984-86 TOPAZ; 1986 SABLE LIGHT TRUCK 1983-86 EAND F-SERIES, BRONCO, RANGER; 1984-86 BRONCO II; 1986 AEROSTAR If your voltmeter has a high impedance, it will not draw enough current to show a voltage drop when testing TFI power circuits for resistive connections. To assure an accurate test, attach a test light between the circuit being tested and ground as shown. The light will draw current through the connection and allow measurement of the voltage drop so a resistive connection can be identified. IMPORTANT Do not use a test light while monitoring the PIP or SPOUT signal. The test light draws more current than the signal circuit can supply. The test light should be used only on power circuits. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > Page 200 Ignition Control Module: Locations LH Inner Fender Well Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > Page 201 Ignition Control Module: Description and Operation Typical Ignition System The Ignition Module shuts off the primary circuit each time it receives a pulse from the magnetic pick-up Fig. 9. A timing circuit in the ignition module turns the primary current back on after a short period of time. High voltage is created each time the magnetic field is built up and collapsed. The red ignition module wire provides operating voltage for the module's electronic components in the Run mode. The white module wire and start bypass provide increased voltage for the module and coil during Start mode. Ignition Modules Dura Spark II systems with UIM (Universal Ignition Module) Fig. 10 can respond to another control signal from either an Ignition Barometric Pressure Switch, Ignition Timing Vacuum Switch, or the Microprocessor Control Unit (MCU), depending on the engine calibration. Responding to this second signal, the UIM provides additional spark timing control for certain operating conditions by shutting off the ignition coil current flow at a different time than with just the distributor pick-up signal. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > Page 202 Module Identification Chart For proper ignition module identification refer to Fig. 1. The modules are not interchangeable, Dura Spark II has 6 wire connector while Dura Spark III has a 5 wire connector. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > Page 203 Ignition Control Module: Service and Repair Open Bowl Distributor 1. Remove distributor cap and adapter. Position cap and wires aside. 2. Disconnect TFI wiring. 3. Remove distributor from engine using tool T82L-12270-A or equivalent to remove security-type hold-down bolt, if equipped. 4. Place distributor on workbench and remove 2 TFI module screws, Fig. 2. 5. Pull right side of module down distributor mounting flange and then back up to disengage module terminals from connector in distributor base. Module may then be pulled toward flange and away from distributor. Do not attempt to lift module from mounting surface before moving entire TFI module toward distributor flange, as pins at distributor/module connector will break otherwise. 6. Coat metal base plate of TFI ignition module with 1/32 inch thick layer of silicone grease D7AZ-19A331-A, or equivalent. 7. Place TFI module on distributor base mounting flange. Carefully position TFI module assembly toward distributor bowl and securely engage 3 distributor connector pins. 8. Install 2 TFI module mounting screws and torque to 9---35 inch lbs. 9. Install distributor on engine. 10. Install distributor cap and adapter. 11. Connect TFI wiring. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > Page 204 12. Check and, if necessary adjust engine timing according to decal. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations Starter Relay: Locations Component Locations - RH Fender Apron On RH fender apron Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Relay > Component Information > Diagrams > Diagram Information and Instructions Windshield Washer Relay: Diagram Information and Instructions Symbol Identification Wire Color Code Identification Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 214 NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 215 Windshield Washer Relay: Electrical Diagrams Fig. 52 Windshield Wiper/Washer Wiring Circuit (L/Interval Wipers) Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 216 Fig. 53 Windshield Wiper/Washer Wiring Circuit (W/Interval Wipers) Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Locations Wiper Control Module: Locations Behind LH Corner Of I/P Under LH Side Of I/P Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams > Diagram Information and Instructions Wiper Relay: Diagram Information and Instructions Symbol Identification Wire Color Code Identification Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 224 NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 225 Wiper Relay: Electrical Diagrams Fig. 52 Windshield Wiper/Washer Wiring Circuit (L/Interval Wipers) Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 226 Fig. 53 Windshield Wiper/Washer Wiring Circuit (W/Interval Wipers) Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Locations Power Door Lock Switch: Locations In Respective Door Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Pressure Sensor/Switch > Component Information > Locations Brake Fluid Pressure Sensor/Switch: Locations RH Frame Member Attached To LH Frame Member Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Locations Parking Brake Warning Switch: Locations On Parking Brake Bracket Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications TEMPERATURE SENSORS Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 244 Coolant Temperature Sensor/Switch (For Computer): Locations RH Side Of V8-351/5. Front Of Engine, Near Distributor Applicable to: 8L Engine With EEC-IV Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 245 Coolant Temperature Sensor/Switch (For Computer): Description and Operation The Engine Coolant Temperature (ECT) Sensor, detects the temperature of engine coolant and supplies the Information to Electronic Control Assembly (ECA). The ECT sensor is threaded into the heater outlet fitting or cooling passage on the engine. For engine control applications, the ECT signal is used to modify ignition timing, EGR flow, and air to fuel ratio as a function of engine coolant temperature. On electronic instrument cluster applications, the ECT output is used to control a coolant temperature indicator. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 246 Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection Ford provides trouble code/symptom driven diagnostics for this component. For complete diagnosis and pinpoint testing, refer to Computers and Control Systems, Testing and Inspection. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Radiator Cooling Fan Temperature Sensor / Switch > Component Information > Specifications Radiator Cooling Fan Temperature Sensor / Switch: Specifications Switch Torque Switch Torque Cooling Fan Switch 8-18 ft.lb Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Locations Temperature Sensor (Gauge): Locations LH Side Of V8-351/5. On Intake Manifold, Near Distributor Applicable to: 8L Engine Less EEC-IV Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Testing and Inspection Brake Switch (Cruise Control): Testing and Inspection Perform this test only when brake application will not disconnect the speed control system. 1. Check operation of stop lamps by applying approximately 6 lbs. of pressure to brake pedal. If more than 6 lbs. is required, check brake pedal actuation and stop lamp switch. 2. If stop lamps do not function properly, check bulbs, circuit fuse or stop lamp switch. 3. If stop lamps function properly, check for battery voltage at 6 way connector using black wire w/green stripe on 1980 models, 1981-83 E-100-350 and 1984-87 E-150-350 series, or white wire w/pink stripe on 1981-82 F-100-350 and Bronco series, or white wire w/purple stripe on 1983 F-100-350, Bronco and Ranger, 1984-87 F-150-350, Ranger, 1984-87 Bronco II and 1986-87 Aerostar. 4. Depress brake pedal until stop lamps are illuminated. Check voltage at red wire w/black stripe on 1980 models, 1981-83 E-100-350 and 1984-87 E-150-350 models, or the light green wire on 1981-83 F-100-350 and Bronco, 1984-87 F-150-350 and Bronco, 1983-87 Ranger, 1984-87 Bronco II and 1986-87 Aerostar. The difference between the two voltage readings must not exceed 1.5 volts. If voltage is greater, a high resistance exists in the circuit and must be found and corrected. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Service and Repair Clutch Switch: Service and Repair 1. Remove bracket mounting screw(s). 2. Disconnect electrical connector and remove switch and bracket assembly. 3. Remove switch from bracket. 4. Reverse procedure to install. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > Customer Interest for Cruise Control Switch: > 871615 > Aug > 87 > M/T - Gear Clash and Hard Shifting Cruise Control Switch: Customer Interest M/T - Gear Clash and Hard Shifting ^ CLUTCH (HYDRAULIC) - PEDAL DOES NOT Article No. FULLY RETURN - DIAGNOSTIC TIPS 87-16-15 ^ TRANSMISSION - MANUAL - GEAR CLASH AND HARD SHIFTING ^ SPEED CONTROL - INOPERATIVE - LOW CLUTCH PEDAL ALLOWS SWITCH CIRCUIT TO REMAIN OPEN LIGHT TRUCK: 1984-87 F-150/350, BRONCO ISSUE: A clutch pedal not fully returning to contact the rubber bumper at the "up" stop may result in any of the following conditions. ^ Transmission gear clash or hard shifting or failure to release into or from gear (particularly reverse and 1st gear) because clutch pedal stroke length is decreased, causing low pedal reserve. ^ Clutch pedal may sometimes stick near the TOP of the stroke, requiring driver to "tip" the pedal with his/her foot in order to get pedal to further return. ^ Speed control is inoperative, due to pedal not returning and permitting "shut off" switch circuit to remain in the open position, i.e., clutch disengaged mode. ACTION: To determine if a new cross-shaft lever is required, use the following diagnostic and servicing procedure. 1. Check under the dash area to be certain that the clutch pedal system has no wiring looms which interfere with pedal return, at the interlock switch rod and the end of the master cylinder pushrod. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > Customer Interest for Cruise Control Switch: > 871615 > Aug > 87 > M/T - Gear Clash and Hard Shifting > Page 268 Figure 7 2. Determine if the clutch master cylinder pushrod and lever pin are correctly aligned by disconnecting the pushrod and seeing if it will reassemble to the pin WITHOUT DEPRESSING THE PUSHROD OR DEPRESSING THE CLUTCH PEDAL. (When the pushrod is disconnected from the pin, the clutch master cylinder piston is fully retracted (rearward) and the clutch pedal blade is contacting the rubber bumper stop), see Figure 7. 3. If the two components are not in alignment, perform the following IN THIS EXACT SEQUENCE: a. Loosen the clutch pedal attaching nut (left hand side). Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > Customer Interest for Cruise Control Switch: > 871615 > Aug > 87 > M/T - Gear Clash and Hard Shifting > Page 269 b. Reinstall the clutch master cylinder pushrod to the cross-shaft lever pin. c. Tighten the clutch pedal attaching nut (left hand side). d. Stroke the clutch pedal several times to reset the position of the shaft to the pedal slot, THIS STEP IS REQUIRED! e. Again, remove the clutch master cylinder pushrod from the lever pin and check the alignment. If the two (2) components are still not in alignment, replace the crossshaft lever. NOTE: If the pushrod is aligned with the pin, no further action is required. Cross-Shaft Lever Replacement Removal 1. Disconnect the master cylinder pushrod from the cross-shaft lever pin. 1984-86 Vehicles Remove the clevis pin. Carefully pull the pushrod from the lever. 1987 Vehicles Disconnect the snap-in bushing by wedging a small screwdriver or putty knife between the lever and the bushing. When the bushing tangs are free at the pin groove, carefully pull the pushrod from the lever. 2. Remove the attaching nut. 3. Remove the lever from the cross-shaft, using a pry tool or puller. Installation NOTE: The proper position of clutch master cylinder pushrod relative to the crossshaft lever (7A554) pin is controlled by this installation PROCEDURE. Therefore, ONLY the following steps should be used. 1. Install the new lever (pin) to the clutch master cylinder pushrod bushing. 2. Install the lever onto the cross-shaft. 3. Install the attaching nut, finger tight. 4. Inspect pedal position to make sure it is against the "up" stop. 5. Tighten the attaching nut. This will permit the knurled teeth on the shaft to cut matching teeth in lever, which then results in the correct positioning of the two (2) components. NOTE: The above procedure is the preferred method of "adjusting" master cylinder pushrod length. Frequently, the master cylinder is replaced or adjustable pushrods are installed to obtain the required pushrod to lever positioning. Cross-shaft lever replacement is a more efficient method and eliminates the potential of pushrod mis-adjustment and introducing air or contamination into the hydraulic system. CROSS-SHAFT LEVER APPLICATION Model Year Truck Series Part Number 1984-86 F Series, Bronco E4TZ-7A554-A 1987 F Series, Bronco E7TZ-7A554-A PART NUMBER PART NAME CLASS E4TZ-7A554-A Cross-Shaft Lever B E7TZ-7A554-A Cross-Shaft Lever B OTHER APPLICABLE ARTICLES: 85-1-20, 85-5-24, 85-5-26 WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual OPERATION: SP871615A Align clutch master cylinder pushrod and cross-shaft lever pin Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > Customer Interest for Cruise Control Switch: > 871615 > Aug > 87 > M/T - Gear Clash and Hard Shifting > Page 270 TIME: 0.4 Hr. - 6.9L diesel 0.3 Hr. - All others OPERATION: SP871615B - Replace cross-shaft lever (includes time to perform previous alignment) TIME: 0.6 Hr. - 6.9L diesel 0.5 Hr. - All others DLR. CODING: Basic Part No. 7A554 - Code: 07 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cruise Control Switch: > 871615 > Aug > 87 > M/T - Gear Clash and Hard Shifting Cruise Control Switch: All Technical Service Bulletins M/T - Gear Clash and Hard Shifting ^ CLUTCH (HYDRAULIC) - PEDAL DOES NOT Article No. FULLY RETURN - DIAGNOSTIC TIPS 87-16-15 ^ TRANSMISSION - MANUAL - GEAR CLASH AND HARD SHIFTING ^ SPEED CONTROL - INOPERATIVE - LOW CLUTCH PEDAL ALLOWS SWITCH CIRCUIT TO REMAIN OPEN LIGHT TRUCK: 1984-87 F-150/350, BRONCO ISSUE: A clutch pedal not fully returning to contact the rubber bumper at the "up" stop may result in any of the following conditions. ^ Transmission gear clash or hard shifting or failure to release into or from gear (particularly reverse and 1st gear) because clutch pedal stroke length is decreased, causing low pedal reserve. ^ Clutch pedal may sometimes stick near the TOP of the stroke, requiring driver to "tip" the pedal with his/her foot in order to get pedal to further return. ^ Speed control is inoperative, due to pedal not returning and permitting "shut off" switch circuit to remain in the open position, i.e., clutch disengaged mode. ACTION: To determine if a new cross-shaft lever is required, use the following diagnostic and servicing procedure. 1. Check under the dash area to be certain that the clutch pedal system has no wiring looms which interfere with pedal return, at the interlock switch rod and the end of the master cylinder pushrod. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cruise Control Switch: > 871615 > Aug > 87 > M/T - Gear Clash and Hard Shifting > Page 276 Figure 7 2. Determine if the clutch master cylinder pushrod and lever pin are correctly aligned by disconnecting the pushrod and seeing if it will reassemble to the pin WITHOUT DEPRESSING THE PUSHROD OR DEPRESSING THE CLUTCH PEDAL. (When the pushrod is disconnected from the pin, the clutch master cylinder piston is fully retracted (rearward) and the clutch pedal blade is contacting the rubber bumper stop), see Figure 7. 3. If the two components are not in alignment, perform the following IN THIS EXACT SEQUENCE: a. Loosen the clutch pedal attaching nut (left hand side). Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cruise Control Switch: > 871615 > Aug > 87 > M/T - Gear Clash and Hard Shifting > Page 277 b. Reinstall the clutch master cylinder pushrod to the cross-shaft lever pin. c. Tighten the clutch pedal attaching nut (left hand side). d. Stroke the clutch pedal several times to reset the position of the shaft to the pedal slot, THIS STEP IS REQUIRED! e. Again, remove the clutch master cylinder pushrod from the lever pin and check the alignment. If the two (2) components are still not in alignment, replace the crossshaft lever. NOTE: If the pushrod is aligned with the pin, no further action is required. Cross-Shaft Lever Replacement Removal 1. Disconnect the master cylinder pushrod from the cross-shaft lever pin. 1984-86 Vehicles Remove the clevis pin. Carefully pull the pushrod from the lever. 1987 Vehicles Disconnect the snap-in bushing by wedging a small screwdriver or putty knife between the lever and the bushing. When the bushing tangs are free at the pin groove, carefully pull the pushrod from the lever. 2. Remove the attaching nut. 3. Remove the lever from the cross-shaft, using a pry tool or puller. Installation NOTE: The proper position of clutch master cylinder pushrod relative to the crossshaft lever (7A554) pin is controlled by this installation PROCEDURE. Therefore, ONLY the following steps should be used. 1. Install the new lever (pin) to the clutch master cylinder pushrod bushing. 2. Install the lever onto the cross-shaft. 3. Install the attaching nut, finger tight. 4. Inspect pedal position to make sure it is against the "up" stop. 5. Tighten the attaching nut. This will permit the knurled teeth on the shaft to cut matching teeth in lever, which then results in the correct positioning of the two (2) components. NOTE: The above procedure is the preferred method of "adjusting" master cylinder pushrod length. Frequently, the master cylinder is replaced or adjustable pushrods are installed to obtain the required pushrod to lever positioning. Cross-shaft lever replacement is a more efficient method and eliminates the potential of pushrod mis-adjustment and introducing air or contamination into the hydraulic system. CROSS-SHAFT LEVER APPLICATION Model Year Truck Series Part Number 1984-86 F Series, Bronco E4TZ-7A554-A 1987 F Series, Bronco E7TZ-7A554-A PART NUMBER PART NAME CLASS E4TZ-7A554-A Cross-Shaft Lever B E7TZ-7A554-A Cross-Shaft Lever B OTHER APPLICABLE ARTICLES: 85-1-20, 85-5-24, 85-5-26 WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual OPERATION: SP871615A Align clutch master cylinder pushrod and cross-shaft lever pin Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cruise Control Switch: > 871615 > Aug > 87 > M/T - Gear Clash and Hard Shifting > Page 278 TIME: 0.4 Hr. - 6.9L diesel 0.3 Hr. - All others OPERATION: SP871615B - Replace cross-shaft lever (includes time to perform previous alignment) TIME: 0.6 Hr. - 6.9L diesel 0.5 Hr. - All others DLR. CODING: Basic Part No. 7A554 - Code: 07 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Diagrams > Diagram Information and Instructions Cruise Control Switch: Diagram Information and Instructions Symbol Identification Wire Color Code Identification Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 281 NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 282 Cruise Control Switch: Electrical Diagrams Fig. 49 Speed Control System Wiring Circuit (Part 1 of 2) Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 283 Fig. 49 Speed Control System Wiring Circuit (Part 2 of 2) Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Diagrams > Page 284 Cruise Control Switch: Testing and Inspection 1980-87 Models Exc. 1983-87 Ranger, 1984-87 Bronco II & 1986 Aerostar Disconnect 6 way connector from control switch at the amplifier, then perform the following checks: 1. Connect a voltmeter between light blue-black hash lead and ground, then depress the ``On'' button and check for battery voltage. 2. Turn ignition ``Off,'' then connect an ohmmeter between light blue-black hash lead and ground. 3. Rotate steering wheel throughout its full range while making the following checks: a. Depress ``Off'' button and check for a reading of 0-1 ohm. b. Depress ``Set'' button and check for a reading of 646-714 ohms. c. Depress and hold ``Coast'' switch and check for a reading of 114-126 ohms. d. On models with ``Resume,'' depress and hold ``Resume'' switch and check for a reading of approximately 2200 ohms. 4. If resistance values are not as specified, inspect wiring, slip rings, turn signal copper brushes, speed control switch and steering column for proper ground. Check for proper ground by connecting an ohmmeter between upper steering column flange and a suitable ground. Resistance should be less then 1/2 ohm. Rotate steering wheel throughout its full range and ensure flexible coupling has a resistance of less than 1 ohm. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Diagrams > Page 285 Cruise Control Switch: Service and Repair 1. Remove steering wheel pad attaching screws from behind steering wheel. 2. While pulling pad away from steering wheel, disconnect horn and speed control wire connectors and remove pad. 3. Remove retaining nuts securing the speed control switches and trim plate retainer to the steering wheel pad. 4. Disconnect wiring connector on rear of steering wheel pad assembly, then remove switch and trim retainer assembly. 5. Remove speed control switches by snapping out of plastic retainer. 6. To remove the ground brush, remove steering wheel for access. 7. Snap the ground brush assembly out of the turn signal switch. 8. Reverse procedure to install. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Vehicle Speed Sensor/Transducer - Cruise Control > Component Information > Locations Vehicle Speed Sensor/Transducer - Cruise Control: Locations LH Side Of Engine Compartment Below LH Side Of Master Cylinder Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Vehicle Speed Sensor/Transducer - Cruise Control > Component Information > Locations > Page 289 Vehicle Speed Sensor/Transducer - Cruise Control: Testing and Inspection 1980-87 Models Exc. 1983-87 Ranger, 1984-87 Bronco II & 1986-87 Aerostar 1. Disconnect 6 way connector from amplifier assembly, then connect an ohmmeter between dark green wire w/white stripe and black wire on 1980 E-100-350, 1981-83 F-100-350 models and Bronco, and 1984-87 F-150-350 and Bronco, or green and black wire on 1980 F-100-350 and 1981-83 E-100-350 models and 1984-87 E-150-350 at the speed sensor end. A reading of 40 ohms should be obtained. A reading of 0 ohms indicates a shorted coil and an infinity reading indicates an open coil. 2. Replace sensor if a correct reading has not been obtained. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Switch <--> [Oil Pressure Sender] > Component Information > Locations Oil Pressure Switch: Locations LH Side Of V8-351/5. LH Front Of Engine Applicable to: 8L Engine Less EEC-IV Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Technical Service Bulletins > Customer Interest: > 91155 > Jul > 91 > A/C System Chemical/Refrigerator Type Odor Refrigerant Pressure Sensor / Switch: Customer Interest A/C System - Chemical/Refrigerator Type Odor Article No. 91-15-5 07/24/91 AIR CONDITIONING - "REFRIGERATOR TYPE SMELL" OR "CHEMICAL TYPE ODOR" A/C SYSTEM - VEHICLES BUILT BEFORE 10/15/90 FORD: 1980-91 CROWN VICTORIA 1981-91 ESCORT 1982-83 FAIRMONT 1982-88 EXP 1982-91 MUSTANG, THUNDERBIRD 1983-86 LTD 1984-91 TEMPO 1986-91 TAURUS 1989-91 PROBE LINCOLN-MERCURY: 1980-91 GRAND MARQUIS, MARK VII, TOWN CAR 1981-87 LYNX 1982-83 LN7, ZEPHYR 1982-86 CAPRI 1982-91 CONTINENTAL, COUGAR 1983-86 MARQUIS 1984-91 TOPAZ 1986-91 SABLE LIGHT TRUCK: 1980-91 BRONCO, F-150-350 SERIES 1982-91 RANGER 1983-90 BRONCO II 1986-91 AEROSTAR 1988-91 ECONOLINE, F SUPER DUTY, F-47 1991 EXPLORER This TSB article is being republished in its entirety to include Labor Standards for the Taurus, Sable and Probe vehicle models. ISSUE: A "refrigerator type smell" or "chemical type" odor may come from some A/C systems. As the calibration of the clutch cycling pressure switch drifts downward, the evaporator core temperature may drop too low. This results in a "refrigerator type smell" or "chemical type" odor as the system cycles on and off. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Technical Service Bulletins > Customer Interest: > 91155 > Jul > 91 > A/C System Chemical/Refrigerator Type Odor > Page 303 Figure 1 ACTION: Install a new recalibrated clutch cycling pressure switch or adjust the existing/non-recalibrated clutch cycling pressure switch. The recalibrated switch can be identified by a specific supplier date code stamped near the fitting end of the switch, Figure 1. ^ Recalibrated switches built in the 1990 calendar year begin with the supplier date code 9041 and run through 9052. ^ Recalibrated switches built in the 1991 calendar year start with the supplier date code 9101 and run through 9152. ADJUSTMENT PROCEDURE Adjust the existing/non-recalibrated A/C cycling pressure switch by using the following service procedure. 1. Disconnect the body wiring harness. 2. Turn the set screw located between the two electrical terminals 3/4 turn clockwise (looking into the electrical connection) Figure 1. 3. Reconnect the body wiring harness. PART NUMBER PART NAME CLASS E35Y-19E561-A A/C Cycling Pressure Switch AM OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 91-11-8 WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION DESCRIPTION TIME 911505A Install A/C Cycling 0.3 Hr. Pressure Switch - Town Car, Escort, Lynx, EXP And LN7. 911505B Install A/C Cycling 0.4 Hr. Pressure Switch - Tempo/ Topaz, Taurus/Sable, Probe. 911505C Install A/C Cycling 0.5 Hr. Pressure Switch - Crown Victoria, Grand Marquis, Mark VII, Continental, Thunderbird, Cougar, Fairmont, Zephyr, Mustang, Capri, LTD And Marquis. 911505D Install A/C Cycling 0.4 Hr. Pressure Switch - All Light Trucks. 911505E Adjust A/C Cycling Switch - 0.2 Hr. All DEALER CODING BASIC PART NO. CONDITION CODE 19E661 53 OASIS CODES: 208000, 208999 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 91155 > Jul > 91 > A/C System - Chemical/Refrigerator Type Odor Refrigerant Pressure Sensor / Switch: All Technical Service Bulletins A/C System Chemical/Refrigerator Type Odor Article No. 91-15-5 07/24/91 AIR CONDITIONING - "REFRIGERATOR TYPE SMELL" OR "CHEMICAL TYPE ODOR" A/C SYSTEM - VEHICLES BUILT BEFORE 10/15/90 FORD: 1980-91 CROWN VICTORIA 1981-91 ESCORT 1982-83 FAIRMONT 1982-88 EXP 1982-91 MUSTANG, THUNDERBIRD 1983-86 LTD 1984-91 TEMPO 1986-91 TAURUS 1989-91 PROBE LINCOLN-MERCURY: 1980-91 GRAND MARQUIS, MARK VII, TOWN CAR 1981-87 LYNX 1982-83 LN7, ZEPHYR 1982-86 CAPRI 1982-91 CONTINENTAL, COUGAR 1983-86 MARQUIS 1984-91 TOPAZ 1986-91 SABLE LIGHT TRUCK: 1980-91 BRONCO, F-150-350 SERIES 1982-91 RANGER 1983-90 BRONCO II 1986-91 AEROSTAR 1988-91 ECONOLINE, F SUPER DUTY, F-47 1991 EXPLORER This TSB article is being republished in its entirety to include Labor Standards for the Taurus, Sable and Probe vehicle models. ISSUE: A "refrigerator type smell" or "chemical type" odor may come from some A/C systems. As the calibration of the clutch cycling pressure switch drifts downward, the evaporator core temperature may drop too low. This results in a "refrigerator type smell" or "chemical type" odor as the system cycles on and off. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 91155 > Jul > 91 > A/C System - Chemical/Refrigerator Type Odor > Page 309 Figure 1 ACTION: Install a new recalibrated clutch cycling pressure switch or adjust the existing/non-recalibrated clutch cycling pressure switch. The recalibrated switch can be identified by a specific supplier date code stamped near the fitting end of the switch, Figure 1. ^ Recalibrated switches built in the 1990 calendar year begin with the supplier date code 9041 and run through 9052. ^ Recalibrated switches built in the 1991 calendar year start with the supplier date code 9101 and run through 9152. ADJUSTMENT PROCEDURE Adjust the existing/non-recalibrated A/C cycling pressure switch by using the following service procedure. 1. Disconnect the body wiring harness. 2. Turn the set screw located between the two electrical terminals 3/4 turn clockwise (looking into the electrical connection) Figure 1. 3. Reconnect the body wiring harness. PART NUMBER PART NAME CLASS E35Y-19E561-A A/C Cycling Pressure Switch AM OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 91-11-8 WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION DESCRIPTION TIME 911505A Install A/C Cycling 0.3 Hr. Pressure Switch - Town Car, Escort, Lynx, EXP And LN7. 911505B Install A/C Cycling 0.4 Hr. Pressure Switch - Tempo/ Topaz, Taurus/Sable, Probe. 911505C Install A/C Cycling 0.5 Hr. Pressure Switch - Crown Victoria, Grand Marquis, Mark VII, Continental, Thunderbird, Cougar, Fairmont, Zephyr, Mustang, Capri, LTD And Marquis. 911505D Install A/C Cycling 0.4 Hr. Pressure Switch - All Light Trucks. 911505E Adjust A/C Cycling Switch - 0.2 Hr. All DEALER CODING BASIC PART NO. CONDITION CODE 19E661 53 OASIS CODES: 208000, 208999 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 891410 > Jul > 89 > A/C Pressure Cycling Switch Diagnostic Procedure Refrigerant Pressure Sensor / Switch: All Technical Service Bulletins A/C - Pressure Cycling Switch Diagnostic Procedure AIR CONDITIONING-CLUTCH PRESSURE CYCLING SWITCH DIAGNOSTIC PROCEDURE Article No. 89-14-10 FORD: 1980-89 CROWN VICTORIA 1981-89 ESCORT 1982-88 EXP 1982-89 MUSTANG, THUNDERBIRD 1983-86 LTD 1984-89 TEMPO 1986-89 TAURUS LINCOLN-MERCURY: 1980-89 GRAND MARQUIS, MARK VI, MARK VII, TOWN CAR 1981-87 LYNX 1982-86 CAPRI 1982-89 CONTINENTAL, COUGAR 1983-86 MARQUIS 1984-89 TOPAZ 1986-89 SABLE LIGHT TRUCK: 1980-89 BRONCO, F SERIES 1983-89 RANGER 1984-89 BRONCO II 1986-89 AEROSTAR 1988-89 ECONOLINE ISSUE: Poor air conditioning cooling caused by low or no refrigerant charge often results in unnecessary replacement of the clutch cycling pressure switch. The switch is designed to work on system pressure. It closes at about 46 psi and opens at about 24.5 psi. It has a normal cycle (on and off) rate of 2 to 5 cycles per minute. ACTION: If an inoperative or fast cycling pressure switch is found, use the following diagnostic charts before replacing the pressure switch. DIAGNOSTIC PROCEDURE: 1. Connect a manifold gauge set to the service ports and check the system pressures. They should be above the closing pressure of the switch (46 psi). 2. If the A/C system pressures are above 46 psi and the clutch will not engage, proceed as follows: ^ Check the pressure switch harness connector and harness wires for a continuous open condition. ^ Check for an intermittent open or a poor connection between the connector and the pressure switch terminals. a. If the harness connector and wires are OK, by-pass the pressure switch by jumping the two terminals of the connector. If the clutch still does not engage, THE PRESSURE SWITCH IS NOT DEFECTIVE. Refer to the respective EVTM for the clutch circuit schematic and circuit diagnosis. Repair as necessary. 3. Check the ambient temperature. If the ambient temperature is below 48~ F (9~ C), the system pressure will not be high enough to close the pressure switch (46 psi). 4. If the system does not contain refrigerant, the pressure will not be high enough to close the switch for compressor operation. Leak test, repair, evacuate and charge the system. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 891410 > Jul > 89 > A/C Pressure Cycling Switch Diagnostic Procedure > Page 314 Figure 1 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 891410 > Jul > 89 > A/C Pressure Cycling Switch Diagnostic Procedure > Page 315 Figure 2 5. If the pressures are above 46 psi and the clutch cycle rate is faster than the normal rate of 2 to 5 cycles per minute, the system is probably low on refrigerant. Check that the system contains the correct refrigerant charge by following the correct diagnostic chart (Figures 1 or 2). WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 2600, 2610 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Technical Service Bulletins > All Other Service Bulletins for Refrigerant Pressure Sensor / Switch: > 932410 > Nov > 93 > Instrument Cluster Warning Lights - Dimly Lit Oil Level Warning Indicator: All Technical Service Bulletins Instrument Cluster Warning Lights Dimly Lit Article No. 93-24-10 11/24/93 ^ LAMP - MALFUNCTION OF FOUR PIN LOW OIL LEVEL RELAY - VEHICLES BUILT AFTER 8/1/92 OR 1983-1993 VEHICLES THAT HAVE HAD SERVICE REPLACEMENT IGNITION SWITCHES AFTER 8/1/92 ^ LAMPS - INSTRUMENT CLUSTER WARNING LIGHTS DIMLY LIT - VEHICLES BUILT AFTER 8/1/92 OR 1983-1993 VEHICLES THAT HAVE HAD SERVICE REPLACEMENT IGNITION SWITCHES AFTER 8/1/92 FORD: 1983 FAIRMONT 1983-89 CROWN VICTORIA, ESCORT 1983-93 MUSTANG, THUNDERBIRD 1983-94 PROBE 1984-86 LTD 1984-94 TEMPO LINCOLN-MERCURY: 1983 LN7, ZEPHYR 1983-87 CONTINENTAL, LYNX 1983-89 GRAND MARQUIS, TOWN CAR 1983-93 COUGAR 1984-86 CAPRI, MARQUIS 1984-94 TOPAZ LIGHT TRUCK: 1983-91 BRONCO 1983-93 ECONOLINE, F-150-350 SERIES, RANGER 1986-91 AEROSTAR 1991-93 EXPLORER ISSUE: The instrument cluster warning light(s) may be dimly lit or there may be a malfunction of the four pin low oil relay on vehicles so equipped. This could be due to the ignition switch. ACTION: If the vehicle displays the subject symptoms and meets the following conditions, replace the ignition switch. Refer to the appropriate Car or Light Truck Service Manual (Section 13-04 for 1983-1990 Cars, Section 11-04 for 1991-1993 Cars and Section 13-05 for 1983-1990 Light Trucks, Section 11-05 for 1991-1993 Light Trucks) for removal and installation procedures. Refer to the Parts Block in this article for correct parts usage. CONDITIONS ^ The vehicle has 14401 wiring attached to the P2 terminal of the ignition switch. Refer to the wiring schematic and/or Electrical And Vacuum Troubleshooting Manual (EVTM) for the concern vehicle. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Technical Service Bulletins > All Other Service Bulletins for Refrigerant Pressure Sensor / Switch: > 932410 > Nov > 93 > Instrument Cluster Warning Lights - Dimly Lit > Page 321 ^ The vehicle is equipped with one of the ignition switches identified in the Ignition Switch Part Number Chart. NOTE: THE SERVICE PART NUMBERS FOR THE REPLACEMENT IGNITION SWITCHES WILL HAVE THE SAME PART NUMBERS AS THOSE REPLACED. THE NEW SWITCH HAS BEEN IMPROVED TO CORRECT THE SUBJECT ISSUE. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of The Bumper To Bumper For 1992/93 Models, Basic Warranty Coverage For All Other Models Except Lincolns. Major Component Warranty Coverage For Lincolns OPERATION DESCRIPTION TIME 932410A Replace Ignition Switch - 0.5 Hr. All Light and Compact Trucks DEALER CODING BASIC PART NO. CONDITION CODE 11572 X1 OASIS CODES: 201000, 201100, 206000 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Technical Service Bulletins > All Other Service Bulletins for Refrigerant Pressure Sensor / Switch: > 932410 > Nov > 93 > Instrument Cluster Warning Lights - Dimly Lit > Page 327 ^ The vehicle is equipped with one of the ignition switches identified in the Ignition Switch Part Number Chart. NOTE: THE SERVICE PART NUMBERS FOR THE REPLACEMENT IGNITION SWITCHES WILL HAVE THE SAME PART NUMBERS AS THOSE REPLACED. THE NEW SWITCH HAS BEEN IMPROVED TO CORRECT THE SUBJECT ISSUE. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of The Bumper To Bumper For 1992/93 Models, Basic Warranty Coverage For All Other Models Except Lincolns. Major Component Warranty Coverage For Lincolns OPERATION DESCRIPTION TIME 932410A Replace Ignition Switch - 0.5 Hr. All Light and Compact Trucks DEALER CODING BASIC PART NO. CONDITION CODE 11572 X1 OASIS CODES: 201000, 201100, 206000 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Technical Service Bulletins > Page 328 Refrigerant Pressure Sensor / Switch: Locations Rear RH Side Of Engine Compartment On Accumulator/Drier Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Throttle Full Open Switch HVAC > Component Information > Description and Operation Throttle Full Open Switch HVAC: Description and Operation A switch assembly, Figure 1 is mounted on the carburetor on some gasoline engines and on the fuel injector pump on the 2.0L Diesel engine to sense a wide open throttle condition. When maximum engine power is required, this switch assembly cuts off the air conditioning compressor to reduce engine loading. Switch closed at throttle opening less than wide open throttle. Switch open at wide open throttle condition. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest: > 87717 > Apr > 87 > Fuel Gauge - Always Reads Full Fuel Gauge Sender: Customer Interest Fuel Gauge - Always Reads Full GAUGE - FUEL - ALWAYS READS "FULL" - Article No. 7.5L - MIDSHIP FUEL TANK 87-7-17 LIGHTTRUCK: 1985-86 F-250/350 Figure 15 - Article 87-7-17 ISSUE: A fuel gauge that always reads "full" may be caused by the float on the electric fuel pump sender catching on the internal fuel fill pipe inside the midship fuel tank. See Figure 15. ACTION: To correct this, install a new design fuel pump sender assembly, E5TZ- 9H307-L, with revised float travel that will not contact the internal fill pipe. PART NUMBER PART NAME CLASS E5TZ-9H307-L Sender and Fuel Pump A Assembly OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual OPERATION: SP870717A TIME: 0.9 Hr. DLR. CODING: Basic Part No. 9H307 - Code: 09 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 89146 > Jul > 89 > Fuel Tank Sending Unit - Connector Replacement Fuel Gauge Sender: All Technical Service Bulletins Fuel Tank Sending Unit - Connector Replacement FUEL SYSTEM-FUEL TANK SENDING UNIT-WIRE HARNESS CONNECTOR REPLACEMENT WIRING-FUEL TANK SENDING UNIT-CONNECTOR REPLACEMENT Article No. 89-14-6 FORD: 1985-89 CROWN VICTORIA, ESCORT 1985-88 EXP 1985-89 MUSTANG, TEMPO, THUNDERBIRD 1986-89 TAURUS LINCOLN-MERCURY: 1985-89 CONTINENTAL, COUGAR, GRAND MARQUIS 1985-87 LYNX 1985-89 MARK VII, TOPAZ, TOWN CAR 1986-89 SABLE LIGHT TRUCK: 1985-89 BRONCO II, ECONOLINE, F-150, F-250, F-350, RANGER Figure 1 ISSUE: Damaged fuel tank sending unit connectors can be serviced by splicing in a new wire harness connector. The new connector can be obtained by ordering the fuel tank sending unit wire harness and cutting off the connector. ACTION: Splice the new fuel tank sending unit connector to the existing wire harness. Refer to the following procedure for service details. 1. Disconnect the battery ground. 2. Cut the connector from the new harness. 3. Leave 6-8 inches of wiring lead on the connector. 4. Remove the old connector from the fuel tank sending unit. 5. Cut the connector off the vehicle's wire harness about 6-8 inches from the old connector. 6. Match the wire colors. 7. Install the new connector. Use a "Duraseal" butt splice connector, Figure 1. 8. Using a heat gun, seal the splice. CAUTION: DO NOT USE AN OPEN FLAME. 9. Connect the battery ground. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 89146 > Jul > 89 > Fuel Tank Sending Unit - Connector Replacement > Page 346 10. Check the operation of the fuel gauge. PART NUMBER PART NAME CLASS E9FZ-9A400-A Wire Harness - Fuel Pump C OTHER APPLICABLE ARTICLES: 86-3-11 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 2300, 2310, 2400, 2770, 4500 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 87717 > Apr > 87 > Fuel Gauge - Always Reads Full Fuel Gauge Sender: All Technical Service Bulletins Fuel Gauge - Always Reads Full GAUGE - FUEL - ALWAYS READS "FULL" - Article No. 7.5L - MIDSHIP FUEL TANK 87-7-17 LIGHTTRUCK: 1985-86 F-250/350 Figure 15 - Article 87-7-17 ISSUE: A fuel gauge that always reads "full" may be caused by the float on the electric fuel pump sender catching on the internal fuel fill pipe inside the midship fuel tank. See Figure 15. ACTION: To correct this, install a new design fuel pump sender assembly, E5TZ- 9H307-L, with revised float travel that will not contact the internal fill pipe. PART NUMBER PART NAME CLASS E5TZ-9H307-L Sender and Fuel Pump A Assembly OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual OPERATION: SP870717A TIME: 0.9 Hr. DLR. CODING: Basic Part No. 9H307 - Code: 09 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 86163 > Aug > 86 > Fuel Pump/Sender - Erratic Operation Prevention Fuel Gauge Sender: All Technical Service Bulletins Fuel Pump/Sender - Erratic Operation Prevention Article No. 86-16-3 FUEL SYSTEM - FUEL PUMP/SENDER-APPLICATION OF GREASE TO ELECTRICAL TERMINALS FORD 1985-86 ESCORT, EXP, TEMPO, MUSTANG, LTD, THUNDERBIRD LINCOLN-MERCURY 1985-86 LYNX, TOPAZ, CAPRI, MARQUIS, COUGAR, MARK VII, CONTINENTAL LIGHT TRUCK 1985-86 RANGER, BRONCO II, AEROSTAR, BRONCO, E SERIES, F SERIES To prevent erratic operation of the fuel gauge or the in-tank fuel pump, a generous application of electrical grease should be applied to the terminals of the fuel pump/sender when service is required. The electrical grease will prevent corrosion and reduce the chance of a repeat repair. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge Sender: > 89146 > Jul > 89 > Fuel Tank Sending Unit - Connector Replacement Fuel Gauge Sender: All Technical Service Bulletins Fuel Tank Sending Unit - Connector Replacement FUEL SYSTEM-FUEL TANK SENDING UNIT-WIRE HARNESS CONNECTOR REPLACEMENT WIRING-FUEL TANK SENDING UNIT-CONNECTOR REPLACEMENT Article No. 89-14-6 FORD: 1985-89 CROWN VICTORIA, ESCORT 1985-88 EXP 1985-89 MUSTANG, TEMPO, THUNDERBIRD 1986-89 TAURUS LINCOLN-MERCURY: 1985-89 CONTINENTAL, COUGAR, GRAND MARQUIS 1985-87 LYNX 1985-89 MARK VII, TOPAZ, TOWN CAR 1986-89 SABLE LIGHT TRUCK: 1985-89 BRONCO II, ECONOLINE, F-150, F-250, F-350, RANGER Figure 1 ISSUE: Damaged fuel tank sending unit connectors can be serviced by splicing in a new wire harness connector. The new connector can be obtained by ordering the fuel tank sending unit wire harness and cutting off the connector. ACTION: Splice the new fuel tank sending unit connector to the existing wire harness. Refer to the following procedure for service details. 1. Disconnect the battery ground. 2. Cut the connector from the new harness. 3. Leave 6-8 inches of wiring lead on the connector. 4. Remove the old connector from the fuel tank sending unit. 5. Cut the connector off the vehicle's wire harness about 6-8 inches from the old connector. 6. Match the wire colors. 7. Install the new connector. Use a "Duraseal" butt splice connector, Figure 1. 8. Using a heat gun, seal the splice. CAUTION: DO NOT USE AN OPEN FLAME. 9. Connect the battery ground. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge Sender: > 89146 > Jul > 89 > Fuel Tank Sending Unit - Connector Replacement > Page 360 10. Check the operation of the fuel gauge. PART NUMBER PART NAME CLASS E9FZ-9A400-A Wire Harness - Fuel Pump C OTHER APPLICABLE ARTICLES: 86-3-11 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 2300, 2310, 2400, 2770, 4500 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge Sender: > 86163 > Aug > 86 > Fuel Pump/Sender - Erratic Operation Prevention Fuel Gauge Sender: All Technical Service Bulletins Fuel Pump/Sender - Erratic Operation Prevention Article No. 86-16-3 FUEL SYSTEM - FUEL PUMP/SENDER-APPLICATION OF GREASE TO ELECTRICAL TERMINALS FORD 1985-86 ESCORT, EXP, TEMPO, MUSTANG, LTD, THUNDERBIRD LINCOLN-MERCURY 1985-86 LYNX, TOPAZ, CAPRI, MARQUIS, COUGAR, MARK VII, CONTINENTAL LIGHT TRUCK 1985-86 RANGER, BRONCO II, AEROSTAR, BRONCO, E SERIES, F SERIES To prevent erratic operation of the fuel gauge or the in-tank fuel pump, a generous application of electrical grease should be applied to the terminals of the fuel pump/sender when service is required. The electrical grease will prevent corrosion and reduce the chance of a repeat repair. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Page 365 Fuel Gauge Sender: Locations Top Of Fuel Tank Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Page 366 Fuel Gauge Sender: Description and Operation DESCRIPTION AND OPERATION FUEL LEVEL INDICATING SYSTEM The fuel indicating system is a bimetal-resistance type system. It consists of an instrument voltage regulator, fuel indicator (gauge) mounted in the instrument cluster and a sender located in the fuel tank, INSTRUMENT VOLTAGE REGULATOR The instrument voltage regulator (IVR) used with the fuel indicator (gauge) controls and maintains an average pulsating voltage of 5.0 volts at the gauge terminals. FUEL INDICATOR (GAUGE) The fuel indicator gauge pointer is attached to a wire wound bimetal strip which when heated by the flow of electrical current controlled by the sender unit, produoes the appropriate indication. Fuel Indicating System Using A Bimetal Gauge - Typical FUEL SENDER The fuel sender consists of a variable screened resistor made up of a ceramic substrate. It is controlled by the action of an attached float in the fuel tank. When the fuel level is low, resistance in the sender is high and allows only a low current to flow through the indicator (gauge) windings, causing the pointer to move a short distance. When the fuel level is high, the resistance in the sender is low and allows a higher current flow and a greater heating effect causing the pointer to move a greater distance. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Page 367 Fuel Gauge Sender: Testing and Inspection DIAGNOSIS AND TESTING WARNING: DO NOT REMOVE THE NIPPLE ON THE END OF THE FUEL RETURN LINE. IT IS THERE TO PREVENT FUEL FROM DRAINING OUT OF THE TANK IN THE EVENT OF A ROLLOVER. NOTE: On vehicles equipped with diesel engines and dual fuel tanks, refer to the diagnosis guide in this Section before proceeding with the calibration testing. CAUTION: DO NOT INTERCHANGE SENDING UNITS BETWEEN GASOLINE-AND DIESEL-POWERED VEHICLES. DOING SO MAY CAUSE SEVERE ENGINE AND FUEL SYSTEM DAMAGE. CALIBRATION TEST (USING ROTUNDA TESTER MODEL 021-00034) Fuel Indicating System Test With Rotunda Tester Model 21-0015 Or Equivalent The Rotunda Instrument Gauge System Tester Model 021-00034 or equivalent is used to diagnose problems in all fuel indicating systems using the bimetal fuel indicator gauge and instrument voltage regulator (IVR). Prior to performing fuel system test the following tester checks should be made. 1. Set tester switch at IVR CHECK position. 2. Attach tester ground wire to the negative (-) terminal of 12-volt battery and touch one of the tester terminals marked with an arrow to the positive (+) battery terminal. 3. If the IVR check lamp does not come on, return tester for service or replacement. TEST SET-UP Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Page 368 CAUTION: DURING IN-VEHICLE TESTS, Do NOT LET TESTER TERMINAL STUDS DESIGNATED BY ARROWS COME IN CONTACT WITH VEHICLE GROUND. THE FUEL GAUGE WILL BE SHORTED TO GROUND, PREVENTING AN ACCURATE TEST AND POSSIBLY DAMAGING THE IVR OR GAUGE. 1. Disconnect connector from fuel sender and hook onto the matching terminals on the tester (Fig. 4). 2. Turn vehicle ignition switch to ACC position. FUNCTIONAL TEST NOTE: The IVR also supplies a common regulated voltage for the temperature gauge indicating system and oil gauge indicating system (when applicable); therefore, the IVR can only be damaged if the other gauges exhibit similar problems (fluctuating movement or high or low indications at the upper calibration band). The IVR has little effect on the lower calibration band of the indicator. 1. Set test switch to IVR check position. 2. If IVR check lamp flashes on and off, the IVR and wiring are functional. Proceed to calibration check. 3. If IVR check lamp is on steady, check IVR ground screw. If ground screw is secure, replace IVR 4. If IVR check lamp does not come on, check for open circuit in gauge and/or circuit wiring. CALIBRATION CHECK With the tester switch in either the HIGH or LOW position, the center line of the gauge pointer should be within the "F" or "E" white band of the graphics for the fuel test function as shown on the tester. If the center line of the pointer registers in the white bands, the fuel indicating system is operating properly and replacement of the fuel sender is necessary. If the pointer center line falls outside the "E" white band, replace the fuel gauge. If the pointer center line falls outside the "F" white band, replace the IVR and retest. If still outside the upper white band, replace the fuel gauge reinstall the original IVR and retest for calibration. CALIBRATION TEST (WITHOUT TESTER) If only the fuel gauge is inoperative or appears to be out of calibration, a calibration test can be conducted on the vehicle fuel gauge system. The calibration test checks the fuel gauge and IVR simultaneously. The required test equipment consists of a 10 ohm resistor and a 73 ohm resistor. Disconnect the wiring connector at the sender unit. Connect one of the resistors between the lead wire terminal and ground, and turn the ignition switch to the ON or ACC position With the 10 ohm resistor, the gauge should indicate a full-scale reading. With the 73 ohm resistor, the gauge should read at the E graduation mark. Without any resistor (open circuit) the gauge reading should be the same as with the ignition switch in the OFF position. If reading is OK, replace wire connection to sender. If the gauge pointer does not move and stays below the E mark, check for an open circuit in the wiring assembly, the gauge windings, or the instrument cluster printed circuit. If the gauge pointer moves without any resistor connected, check for a short circuit in the lead to the sender unit. If the gauge reads out of calibration, replace IVR and retest. If still out of calibration, replace the gauge. GAUGE BENCH TEST FOR OPEN WINDINGS To test the gauge for open windings, remove the gauge from the vehicle. Connect the gauge to an ohmmeter and read the resistance. An upward movement of the needle from 10 to 14 ohms is normal, because the current increases the temperature of the gauge coil (windings). If the ohmmeter reads below 10 ohms or above 14 ohms, replace the gauge. FUEL TANK DAMAGE If fuel indicating system components are functioning properly and inaccurate indications continue, check the fuel tank for damage which may have changed the fuel sender mounting angle and/or damaged the fuel sender. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Locations Parking Brake Warning Switch: Locations On Parking Brake Bracket Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations Backup Lamp Switch: Locations Manual Transmission Wiring On Transmission Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations Brake Light Switch: Locations Underneath LH Side Of I/P Top Of Brake Pedal Bracket Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 379 Brake Light Switch: Service and Repair Fig. 6 Stop light switch replacement. Exc. 1980---83 E-100 w/manual brakes. Fig. 7 Stop light switch replacement. 1980---83 E-100 w/manual brakes 1. Disconnect battery ground cable. 2. Disconnect electrical connector from switch, Figs. 6 and 7. 3. Remove hairpin retainer, then slide stop light switch, pushrod, nylon washers and bushings away from pedal and remove the switch from vehicle. 4. Reverse procedure to install. Ensure stop light switch wires are of sufficient length to allow full travel of the brake pedal. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Diagram Information and Instructions Hazard Warning Switch: Diagram Information and Instructions Symbol Identification Wire Color Code Identification Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 384 NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 385 Fig. 24 Exterior Lamp (Turn, Stop & Hazard) Wiring Circuit. F150-350 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Locations Headlamp Dimmer Switch: Locations On Floor Pan, At LH Side Of Cab Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions Headlamp Dimmer Switch: Diagram Information and Instructions Symbol Identification Wire Color Code Identification Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 391 NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 392 Fig. 38 Headlamp Wiring Circuit Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Service and Repair Headlamp Switch: Service and Repair Fig. 6 Light Switch F-100---350 & BRONCO 1. Disconnect battery ground cable. 2. Remove knobs from headlight switch, windshield wiper switch and fog light switch (if equipped). Use a suitable hook tool to release each knob lock tab. 3. Remove steering column shroud, then the cluster finish panel assembly, Fig. 5. 4. Remove switch attaching nut, Fig. 5. 5. Disconnect electrical connector from switch and remove switch from vehicle. 6. Reverse procedure to install. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Technical Service Bulletins > Customer Interest for Turn Signal Switch: > 862318 > Nov > 86 > Tilt Steering Column - Release Lever Feels Loose Turn Signal Switch: Customer Interest Tilt Steering Column - Release Lever Feels Loose Article No. 86-23-18 STEERING - TILT STEERING COLUMN - RELEASE LEVER FEELS LOOSE LIGHT TRUCK 1986 F-150/350, BRONCO, ECONOLINE Tilt release lever feels "limp" when attempting to adjust steering wheel. Tilt function is fully operable but lever has a loose feel during initial portion of the lever travel. Some vehicles built during June and July, 1986 have been found to have this condition because preload on the tilt lever is insufficient. This can be corrected by replacing the turn signal switch assembly. Refer to Volume A, Section 32-41 of the 1986 Light Truck Shop Manual on installation procedures. PART NUMBER PART NAME CLASS E5TZ-13341-B Turn Signal Switch B Assembly - F Series, Bronco E5TZ-13341-B Turn Signal Switch B Assembly - Econoline/4 Speed E5UZ-13341-D Turn Signal Switch B Assembly - Econoline/Automatic OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION: 13319A TIME: 0.7 Hr. DLR. CODING: Basic Part No. 13341 - Code: 33 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Turn Signal Switch: > 862318 > Nov > 86 > Tilt Steering Column - Release Lever Feels Loose Turn Signal Switch: All Technical Service Bulletins Tilt Steering Column - Release Lever Feels Loose Article No. 86-23-18 STEERING - TILT STEERING COLUMN - RELEASE LEVER FEELS LOOSE LIGHT TRUCK 1986 F-150/350, BRONCO, ECONOLINE Tilt release lever feels "limp" when attempting to adjust steering wheel. Tilt function is fully operable but lever has a loose feel during initial portion of the lever travel. Some vehicles built during June and July, 1986 have been found to have this condition because preload on the tilt lever is insufficient. This can be corrected by replacing the turn signal switch assembly. Refer to Volume A, Section 32-41 of the 1986 Light Truck Shop Manual on installation procedures. PART NUMBER PART NAME CLASS E5TZ-13341-B Turn Signal Switch B Assembly - F Series, Bronco E5TZ-13341-B Turn Signal Switch B Assembly - Econoline/4 Speed E5UZ-13341-D Turn Signal Switch B Assembly - Econoline/Automatic OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION: 13319A TIME: 0.7 Hr. DLR. CODING: Basic Part No. 13341 - Code: 33 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Technical Service Bulletins > Page 409 Turn Signal Switch: Locations In Upper Part Of Steering Column Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Diagram Information and Instructions Turn Signal Switch: Diagram Information and Instructions Symbol Identification Wire Color Code Identification Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 412 NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 413 Fig. 24 Exterior Lamp (Turn, Stop & Hazard) Wiring Circuit. F150-350 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Page 414 Turn Signal Switch: Service and Repair 1. Disconnect battery ground cable. 2. Remove horn switch, then the steering wheel. 3. Remove turn signal switch lever by unscrewing from steering column. 4. On 1981---87 F-100---350 and Bronco models, remove lower steering column shroud. 5. On 1981---87 E-100---350 models, remove upper and lower steering column shrouds. 6. On all models, disconnect electrical connector from turn signal switch and remove switch attaching screws. 7. On all models with tilt column and 1980 E-100---350, F-100---350 and Bronco with fixed column, remove wires and terminals from steering column electrical connector, after noting color code and location of each connector. Remove plastic cover sleeve, if equipped, from wiring harness, then lift switch assembly out through top of column. On 1981---87 E-100---350 models equipped with tilt column and automatic transmission, disconnect transmission selector indicator light electrical connector from turn signal switch harness prior to removing the switch. 8. On all models with fixed column, except 1980 E-100---350, F-100---350 and Bronco, remove switch assembly by lifting out of column while guiding connector plug through opening in shift socket. On 1981---87 E-100---350 models equipped with fixed column and automatic transmission, remove transmission selector indicator light assembly with turn signal switch. 9. Reverse procedure to install. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Barometric Pressure Switch > Component Information > Description and Operation Barometric Pressure Switch: Description and Operation The Ignition Barometric Pressure Switch, is used to control spark timing and/or other electrical devices in response to changes in barometric pressure (i.e., altitude). When controlling spark timing, the ignition module (12A244) is made to vary the spark timing by an amount determined by calibration resistors in the switch assembly. In normal operation, spark timing is increased for vehicle operation above the switching point (increasing altitude) and retarded for vehicle operation below the switching point (decreasing altitude). When controlling other electrical devices, only On/Off control is provided; with On (switch closed) above the switching point and Off (switch open) below the switching point. Some switch assemblies control both spark timing and another device (dual switch assembly) and other switch assemblies control only one or the other (single switch assembly). Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Barometric Pressure Switch > Component Information > Testing and Inspection > Component Testing Barometric Pressure Switch: Testing and Inspection Component Testing ^ Dual switch assembly shown. ^ Attaching brackets vary according to installation requirements. ^ Connectors may vary. Either resistance value is correct if altitude is between 3,000 and 4,600 feet. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Barometric Pressure Switch > Component Information > Testing and Inspection > Component Testing > Page 422 Barometric Pressure Switch: Testing and Inspection Computer Related Diagnostic Information Ford provides trouble code/symptom driven diagnostics for this component. For complete diagnosis and pinpoint testing, refer to Computers and Control Systems, Testing and Inspection. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Camshaft Position Sensor: Diagram Information and Instructions Symbol Identification Wire Color Code Identification Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 427 NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications TEMPERATURE SENSORS Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 431 Coolant Temperature Sensor/Switch (For Computer): Locations RH Side Of V8-351/5. Front Of Engine, Near Distributor Applicable to: 8L Engine With EEC-IV Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 432 Coolant Temperature Sensor/Switch (For Computer): Description and Operation The Engine Coolant Temperature (ECT) Sensor, detects the temperature of engine coolant and supplies the Information to Electronic Control Assembly (ECA). The ECT sensor is threaded into the heater outlet fitting or cooling passage on the engine. For engine control applications, the ECT signal is used to modify ignition timing, EGR flow, and air to fuel ratio as a function of engine coolant temperature. On electronic instrument cluster applications, the ECT output is used to control a coolant temperature indicator. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 433 Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection Ford provides trouble code/symptom driven diagnostics for this component. For complete diagnosis and pinpoint testing, refer to Computers and Control Systems, Testing and Inspection. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Crankshaft Position Sensor: Diagram Information and Instructions Symbol Identification Wire Color Code Identification Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 438 NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision Technical Service Bulletin # 8918A9 Date: 890915 EVP Sensor - Manual Revision ENGINE EMISSIONS DIAGNOSTIC MANUALS, VOLUME H - 1985 THROUGH 1989 - EGR VALVE POSITION SENSOR (EVP) DIAGNOSTIC PROCEDURES REVISED Article No. 89-18A-9 FORD: 1985-89 CROWN VICTORIA, ESCORT 1985-88 EXP 1985-86 LTD 1985-89 MUSTANG, TEMPO, THUNDERBIRD 1986-89 TAURUS 1988-89 FESTIVA 1989 PROBE LINCOLN-MERCURY: 1985-86 CAPRI 1985-89 CONTINENTAL, COUGAR, GRAND MARQUIS 1985-87 LYNX 1985-89 MARK VII 1985-86 MARQUIS 1985-89 TOPAZ, TOWN CAR 1986-89 SABLE 1987-89 TRACER MERKUR: 1986-89 XR4TI 1988-89 SCORPIO LIGHT TRUCK: 1985-89 BRONCO, BRONCO II, ECONOLINE, F-150, F-250, F-350, RANGER 1986-89 AEROSTAR ISSUE: The EGR Valve Position Sensor (EVP) diagnostic procedures in 1985 through 1989 Engine Emissions Diagnosis Shop Manuals, Volume H, have been revised. EVP Sensors may exhibit internal wear problems that can cause driveability symptoms and display a Continuous Self-Test Code 32. This is not associated to correcting the problem using the existing diagnostic procedures. ACTION: Refer to the pages following this TSB article for the revised diagnostic procedures. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 680000 1985 Pinpoint Tests - DM - EGR, EVP and EVR Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 443 1985 EEC IV - Pinpoint Tests - All Vehicles 22-77 EGR Valve Position Sensor (EVP) EGR Valve Regulator (EVR) Pinpoint DM Test 1985 Pinpoint Tests - Fa - Neutral Drive Switch -A/C Input Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 444 1985 22-78 EEC IV - Pinpoint Tests - All Vehicles Neutral Drive Switch FA A/C Input PinpointTest 1986 (EGR) Systems Functional Diagnosis 1986 Exhaust Gas Recirculation (EGR) Systems 6-11 Functional Diagnosis Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 445 PORTED EGR VALVE 1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked, crimped or broken hoses. 2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating temperature. 3. Install a tachometer. 4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (EFI engines only). 5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose. 6. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If necessary, adjust idle speed to the emission decal specification. 7. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand vacuum pump. 8. When vacuum is applied to the EGR valve and any of the following occur, replace the valve: ^ Engine does not stall. ^ Idle speed does not drop more than 100 rpm. ^ Idle speed does not return to normal (+/- 25 rpm) after the vacuum is removed. 9. Reconnect the idle air bypass valve electrical connector. 10. Unplug and reconnect the EGR vacuum supply hose. 11. The EGR system is OK, refer to the Diagnostic Routines in Section 2. 1986 6-12 Exhaust Gas Recirculation (EGR) Systems Functional Diagnosis ELECTRONIC VALVE 1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked, crimped or broken hoses. 2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating temperature. 3. Install a tachometer. 4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (EFI engines only). Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 446 5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose. 6. Disconnect the 9G428 EVP sensor electrical connector mounted on top of the 9H473 valve. 7. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If necessary, adjust idle speed to the emission decal specification. 8. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand vacuum pump. 9. When vacuum is applied to the EGR valve and any of the following occur, replace the valve: ^ Engine does not stall. ^ Idle speed does not drop more than 100 rpm. ^ Idle speed does not return to normal (+/- 25 rpm) after the vacuum is removed. 10. Reconnect the idle air bypass valve electrical connector. 11. Unplug and reconnect the EGR vacuum supply hose. 12. Reconnect the EVP sensor electrical connector. 13. The EGR valve is OK, REPLACE EVP sensor if the Continuous Code 32 was present. If the Continuous Code 32 was not present, refer to the Diagnostic Routines in Section 2. 1986 Quick Test: Continuous Self-Test 6.0 EEC IV - Quick Test - All Engines 18-13 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 447 QUICK TEST: Continuous Self-Test 6.0 1986 18-14 EEC IV-Quick Test-All Engines QUICK TEST: Continuous Self-Test 6.0 Pinpoint Test - DN - EGR - EVP & EVR Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 448 1986 EEC IV-Pinpoint Tests - All Vehicles 21-95 EGR Valve Position Sensor (EVP) PinpointTest DN EGR Valve Regulator (EVR) Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 449 21-96 1986 EEC IV-Pinpoint Tests-All Vehicles EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Valve Regulator (EVR) Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 450 EEC IV-Pinpoint Tests-All Vehicles 1986 21-97A EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Valve Regulator (EVR) Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 451 1986 21-97B EEC IV-Pinpoint Tests-All Vehicles EGR Valve Position Sensor (EVP) EGR Valve Regulator (EVR) Pinpoint Test DN Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 452 1986 EEC IV-Pinpoint Tests-All Vehicles 21-98 EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Valve Regulator (EVR) 1987 (EGR) Systems - Functional Diagnosis 1987 6-11 Exhaust Gas Recirculation (EGR) Systems Functional Diagnosis PORTED EGR VALVE 1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked, crimped or broken hoses. 2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating temperature. 3. Install a tachometer, Rotunda 059-00010 or equivalent. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 453 4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (EFI engines only). 5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose. 6. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If necessary, adjust idle speed according to Section 4. 7. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand vacuum pump, Rotunda 021-00014 or equivalent. 8. When vacuum is applied to the EGR valve and any of the following occur, replace the valve: ^ Engine does not stall. ^ Idle speed does not drop more than 100 rpm. ^ Idle speed does not return to normal (+/- 25 rpm) after the vacuum is removed. 9. Reconnect the idle air bypass valve electrical connector. 10. Unplug and reconnect the EGR vacuum supply hose. 11. The EGR system is OK, refer to the Diagnostic Routines in Section 2. 1987 6-12 Exhaust Gas Recirculation (EGR) Systems Functional Diagnosis ELECTRONIC EGR (EEGR) VALVE 1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked, crimped or broken hoses. 2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating temperature. 3. Install a tachometer, Rotunda 059-00010 or equivalent. 4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (EFI engines only). 5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose. 6. Disconnect the 9G428 EVP sensor electrical connector mounted on top of the 9H473 valve. 7. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If necessary, adjust idle speed according to Section 4. 8. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand vacuum pump, Rotunda 021-00014 or equivalent. 9. When vacuum is applied to the EGR valve and any of the following occur, replace the valve: ^ Engine does not stall. ^ Idle speed does not drop more than 100 rpm. ^ Idle speed does not return to normal (+/- 25 rpm) after the vacuum is removed. 10. Reconnect the idle air bypass valve electrical connector. 11. Unplug and reconnect the EGR vacuum supply hose. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 454 12. Reconnect the EVP sensor electrical connector. 13. The EGR valve is OK, REPLACE EVP sensor if the Continuous Code 32 was present. If the Continous Code 32 was not present, refer to the Diagnostic Routines in Section 2. 1987 Quick Test: Continuous Self-Test - 6.0 1987 EEC-IV Quick Test-All Engines 16-15 QUICK TEST: Continuous 6.0 Self-Test Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 455 16-16 1987 EEC-IV Quick Test-All Engines QUICK TEST: Continuous 6.0 Self-Test Pinpoint Test - DN - EGR - EVP & EVR 1987 EEC IV - Pinpoint Tests - All Vehicles 19-91 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 456 EGR VALVE Position Sensor (EVP) EGR Valve Regulator (EVR) - 2.3L HSC, 2.5L, 5.0L SEFI Passenger Car and 4.9L and 5.0L Truck Pinpoint Test DN 19-92A 1987 EEC IV Pinpoint Tests-All Vehicles EGR Valve Position Sensor (EVP) EGR Valve Regulator (EVR) - 2.3L HSC, 2.5L, Pinpoint Test DN 5.0L SEFI Passenger Car and 4.9L and 5.0L Truck Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 457 1987 EEC IV-Pinpoint Tests-All Vehicles 19-92B EGR Valve Position Sensor (EVP) EGR Valve Regulator (EVR) - 2.3L HSC, 2.5L, 5.0L SEFI Passenger Car and 4.9L and 5.0L Truck Pinpoint Test DN Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 458 1987 19-93-A EEC IV-Pinpoint Tests-All Vehicles EGR Valve Position Sensor (EVP) EGR Valve Regulator (EVR) - 2.3L HSC, 2.5L, 5.0L SEFI Passenger Car 4.9L and 5.0L Truck Pinpoint Test DN Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 459 EEC IV-Pinpoint Tests-All Vehicles 1987 19-94 EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Valve Regulator (EVR) (EGR) Systems - Functional Diagnosis 1988 Exhaust Gas Recirculation (EGR) Systems 6-11 Functional Diagnosis Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 460 PORTED EGR VALVE 1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked, crimped or broken hoses. 2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating temperature. 3. Install a tachometer, Rotunda 059-00010 or equivalent. 4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (EFI engines only). 5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose. 6. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If necessary, adjust idle speed according to Section 4. 7. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand vacuum pump, Rotunda 021-00014 or equivalent. 8. When vacuum is fully applied to the EGR valve: ^ If idle speed drops more than 100 rpm or if engine stalls, perform the next step. Otherwise, replace the EGR valve. ^ Remove the vacuum from the EGR valve. If idle speed does not return to normal (+/- 25 rpm), replace the EGR valve. 9. Reconnect the idle air bypass valve electrical connector. 10. Unplug and reconnect the EGR vacuum supply hose. 11. The EGR system is OK, refer to the Diagnostic Routines in Section 2. 6-12 1988 Exhaust Gas Recirculation (EGR) Systems Functional Diagnosis ELECTRONIC EGR (EEGR) VALVE 1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked, crimped or broken hoses. 2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating temperature. NOTE: The EVR solenoid has a constant internal leak. You will notice a small vacuum signal. This signal should be less than 2-1/2 in-Hg at idle. 3. Install a tachometer, Rotunda 059-00010 or equivalent. 4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (1.9L EFI engines only). 5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose. 6. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If necessary, adjust idle speed according to Section 4. 7. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand vacuum pump, Rotunda 021-00014 or equivalent. 8. When vacuum is applied to the EGR valve and any of the following occur, replace the valve: ^ Engine does not stall. ^ Idle speed does not drop more than 100 rpm. ^ Idle speed does not return to normal (+/- 25 rpm) after the vacuum is removed. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 461 9. Reconnect the idle air bypass valve electrical connector. 10. Unplug and reconnect the EGR vacuum supply hose. 11. The EGR is OK, REPLACE EVP sensor if the Continuous Code 32 was present. If the Continuous Code 32 was not present, refer to the Diagnostic Routines in Section 2. Quick Test:Continuous Self-Test - 6.0 1988 EEC-IV - Quick Test - All Engines 16-15 QUICK TEST: Continuous Self-Test 6.0 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 462 1988 16-16 EEC-IV - Quick Test - All Engines QUICK TEST: Continuous 6.0 Self-Test Pinpoint Test - DN - EGR - EVP & EVR Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 463 EEC-IV - Pinpoint Tests - All Vehicles 1988 19-101 EGR Valve Position Sensor (EVP) EGR Valve Regulator (EVR) Pinpoint Test DN Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 464 19-102 1988 EEC-IV - Pinpoint Tests - All Vehicles EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Valve Regulator (EVR) Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 465 1988 EEC-IV - Pinpoint Tests - All Vehicles 19-102A EGR Valve Position Sensor (EVP) EGR Valve Regulator (EVR) Pinpoint Test DN Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 466 1988 19-103 EEC-IV - Pinpoint Tests - All Vehicles EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Valve Regulator (EVR) Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 467 1988 EEC-IV - Pinpoint Tests - All Vehicles 19-104 EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Valve Regulator (EVR) (EGR) Systems - Functional Diagnosis 1989 6-11 Exhaust Gas Recirculation (EGR) Systems Functional Diagnosis Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 468 PORTED EGR VALVE 1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked, crimped or broken hoses. 2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating temperature. 3. Install a tachometer, Rotunda 059-00010 or equivalent. 4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (EFI engines only). 5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose. 6. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If necessary, adjust idle speed according to Section 4. 7. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand vacuum pump, Rotunda 021-00014 or equivalent. 8. When vacuum is fully applied to the EGR valve: ^ If idle speed drops more than 100 rpm or if engine stalls, perform the next step. Otherwise, for vacuum leak at EGR valve, replace the valve. ^ If EGR passages are blocked, clean the valve using Rotunda 021-80056 EGR valve cleaner. ^ Remove the vacuum from the EGR valve. If idle speed does not return to normal (+/- 25 rpm), check for contamination, clean the valve. ^ Make sure there is no sand left in the valve or pick-up tube. Replace the valve if necessary. 9. Reconnect the idle air bypass valve electrical connector. 10. Unplug and reconnect the EGR vacuum supply hose. 11. The EGR system is OK, refer to the Diagnostic Routines in Section 2. 1989 6-12 Exhaust Gas Recirculation (EGR) Systems Functional Diagnosis ELECTRONIC EGR (EEGR) VALVE 1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked, crimped or broken hoses. 2. Make certain there is less than 2.5 in-Hg vacuum to the EGR valve at idle with the engine at normal operating temperature. NOTE: The EVR solenoid has a constant internal leak. You will notice a small vacuum signal. This signal should be less than 1.0 in-Hg at idle. 3. Install a tachometer, Rotunda 059-00010 or equivalent. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 469 4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (1.9L EFI engines only). 5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose. 6. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If necessary, adjust idle speed according to Section 4. 7. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand vacuum pump, Rotunda 021-00014 or equivalent. 8. When vacuum is applied to the EGR valve and any of the following occur: ^ Engine does not stall ^ Idle speed does not drop more than 100 rpm ^ Idle speed does not return to normal (+/- 25 rpm) after the vacuum is removed Then: ^ For vacuum leak at EGR valve, replace the valve. ^ Check for contamination, clean the EGR valve, using Rotunda 021-80056 EGR valve cleaner or equivalent. ^ Make sure there is no sand left in the valve. ^ Replace the EGR valve if necessary. 9. Reconnect the idle air bypass valve electrical connector. Unplug and reconnect the EGR vacuum supply hose. 10. If EGR valve is OK, REPLACE EVP sensor if Continuous Code 32 was present. If the Continuous Code 32 was not present, refer to the Diagnostic Routines in Section 2. Quick Test:Continuous Self-Test - 6.0 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 470 1989 EEC-IV - Quick Test - All Engines 14-17 QUICK TEST: Continuous 6.0 Self-Test Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 471 1989 14-18 EEC-IV - Quick Test - All Engines QUICK TEST: Continuous 6.0 Self-Test 1989 EEC-IV - Quick Test - All Engines 14-19 QUICK TEST: Continuous 6.0 Self-Test Quick Test:Diagnostic By Symptom - 7.0 1989 14-20 EEC-IV - Quick Test - All Engines QUICK TEST: Diagnostic By Symptom 7.0 A DIAGNOSTIC BY SYMPTOM SPECIAL NOTES: ^ Verify that a Pass Code 11 was received in Key On Engine Off, Engine Running and Continuous Self-Tests before continuing with this test. ^ If a symptom is present and the EEC system is suspected, Go to part B of Diagnostic By Symptom. If the EEC system is not suspected, GO to Section 2, Diagnostic Routines. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 472 Pinpoint Test - DN - EGR - EVP & EVR 1989 EEC-IV - Pinpoint Tests-All Vehicles 17-133 EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Vacuum Regulator Solenoid (EVR) Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 473 1989 17-134 EEC-IV - Pinpoint Tests - All Vehicles EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Vacuum Regulator Solenoid (EVR) Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 474 1989 EEC-IV-Pinpoint Tests - All Vehicles 17-134A Pinpoint Test DN EGR Valve Position Sensor (EVP) EGR Vacuum Regulator Solenoid (EVR) Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 475 1989 17-135 EEC-IV - Pinpoint Tests - All Vehicles EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Vacuum Regulator Solenoid (EVR) Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 476 1989 EEC-IV - Pinpoint Tests - All Vehicles 17-136A EGR Valve Position Sensor (EVP) 04GPinpoint Test DN EGR Vacuum Regulator Solenoid (EVR) Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > Page 477 EGR Valve Position Sensor: Locations Attached To EGR Valve Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > Page 478 EGR Valve Position Sensor: Description and Operation The EVP Sensor provides EEC System with a signal indicating position of the EGR valve. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Description and Operation Knock Sensor: Description and Operation The Knock Sensor, is a piezoelectric accelerometer with the sensor designed to resonate at approximately the same frequency as the engine knock frequency. The sensor uses the resonant frequency to mechanically amplify the vibrations. This method allows relatively large signals to be achieved without electrical amplification and with small package size. The sensor has a thin circular piezoelectric ceramic disk which is bonded to a metal diaphragm. Electrical connections are made through a two pin integral connector. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Description and Operation > Page 482 Knock Sensor: Testing and Inspection Ford provides trouble code/symptom driven diagnostics for this component. For complete diagnosis and pinpoint testing, refer to Computers and Control Systems, Testing and Inspection. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications MANIFOLD ABSOLUTE AND BAROMETRIC PRESSURE SENSORS Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 486 Right Hand Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 487 Manifold Pressure/Vacuum Sensor: Testing and Inspection Ford provides trouble code/symptom driven diagnostics for this component. For complete diagnosis and pinpoint testing, refer to Computers and Control Systems, Testing and Inspection. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Engine - Lack of Power/No Start Diagnosis Oxygen Sensor: Technical Service Bulletins Engine - Lack of Power/No Start Diagnosis Article No. 91-12-11 06/12/91 LACK OF POWER 7.5L, 5.8L, 5.0L, 4.9L - CATALYTIC CONVERTER DIAGNOSTIC TIPS LIGHT TRUCK: 1986-91 BRONCO, ECONOLINE, F-150-350 SERIES 1988-91 F SUPER DUTY, F47 ISSUE: Lack of power or a no start condition may be diagnosed as an exhaust restriction caused by a plugged catalytic converter. A plugged catalytic converter (internal deterioration) is usually caused by abnormal engine operation. ACTION: Diagnose the catalytic converter to confirm internal failure. Refer to the Catalyst and Exhaust System Diagnostic Section, in the Engine/Emissions Diagnostic Shop Manual and the following procedures for service details. 1. Lack of proper HEGO operation may cause, or be the result of a rich or lean fuel condition, which could cause additional heat in the catalyst. Perform self test KOEO and KOER, service any codes. NOTE: IF TWO DIGIT CODES 41, 42, 85 OR THREE DIGIT CODES 171, 172, 173, 179, 181, 182, 183 AND 565 ARE RECEIVED, CHECK FOR PROPER HEGO GROUND. If the HEGO ground is good, the following areas may be at fault: ^ Ignition Coil ^ Distributor Cap ^ Distributor Rotor ^ Fouled Spark Plug ^ Spark Plug Wires ^ Air Filter ^ Stuck Open Injector ^ Fuel Contamination Engine OIL ^ Manifold Leaks Intake/ Exhaust ^ Fuel Pressure ^ Poor Power Ground ^ Engine Not At Normal Operating Temperature ^ HEGO Sensor 2. Spark timing that is retarded from specification may increase exhaust gas temperature and shorten catalyst life. Refer to the following procedure for service details. a. Check spark timing. Check base timing with spout disconnected. Set base timing to the specification on the vehicle emission decal. b. Check computed timing with spout connected. NOTE: COMPUTED TIMING IS EQUAL TO BASE TIMING PLUS 20~ BTDC +/- 3~. 3. Misfiring spark plugs may cause an unburned fuel air mixture to pass through the catalyst, which could cause higher than normal catalyst temperatures. Refer to the following procedure for service details. a. Check secondary ignition, hook the vehicle up to an engine analyzer and check for a secondary ignition misfire. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Engine - Lack of Power/No Start Diagnosis > Page 492 NOTE: SERVICE ANY ITEM THAT IS NOT PERFORMING AT PROPER SPECIFICATIONS BEFORE CONTINUING. 4. Fuel pressure that is too high may cause rich air fuel mixtures to pass through the catalyst which could cause higher than normal catalyst temperatures. Refer to the following procedure for service details. a. Check fuel pressure, install fuel pressure gauge, start and run the engine at idle. Fuel pressures between 28 and 34 PSI are typical (4.9L typically is 15 PSI higher). b. Disconnect the vacuum line going to the fuel pressure regulator. Fuel pressure typically jumps to 40 PSI +/- 3 PSI (4.9L typically is 15 PSI higher). Visually inspect vacuum line for raw fuel. NOTE: FUEL PRESSURES ABOVE THESE VALUES SHOULD BE CORRECTED. HOWEVER, THIS MAY NOT BE THE CAUSE OF THE CONCERN. SERVICE AS NECESSARY. 5. Throttle plates in the throttle body not returning to the proper closed position may cause excessive catalyst temperatures during downhill grades. Refer to the following procedure for service details. a. Visually inspect the throttle body and linkage for: ^ Binding or sticking throttle linkage. ^ Tight speed control linkage or cable. ^ Vacuum line interference. ^ Electrical harness interference. NOTE: AFTERMARKET GOVERNORS, THROTTLE LINKAGE AND CABLES ASSOCIATED WITH POWER TAKE-OFF UNITS, MAY ALSO INTERFERE WITH PROPER THROTTLE RETURN. SERVICE AS NECESSARY. 6. It is extremely important that all systems related to the engine and emission systems operate properly. a. Visually inspect the engine compartment to make sure all vacuum hoses and spark plug wires are properly routed and securely connected. b. Inspect all wiring harnesses and connectors for insulation damage, burned, overheated, loose or broken conditions. c. Verify proper operation of the thermactor system. Thermactor systems that fail to dump thermactor air to the atmosphere properly or at the correct time can cause high catalyst temperatures. d. Visually inspect thermactor system for damaged or kinked hoses and perform a function test on following components: air control valve, check valve, silencer, filter and the air bypass solenoid. e. Verify proper operation of the engine cooling system thermostat. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under Basic Warranty Coverage, Emissions Warranty Coverage OPERATION DESCRIPTION TIME 911211A Diagnostics - Perform 0.5 Hrs. KOEO And KOER Self Tests 911211B Timing - Check Or Adjust 0.5 Hrs. Spark Timing, Check Computed Timing And Check Secondary Ignition System With Engine Analyzer. 911211C Check - Fuel Pressure And 0.2 Hrs. Inspect Vacuum Line For Raw Fuel. 911211D Inspect - Throttle Body And 0.1 Hrs. Linkage. 911211E Inspect - Vacuum Hoses, 0.1 Hrs. Electrical Harnesses, Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Engine - Lack of Power/No Start Diagnosis > Page 493 Connectors And Spark Plug Wires For Routing Damage. 911211F Thermactor System - 0.3 Hrs. Inspect For Proper Operation And Damaged Component. Includes Function Check Of Air Control Valve, Thermactor Air Bypass Solenoid, Check Valves, Silencer And Filter. 911211G Thermostat - Check For 0.2 Hrs. Proper Operation. DEALER CODING BASIC PART NO. CONDITION CODE 5E212 25 OASIS CODES: 403000, 603300, 614000 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Engine - Lack of Power/No Start Diagnosis > Page 494 Oxygen Sensor: Technical Service Bulletins EGO Sensors - Silicone Contamination Article No. 93-23-6 11/10/93 ^ EGO SENSORS - SILICONE CONTAMINATION ^ ENGINE - SEALANTS, LOW VOLATILITY SILICONE REQUIRED ^ EXHAUST SYSTEM - SILICONE CONTAMINATION OF EXHAUST GAS OXYGEN (EGO) SENSORS FORD: 1984-86 LTD 1984-88 EXP 1984-94 CROWN VICTORIA, ESCORT, MUSTANG, TEMPO, THUNDERBIRD 1986-94 TAURUS 1988-93 FESTIVA 1989-94 PROBE 1994 ASPIRE LINCOLN-MERCURY: 1984-86 CAPRI, MARQUIS 1984-87 LYNX 1984-92 MARK VII 1984-94 CONTINENTAL, COUGAR, GRAND MARQUIS, TOPAZ, TOWN CAR 1986-94 SABLE 1988-89 TRACER 1991-94 CAPRI, TRACER 1993-94 MARK VIII MERKUR: 1985-89 XR4TI 1988-89 SCORPIO LIGHT TRUCK: 1983-94 RANGER 1984-90 BRONCO II 1984-94 BRONCO, ECONOLINE, F-150-350 SERIES 1986-94 AEROSTAR 1988-94 F-47, F-53 1991-94 EXPLORER 1993-94 VILLAGER This TSB article is being republished in its entirety to update model applicability and to revise the part number of the Low Volatility Sealant. ISSUE: EGO sensors can be contaminated if volatile types of silicone are used when servicing the engine. Volatile silicones can migrate throughout the system during the first one hundred hours of service. They are commonly found in liquid "silicone rubber" sealants and gasket material. These products are commonly sold in tubes and caulking-type cartridges. ACTION: When service is performed on the engine, only use new low volatility silicone sealant (F1AZ-19662-A) where specified. Also replace the contaminated EGO sensor if required. CAUTION: DO NOT SUBSTITUTE CONVENTIONAL SILICONE RUBBER SEALANTS WHEN LOW VOLATILITY SILICONE SEALANT IS SPECIFIED. PART NUMBER PART NAME CLASS F1AZ-19662-A Low Volatility RTV Sealant B OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 89-14-5 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Engine - Lack of Power/No Start Diagnosis > Page 495 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 403000, 490000, 499000 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Page 496 Engine View Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Description and Operation > Exhaust Gas Oxygen Sensor Oxygen Sensor: Description and Operation Exhaust Gas Oxygen Sensor The EGO Sensor supplies ECA with a signal which indicates either a rich or lean condition during engine operation. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Description and Operation > Exhaust Gas Oxygen Sensor > Page 499 Oxygen Sensor: Description and Operation Heated Exhaust Gas Oxygen Sensor The Heated Exhaust Gas Oxygen Sensor (HEGO), supplies the ECA with a signal which indicates a rich or lean condition during engine operation. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Description and Operation > Page 500 Oxygen Sensor: Testing and Inspection Ford provides trouble code/symptom driven diagnostics for this component. For complete diagnosis and pinpoint testing, refer to Computers and Control Systems, Testing and Inspection. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Locations Power Steering Pressure Switch: Locations In Power Steering Hose, Near Steering Gear Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Locations > Page 504 Power Steering Pressure Switch: Testing and Inspection Ford provides trouble code/symptom driven diagnostics for this component. For complete diagnosis and pinpoint testing, refer to Computers and Control Systems, Testing and Inspection. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Description and Operation Pressure Feedback Exhaust Sensor: Description and Operation The Pressure Feedback Electronic (PFE) EGR transducer converts a varying exhaust pressure signal into a proportional analog voltage which is digitized by the EEC IV processor. The EEC IV processor uses the signal received from the PFE transducer to complete the optimum EGR flow. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Throttle Position Sensor - Request For Return Throttle Position Sensor: Technical Service Bulletins Throttle Position Sensor - Request For Return Number: 92686 To: All Ford and Lincoln-Mercury Dealers Subject: Request for Return of Throttle Position Sensor E5ZZ-9B989-B (CX-1022) and E6ZZ-9B989-B (CX-1130) Because the subject parts may not meet Ford's high quality requirements, they should be withdrawn from all inventories. All used E5ZZ-9B989-B (CX-1022) and E6ZZ-9B989-B (CX-1130) should be returned to your facing PDC within 30 days from the date of this letter. Use the least expensive mode of transportation for your return. The subject parts are obsolete and replaced by E7SZ-9B989-B (CX-1200), which is available for ordering immediately. You are requested to complete a separate FPS-340 form in accordance with the instructions on the front of the form. Annotate "Return Per FPSD Instructions Purge No. PN 1026" in the Customer's Detail Explanation Section and use Reason Code J (Unsatisfactory Service Stock). You will receive full credit in your parts statement for the price of each unused part returned, plus the prepaid transportation cost. In order to receive credit, all parts must be received at the Parts Distribution Center within 30 days from the date of this letter. Material other than subject parts received on this return will be sent back to you freight collect. Any questions should be referred to your Zone Manager or facing PDC Manager. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Throttle Position Sensor - Request For Return > Page 512 Throttle Position Sensor: Technical Service Bulletins Throttle Position Sensor - Diagnostic Tips Article No. 85-20-11 SELF-TEST CODE 53 - EEC IV - THROTTLE POSITION SENSOR DIAGNOSTIC TIP FORD 1985-86 ESCORT, EXP, TEMPO, MUSTANG, LTD, THUNDERBIRD LINCOLN-MERCURY 1985-86 LYNX, TOPAZ, CAPRI, MARQUIS, COUGAR LIGHT TRUCK 1985-86 RANGER, BRONCO II, ECONOLINE, F-SERIES CALIBRATION: All with EEC IV WARNING: This modification is authorized only for the listed engines. Performing this modification on other engine calibrations is unauthorized and could create liability under applicable federal or local laws. A new design Throttle Position Sensor (TPS) has been released for all 1986 EEC IV applications. The new TPS is designed to eliminate a false Self-Test Code 53. A Code 53 indicates the TPS system has failed at the wide open throttle position (approximately 5.0 volts), The new TPS eliminates false Code 53 by limiting the wide open throttle voltage to 4.75 volts. With the new TPS, Code 53 will only result from a circuit or TPS malfunction. The new Throttle Position Sensors can be used to replace faulty sensors on 1985 vehicles. If the old design service part is used, a false Code 53 may result. PART NUMBER PART NAME CLASS E6DZ-9B989-A Throttle Position Sensor C E6TZ-9B989-C Throttle Position Sensor WC E6DZ-9B989-C Throttle Position Sensor WC E6FZ-9B989-A Throttle Position Sensor B E6ZZ-9B989-A Throttle Position Sensor B E6ZZ-9B989-B Throttle Position Sensor WC E6TZ-9B989-A Throttle Position Sensor C OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Throttle Position Sensor - Request For Return > Page 513 Throttle Position Sensor: Technical Service Bulletins Throttle Position Sensor - Application Chart EEC-IV THROTTLE POSITION SENSOR-APPLICATION CHART-SERVICE TIP Article No. 89-16-4 FORD: 1984-88 CROWN VICTORIA, ESCORT, EXP, MUSTANG, TAURUS, TEMPO, THUNDERBIRD LINCOLN-MERCURY: 1984-88 COUGAR, GRAND MARQUIS, LYNX, MARK VI, MARK VII, SABLE, TOPAZ, TOWN CAR LIGHT TRUCK: 1984-88 ALL LIGHT TRUCK LINES ISSUE: A quick reference throttle position sensor (TPS) application chart has been put together to assist technicians in correct part useage. If the wrong TPS is installed, it could fail prematurely. ACTION: Refer to one of the following TPS service replacement charts to make sure that the correct service part is installed. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Throttle Position Sensor - Request For Return > Page 514 OASIS CODES: 680000 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Throttle Position Sensor - Request For Return > Page 515 Throttle Position Sensor: Technical Service Bulletins TPS Mounting Screws - Hard to Remove THROTTLE POSITION SENSOR-MOUNTING SCREWS HARD TO REMOVE-SERVICE TIP Article No. 89-14-7 FORD: 1983-89 CROWN VICTORIA, MUSTANG, TEMPO, THUNDERBIRD 1984-89 ESCORT 1986-89 TAURUS LINCOLN-MERCURY: 1983-89 CONTINENTAL, COUGAR, GRAND MARQUIS, MARK VII, TOPAZ, TOWN CAR 1984-87 LYNX MERKUR: 1985-89 ALL MERKUR LINES LIGHT TRUCK: 1983-89 ALL LIGHT TRUCK LINES ISSUE: All Throttle Position Sensor (TPS) mounting screws have a "Pozidrive" head. The "Pozidrive" head looks a lot like a Phillips screw head. Use of a Phillips head screwdriver to remove a "Pozidrive" screw will normally result in a rounded or damaged screw head. Many technicians think it is an overtorqued or "frozen" screw. An adhesive was also used as a thread sealant starting with the 1988 model year. This adhesive requires still more effort to loosen and remove the screw. ACTION: To prevent rounded or damages screw heads when servicing the TPS mounting screws, technicians should always use a # 2 "Pozidrive" screwdriver. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 4800, 680000 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 516 THROTTLE POSITION SENSOR SPECIFICATIONS Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 517 Engine View Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 518 Throttle Position Sensor: Description and Operation The Throttle Position (TP) Sensor (Rotary), Figure 1 supplies the ECA with a signal proportional to opening angle of carburetor throttle plates. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 519 Throttle Position Sensor: Testing and Inspection Ford provides trouble code/symptom driven diagnostics for this component. For complete diagnosis and pinpoint testing, refer to Computers and Control Systems, Testing and Inspection. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 520 Throttle Position Sensor: Adjustments ADJUSTMENT This procedure can be used to check and/or adjust level C sensors only: 1. Install an EEC-IV Breakout Box, Rotunda T83L-50 EEC-IV, or equivalent. 2. Attach a DVOM, Rotunda 014-00407 or equivalent, on 20V scale. Connect the positive lead (+) to test Pin 47 and the negative lead (-) to test Pin 46. 3. Turn ignition key to Run position (do not start engine). 4. Adjust TP Sensor (rotate) until the DVOM reads 1.0V (0.9-1.1). 5. Tighten TP Sensor screws to 1.2-1.8 N-m (11-16 lb-in). 6. While watching the DVOM, move the throttle to wide open and back to idle position. For proper operation, the DVOM should move from 1.0 to at least 4.0 and back to 1.0V. 7, Perform EEC-IV Quick Test. Refer to Powertrain Management/Computers and Control Systems/System Diagnosis Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Specifications VEHICLE SPEED SENSOR Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Specifications > Page 524 Vehicle Speed Sensor: Locations At Transmission Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Testing and Inspection > Speed Control/Speedometer Vehicle Speed Sensor: Testing and Inspection Speed Control/Speedometer 1980-87 Models Exc. 1983-87 Ranger, 1984-87 Bronco II & 1986-87 Aerostar 1. Disconnect 6 way connector from amplifier assembly, then connect an ohmmeter between dark green wire w/white stripe and black wire on 1980 E-100-350, 1981-83 F-100-350 models and Bronco, and 1984-87 F-150-350 and Bronco, or green and black wire on 1980 F-100-350 and 1981-83 E-100-350 models and 1984-87 E-150-350 at the speed sensor end. A reading of 40 ohms should be obtained. A reading of 0 ohms indicates a shorted coil and an infinity reading indicates an open coil. 2. Replace sensor if a correct reading has not been obtained. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Testing and Inspection > Speed Control/Speedometer > Page 527 Vehicle Speed Sensor: Testing and Inspection Computer Related Diagnostic Information Ford provides trouble code/symptom driven diagnostics for this component. For complete diagnosis and pinpoint testing, refer to Computers and Control Systems, Testing and Inspection. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Testing and Inspection > Page 528 Vehicle Speed Sensor: Service and Repair 1. Separate electrical connector leading to the amplifier assembly. 2. Disconnect upper and lower speedometer cables at the speed sensor. Remove speed sensor. 3. Reverse procedure to install. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision Technical Service Bulletin # 8918A9 Date: 890915 EVP Sensor - Manual Revision ENGINE EMISSIONS DIAGNOSTIC MANUALS, VOLUME H - 1985 THROUGH 1989 - EGR VALVE POSITION SENSOR (EVP) DIAGNOSTIC PROCEDURES REVISED Article No. 89-18A-9 FORD: 1985-89 CROWN VICTORIA, ESCORT 1985-88 EXP 1985-86 LTD 1985-89 MUSTANG, TEMPO, THUNDERBIRD 1986-89 TAURUS 1988-89 FESTIVA 1989 PROBE LINCOLN-MERCURY: 1985-86 CAPRI 1985-89 CONTINENTAL, COUGAR, GRAND MARQUIS 1985-87 LYNX 1985-89 MARK VII 1985-86 MARQUIS 1985-89 TOPAZ, TOWN CAR 1986-89 SABLE 1987-89 TRACER MERKUR: 1986-89 XR4TI 1988-89 SCORPIO LIGHT TRUCK: 1985-89 BRONCO, BRONCO II, ECONOLINE, F-150, F-250, F-350, RANGER 1986-89 AEROSTAR ISSUE: The EGR Valve Position Sensor (EVP) diagnostic procedures in 1985 through 1989 Engine Emissions Diagnosis Shop Manuals, Volume H, have been revised. EVP Sensors may exhibit internal wear problems that can cause driveability symptoms and display a Continuous Self-Test Code 32. This is not associated to correcting the problem using the existing diagnostic procedures. ACTION: Refer to the pages following this TSB article for the revised diagnostic procedures. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 680000 1985 Pinpoint Tests - DM - EGR, EVP and EVR Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 534 1985 EEC IV - Pinpoint Tests - All Vehicles 22-77 EGR Valve Position Sensor (EVP) EGR Valve Regulator (EVR) Pinpoint DM Test 1985 Pinpoint Tests - Fa - Neutral Drive Switch -A/C Input Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 535 1985 22-78 EEC IV - Pinpoint Tests - All Vehicles Neutral Drive Switch FA A/C Input PinpointTest 1986 (EGR) Systems Functional Diagnosis 1986 Exhaust Gas Recirculation (EGR) Systems 6-11 Functional Diagnosis Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 536 PORTED EGR VALVE 1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked, crimped or broken hoses. 2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating temperature. 3. Install a tachometer. 4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (EFI engines only). 5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose. 6. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If necessary, adjust idle speed to the emission decal specification. 7. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand vacuum pump. 8. When vacuum is applied to the EGR valve and any of the following occur, replace the valve: ^ Engine does not stall. ^ Idle speed does not drop more than 100 rpm. ^ Idle speed does not return to normal (+/- 25 rpm) after the vacuum is removed. 9. Reconnect the idle air bypass valve electrical connector. 10. Unplug and reconnect the EGR vacuum supply hose. 11. The EGR system is OK, refer to the Diagnostic Routines in Section 2. 1986 6-12 Exhaust Gas Recirculation (EGR) Systems Functional Diagnosis ELECTRONIC VALVE 1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked, crimped or broken hoses. 2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating temperature. 3. Install a tachometer. 4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (EFI engines only). Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 537 5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose. 6. Disconnect the 9G428 EVP sensor electrical connector mounted on top of the 9H473 valve. 7. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If necessary, adjust idle speed to the emission decal specification. 8. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand vacuum pump. 9. When vacuum is applied to the EGR valve and any of the following occur, replace the valve: ^ Engine does not stall. ^ Idle speed does not drop more than 100 rpm. ^ Idle speed does not return to normal (+/- 25 rpm) after the vacuum is removed. 10. Reconnect the idle air bypass valve electrical connector. 11. Unplug and reconnect the EGR vacuum supply hose. 12. Reconnect the EVP sensor electrical connector. 13. The EGR valve is OK, REPLACE EVP sensor if the Continuous Code 32 was present. If the Continuous Code 32 was not present, refer to the Diagnostic Routines in Section 2. 1986 Quick Test: Continuous Self-Test 6.0 EEC IV - Quick Test - All Engines 18-13 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 538 QUICK TEST: Continuous Self-Test 6.0 1986 18-14 EEC IV-Quick Test-All Engines QUICK TEST: Continuous Self-Test 6.0 Pinpoint Test - DN - EGR - EVP & EVR Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 539 1986 EEC IV-Pinpoint Tests - All Vehicles 21-95 EGR Valve Position Sensor (EVP) PinpointTest DN EGR Valve Regulator (EVR) Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 540 21-96 1986 EEC IV-Pinpoint Tests-All Vehicles EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Valve Regulator (EVR) Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 541 EEC IV-Pinpoint Tests-All Vehicles 1986 21-97A EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Valve Regulator (EVR) Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 542 1986 21-97B EEC IV-Pinpoint Tests-All Vehicles EGR Valve Position Sensor (EVP) EGR Valve Regulator (EVR) Pinpoint Test DN Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 543 1986 EEC IV-Pinpoint Tests-All Vehicles 21-98 EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Valve Regulator (EVR) 1987 (EGR) Systems - Functional Diagnosis 1987 6-11 Exhaust Gas Recirculation (EGR) Systems Functional Diagnosis PORTED EGR VALVE 1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked, crimped or broken hoses. 2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating temperature. 3. Install a tachometer, Rotunda 059-00010 or equivalent. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 544 4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (EFI engines only). 5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose. 6. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If necessary, adjust idle speed according to Section 4. 7. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand vacuum pump, Rotunda 021-00014 or equivalent. 8. When vacuum is applied to the EGR valve and any of the following occur, replace the valve: ^ Engine does not stall. ^ Idle speed does not drop more than 100 rpm. ^ Idle speed does not return to normal (+/- 25 rpm) after the vacuum is removed. 9. Reconnect the idle air bypass valve electrical connector. 10. Unplug and reconnect the EGR vacuum supply hose. 11. The EGR system is OK, refer to the Diagnostic Routines in Section 2. 1987 6-12 Exhaust Gas Recirculation (EGR) Systems Functional Diagnosis ELECTRONIC EGR (EEGR) VALVE 1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked, crimped or broken hoses. 2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating temperature. 3. Install a tachometer, Rotunda 059-00010 or equivalent. 4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (EFI engines only). 5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose. 6. Disconnect the 9G428 EVP sensor electrical connector mounted on top of the 9H473 valve. 7. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If necessary, adjust idle speed according to Section 4. 8. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand vacuum pump, Rotunda 021-00014 or equivalent. 9. When vacuum is applied to the EGR valve and any of the following occur, replace the valve: ^ Engine does not stall. ^ Idle speed does not drop more than 100 rpm. ^ Idle speed does not return to normal (+/- 25 rpm) after the vacuum is removed. 10. Reconnect the idle air bypass valve electrical connector. 11. Unplug and reconnect the EGR vacuum supply hose. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 545 12. Reconnect the EVP sensor electrical connector. 13. The EGR valve is OK, REPLACE EVP sensor if the Continuous Code 32 was present. If the Continous Code 32 was not present, refer to the Diagnostic Routines in Section 2. 1987 Quick Test: Continuous Self-Test - 6.0 1987 EEC-IV Quick Test-All Engines 16-15 QUICK TEST: Continuous 6.0 Self-Test Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 546 16-16 1987 EEC-IV Quick Test-All Engines QUICK TEST: Continuous 6.0 Self-Test Pinpoint Test - DN - EGR - EVP & EVR 1987 EEC IV - Pinpoint Tests - All Vehicles 19-91 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 547 EGR VALVE Position Sensor (EVP) EGR Valve Regulator (EVR) - 2.3L HSC, 2.5L, 5.0L SEFI Passenger Car and 4.9L and 5.0L Truck Pinpoint Test DN 19-92A 1987 EEC IV Pinpoint Tests-All Vehicles EGR Valve Position Sensor (EVP) EGR Valve Regulator (EVR) - 2.3L HSC, 2.5L, Pinpoint Test DN 5.0L SEFI Passenger Car and 4.9L and 5.0L Truck Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 548 1987 EEC IV-Pinpoint Tests-All Vehicles 19-92B EGR Valve Position Sensor (EVP) EGR Valve Regulator (EVR) - 2.3L HSC, 2.5L, 5.0L SEFI Passenger Car and 4.9L and 5.0L Truck Pinpoint Test DN Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 549 1987 19-93-A EEC IV-Pinpoint Tests-All Vehicles EGR Valve Position Sensor (EVP) EGR Valve Regulator (EVR) - 2.3L HSC, 2.5L, 5.0L SEFI Passenger Car 4.9L and 5.0L Truck Pinpoint Test DN Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 550 EEC IV-Pinpoint Tests-All Vehicles 1987 19-94 EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Valve Regulator (EVR) (EGR) Systems - Functional Diagnosis 1988 Exhaust Gas Recirculation (EGR) Systems 6-11 Functional Diagnosis Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 551 PORTED EGR VALVE 1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked, crimped or broken hoses. 2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating temperature. 3. Install a tachometer, Rotunda 059-00010 or equivalent. 4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (EFI engines only). 5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose. 6. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If necessary, adjust idle speed according to Section 4. 7. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand vacuum pump, Rotunda 021-00014 or equivalent. 8. When vacuum is fully applied to the EGR valve: ^ If idle speed drops more than 100 rpm or if engine stalls, perform the next step. Otherwise, replace the EGR valve. ^ Remove the vacuum from the EGR valve. If idle speed does not return to normal (+/- 25 rpm), replace the EGR valve. 9. Reconnect the idle air bypass valve electrical connector. 10. Unplug and reconnect the EGR vacuum supply hose. 11. The EGR system is OK, refer to the Diagnostic Routines in Section 2. 6-12 1988 Exhaust Gas Recirculation (EGR) Systems Functional Diagnosis ELECTRONIC EGR (EEGR) VALVE 1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked, crimped or broken hoses. 2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating temperature. NOTE: The EVR solenoid has a constant internal leak. You will notice a small vacuum signal. This signal should be less than 2-1/2 in-Hg at idle. 3. Install a tachometer, Rotunda 059-00010 or equivalent. 4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (1.9L EFI engines only). 5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose. 6. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If necessary, adjust idle speed according to Section 4. 7. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand vacuum pump, Rotunda 021-00014 or equivalent. 8. When vacuum is applied to the EGR valve and any of the following occur, replace the valve: ^ Engine does not stall. ^ Idle speed does not drop more than 100 rpm. ^ Idle speed does not return to normal (+/- 25 rpm) after the vacuum is removed. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 552 9. Reconnect the idle air bypass valve electrical connector. 10. Unplug and reconnect the EGR vacuum supply hose. 11. The EGR is OK, REPLACE EVP sensor if the Continuous Code 32 was present. If the Continuous Code 32 was not present, refer to the Diagnostic Routines in Section 2. Quick Test:Continuous Self-Test - 6.0 1988 EEC-IV - Quick Test - All Engines 16-15 QUICK TEST: Continuous Self-Test 6.0 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 553 1988 16-16 EEC-IV - Quick Test - All Engines QUICK TEST: Continuous 6.0 Self-Test Pinpoint Test - DN - EGR - EVP & EVR Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 554 EEC-IV - Pinpoint Tests - All Vehicles 1988 19-101 EGR Valve Position Sensor (EVP) EGR Valve Regulator (EVR) Pinpoint Test DN Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 555 19-102 1988 EEC-IV - Pinpoint Tests - All Vehicles EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Valve Regulator (EVR) Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 556 1988 EEC-IV - Pinpoint Tests - All Vehicles 19-102A EGR Valve Position Sensor (EVP) EGR Valve Regulator (EVR) Pinpoint Test DN Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 557 1988 19-103 EEC-IV - Pinpoint Tests - All Vehicles EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Valve Regulator (EVR) Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 558 1988 EEC-IV - Pinpoint Tests - All Vehicles 19-104 EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Valve Regulator (EVR) (EGR) Systems - Functional Diagnosis 1989 6-11 Exhaust Gas Recirculation (EGR) Systems Functional Diagnosis Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 559 PORTED EGR VALVE 1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked, crimped or broken hoses. 2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating temperature. 3. Install a tachometer, Rotunda 059-00010 or equivalent. 4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (EFI engines only). 5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose. 6. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If necessary, adjust idle speed according to Section 4. 7. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand vacuum pump, Rotunda 021-00014 or equivalent. 8. When vacuum is fully applied to the EGR valve: ^ If idle speed drops more than 100 rpm or if engine stalls, perform the next step. Otherwise, for vacuum leak at EGR valve, replace the valve. ^ If EGR passages are blocked, clean the valve using Rotunda 021-80056 EGR valve cleaner. ^ Remove the vacuum from the EGR valve. If idle speed does not return to normal (+/- 25 rpm), check for contamination, clean the valve. ^ Make sure there is no sand left in the valve or pick-up tube. Replace the valve if necessary. 9. Reconnect the idle air bypass valve electrical connector. 10. Unplug and reconnect the EGR vacuum supply hose. 11. The EGR system is OK, refer to the Diagnostic Routines in Section 2. 1989 6-12 Exhaust Gas Recirculation (EGR) Systems Functional Diagnosis ELECTRONIC EGR (EEGR) VALVE 1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked, crimped or broken hoses. 2. Make certain there is less than 2.5 in-Hg vacuum to the EGR valve at idle with the engine at normal operating temperature. NOTE: The EVR solenoid has a constant internal leak. You will notice a small vacuum signal. This signal should be less than 1.0 in-Hg at idle. 3. Install a tachometer, Rotunda 059-00010 or equivalent. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 560 4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (1.9L EFI engines only). 5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose. 6. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If necessary, adjust idle speed according to Section 4. 7. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand vacuum pump, Rotunda 021-00014 or equivalent. 8. When vacuum is applied to the EGR valve and any of the following occur: ^ Engine does not stall ^ Idle speed does not drop more than 100 rpm ^ Idle speed does not return to normal (+/- 25 rpm) after the vacuum is removed Then: ^ For vacuum leak at EGR valve, replace the valve. ^ Check for contamination, clean the EGR valve, using Rotunda 021-80056 EGR valve cleaner or equivalent. ^ Make sure there is no sand left in the valve. ^ Replace the EGR valve if necessary. 9. Reconnect the idle air bypass valve electrical connector. Unplug and reconnect the EGR vacuum supply hose. 10. If EGR valve is OK, REPLACE EVP sensor if Continuous Code 32 was present. If the Continuous Code 32 was not present, refer to the Diagnostic Routines in Section 2. Quick Test:Continuous Self-Test - 6.0 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 561 1989 EEC-IV - Quick Test - All Engines 14-17 QUICK TEST: Continuous 6.0 Self-Test Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 562 1989 14-18 EEC-IV - Quick Test - All Engines QUICK TEST: Continuous 6.0 Self-Test 1989 EEC-IV - Quick Test - All Engines 14-19 QUICK TEST: Continuous 6.0 Self-Test Quick Test:Diagnostic By Symptom - 7.0 1989 14-20 EEC-IV - Quick Test - All Engines QUICK TEST: Diagnostic By Symptom 7.0 A DIAGNOSTIC BY SYMPTOM SPECIAL NOTES: ^ Verify that a Pass Code 11 was received in Key On Engine Off, Engine Running and Continuous Self-Tests before continuing with this test. ^ If a symptom is present and the EEC system is suspected, Go to part B of Diagnostic By Symptom. If the EEC system is not suspected, GO to Section 2, Diagnostic Routines. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 563 Pinpoint Test - DN - EGR - EVP & EVR 1989 EEC-IV - Pinpoint Tests-All Vehicles 17-133 EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Vacuum Regulator Solenoid (EVR) Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 564 1989 17-134 EEC-IV - Pinpoint Tests - All Vehicles EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Vacuum Regulator Solenoid (EVR) Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 565 1989 EEC-IV-Pinpoint Tests - All Vehicles 17-134A Pinpoint Test DN EGR Valve Position Sensor (EVP) EGR Vacuum Regulator Solenoid (EVR) Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 566 1989 17-135 EEC-IV - Pinpoint Tests - All Vehicles EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Vacuum Regulator Solenoid (EVR) Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 567 1989 EEC-IV - Pinpoint Tests - All Vehicles 17-136A EGR Valve Position Sensor (EVP) 04GPinpoint Test DN EGR Vacuum Regulator Solenoid (EVR) Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > Page 568 EGR Valve Position Sensor: Locations Attached To EGR Valve Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > Page 569 EGR Valve Position Sensor: Description and Operation The EVP Sensor provides EEC System with a signal indicating position of the EGR valve. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Description and Operation Pressure Feedback Exhaust Sensor: Description and Operation The Pressure Feedback Electronic (PFE) EGR transducer converts a varying exhaust pressure signal into a proportional analog voltage which is digitized by the EEC IV processor. The EEC IV processor uses the signal received from the PFE transducer to complete the optimum EGR flow. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Tank Selector Switch > Component Information > Locations > Fuel Tank Selector Switch Fuel Tank Selector Switch: Locations Fuel Tank Selector Switch On Instrument Panel Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Tank Selector Switch > Component Information > Locations > Fuel Tank Selector Switch > Page 578 Fuel Tank Selector Switch: Locations Fuel Tank Selector Relay LH Corner Of Dash Panel Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Tank Selector Switch > Component Information > Diagrams > Diagram Information and Instructions Fuel Tank Selector Switch: Diagram Information and Instructions Symbol Identification Wire Color Code Identification Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Tank Selector Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 581 NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Tank Selector Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 582 Fuel Tank Selector Switch: Electrical Diagrams Fig. 26 Fuel Tank Selector & Gauges Wiring Circuit. Models W/6-300 (4.9L) & V8-351 (5.8L) Engines With 8,500 GVW Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Tank Selector Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 583 Fig. 27 Fuel Tank Selector & Gauges Wiring Circuit. F150-350 W/V8-351 (5.8L) & V8-460 (7.5L) Engines & Dual Tanks (Less Electric Fuel Pumps) Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pump Inertia Switch <--> [Inertia Fuel Shutoff Switch] > Component Information > Locations Fuel Pump Inertia Switch: Locations The inertia switch is located below the heater duct on the right hand side. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pump Inertia Switch <--> [Inertia Fuel Shutoff Switch] > Component Information > Diagrams > Diagram Information and Instructions Fuel Pump Inertia Switch: Diagram Information and Instructions Symbol Identification Wire Color Code Identification Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pump Inertia Switch <--> [Inertia Fuel Shutoff Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 589 NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pump Inertia Switch <--> [Inertia Fuel Shutoff Switch] > Component Information > Diagrams > Page 590 Fuel Pump Inertia Switch: Description and Operation The inertia Switch, is used in conjunction with an electric fuel pump. The purpose of the inertia switch is to shut off the fuel pump in the event of an accident. It consists of a steel ball held in place by a magnet. When a sharp impact occurs, the ball breaks loose from the magnet, rolls up a conical ramp and strikes a target plate which opens the electrical contacts of the switch and thereby shuts off the electric fuel pump. Once the switch is open, it must be manually reset before re-starting the vehicle. The location of the switch is discussed in the owners guide. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pump Inertia Switch <--> [Inertia Fuel Shutoff Switch] > Component Information > Diagrams > Page 591 Fuel Pump Inertia Switch: Testing and Inspection Push down on the reset button to make sure the switch is closed. Use DVOM with LOS button On and measure voltage across both terminals of the inertia switch. If DVOM reading is greater than 0.3V, replace the inertia switch. NOTE: In the closed position, the button can be depressed an additional 1/16-inch against a spring. This is a normal condition and does not adversely effect the switch operation. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pump Inertia Switch <--> [Inertia Fuel Shutoff Switch] > Component Information > Diagrams > Page 592 Fuel Pump Inertia Switch: Service and Repair 1. Turn ignition to Off. 2. Check for leaking fuel in the engine compartment, fuel lines and tank(s). 3. If no fuel leak is apparent, reset the switch by pushing the reset button on the top of the switch. 4. Turn ignition switch to Start for a few seconds, then to Off. 5. Again, check for leaking fuel. WARNING: It you see or smell gasoline at any time other than during fueling, do not reset the switch. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Full Open Switch HVAC > Component Information > Description and Operation Throttle Full Open Switch HVAC: Description and Operation A switch assembly, Figure 1 is mounted on the carburetor on some gasoline engines and on the fuel injector pump on the 2.0L Diesel engine to sense a wide open throttle condition. When maximum engine power is required, this switch assembly cuts off the air conditioning compressor to reduce engine loading. Switch closed at throttle opening less than wide open throttle. Switch open at wide open throttle condition. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Throttle Position Sensor - Request For Return Throttle Position Sensor: Technical Service Bulletins Throttle Position Sensor - Request For Return Number: 92686 To: All Ford and Lincoln-Mercury Dealers Subject: Request for Return of Throttle Position Sensor E5ZZ-9B989-B (CX-1022) and E6ZZ-9B989-B (CX-1130) Because the subject parts may not meet Ford's high quality requirements, they should be withdrawn from all inventories. All used E5ZZ-9B989-B (CX-1022) and E6ZZ-9B989-B (CX-1130) should be returned to your facing PDC within 30 days from the date of this letter. Use the least expensive mode of transportation for your return. The subject parts are obsolete and replaced by E7SZ-9B989-B (CX-1200), which is available for ordering immediately. You are requested to complete a separate FPS-340 form in accordance with the instructions on the front of the form. Annotate "Return Per FPSD Instructions Purge No. PN 1026" in the Customer's Detail Explanation Section and use Reason Code J (Unsatisfactory Service Stock). You will receive full credit in your parts statement for the price of each unused part returned, plus the prepaid transportation cost. In order to receive credit, all parts must be received at the Parts Distribution Center within 30 days from the date of this letter. Material other than subject parts received on this return will be sent back to you freight collect. Any questions should be referred to your Zone Manager or facing PDC Manager. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Throttle Position Sensor - Request For Return > Page 600 Throttle Position Sensor: Technical Service Bulletins Throttle Position Sensor - Diagnostic Tips Article No. 85-20-11 SELF-TEST CODE 53 - EEC IV - THROTTLE POSITION SENSOR DIAGNOSTIC TIP FORD 1985-86 ESCORT, EXP, TEMPO, MUSTANG, LTD, THUNDERBIRD LINCOLN-MERCURY 1985-86 LYNX, TOPAZ, CAPRI, MARQUIS, COUGAR LIGHT TRUCK 1985-86 RANGER, BRONCO II, ECONOLINE, F-SERIES CALIBRATION: All with EEC IV WARNING: This modification is authorized only for the listed engines. Performing this modification on other engine calibrations is unauthorized and could create liability under applicable federal or local laws. A new design Throttle Position Sensor (TPS) has been released for all 1986 EEC IV applications. The new TPS is designed to eliminate a false Self-Test Code 53. A Code 53 indicates the TPS system has failed at the wide open throttle position (approximately 5.0 volts), The new TPS eliminates false Code 53 by limiting the wide open throttle voltage to 4.75 volts. With the new TPS, Code 53 will only result from a circuit or TPS malfunction. The new Throttle Position Sensors can be used to replace faulty sensors on 1985 vehicles. If the old design service part is used, a false Code 53 may result. PART NUMBER PART NAME CLASS E6DZ-9B989-A Throttle Position Sensor C E6TZ-9B989-C Throttle Position Sensor WC E6DZ-9B989-C Throttle Position Sensor WC E6FZ-9B989-A Throttle Position Sensor B E6ZZ-9B989-A Throttle Position Sensor B E6ZZ-9B989-B Throttle Position Sensor WC E6TZ-9B989-A Throttle Position Sensor C OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Throttle Position Sensor - Request For Return > Page 601 Throttle Position Sensor: Technical Service Bulletins Throttle Position Sensor - Application Chart EEC-IV THROTTLE POSITION SENSOR-APPLICATION CHART-SERVICE TIP Article No. 89-16-4 FORD: 1984-88 CROWN VICTORIA, ESCORT, EXP, MUSTANG, TAURUS, TEMPO, THUNDERBIRD LINCOLN-MERCURY: 1984-88 COUGAR, GRAND MARQUIS, LYNX, MARK VI, MARK VII, SABLE, TOPAZ, TOWN CAR LIGHT TRUCK: 1984-88 ALL LIGHT TRUCK LINES ISSUE: A quick reference throttle position sensor (TPS) application chart has been put together to assist technicians in correct part useage. If the wrong TPS is installed, it could fail prematurely. ACTION: Refer to one of the following TPS service replacement charts to make sure that the correct service part is installed. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Throttle Position Sensor - Request For Return > Page 602 OASIS CODES: 680000 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Throttle Position Sensor - Request For Return > Page 603 Throttle Position Sensor: Technical Service Bulletins TPS Mounting Screws - Hard to Remove THROTTLE POSITION SENSOR-MOUNTING SCREWS HARD TO REMOVE-SERVICE TIP Article No. 89-14-7 FORD: 1983-89 CROWN VICTORIA, MUSTANG, TEMPO, THUNDERBIRD 1984-89 ESCORT 1986-89 TAURUS LINCOLN-MERCURY: 1983-89 CONTINENTAL, COUGAR, GRAND MARQUIS, MARK VII, TOPAZ, TOWN CAR 1984-87 LYNX MERKUR: 1985-89 ALL MERKUR LINES LIGHT TRUCK: 1983-89 ALL LIGHT TRUCK LINES ISSUE: All Throttle Position Sensor (TPS) mounting screws have a "Pozidrive" head. The "Pozidrive" head looks a lot like a Phillips screw head. Use of a Phillips head screwdriver to remove a "Pozidrive" screw will normally result in a rounded or damaged screw head. Many technicians think it is an overtorqued or "frozen" screw. An adhesive was also used as a thread sealant starting with the 1988 model year. This adhesive requires still more effort to loosen and remove the screw. ACTION: To prevent rounded or damages screw heads when servicing the TPS mounting screws, technicians should always use a # 2 "Pozidrive" screwdriver. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 4800, 680000 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 604 THROTTLE POSITION SENSOR SPECIFICATIONS Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 605 Engine View Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 606 Throttle Position Sensor: Description and Operation The Throttle Position (TP) Sensor (Rotary), Figure 1 supplies the ECA with a signal proportional to opening angle of carburetor throttle plates. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 607 Throttle Position Sensor: Testing and Inspection Ford provides trouble code/symptom driven diagnostics for this component. For complete diagnosis and pinpoint testing, refer to Computers and Control Systems, Testing and Inspection. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 608 Throttle Position Sensor: Adjustments ADJUSTMENT This procedure can be used to check and/or adjust level C sensors only: 1. Install an EEC-IV Breakout Box, Rotunda T83L-50 EEC-IV, or equivalent. 2. Attach a DVOM, Rotunda 014-00407 or equivalent, on 20V scale. Connect the positive lead (+) to test Pin 47 and the negative lead (-) to test Pin 46. 3. Turn ignition key to Run position (do not start engine). 4. Adjust TP Sensor (rotate) until the DVOM reads 1.0V (0.9-1.1). 5. Tighten TP Sensor screws to 1.2-1.8 N-m (11-16 lb-in). 6. While watching the DVOM, move the throttle to wide open and back to idle position. For proper operation, the DVOM should move from 1.0 to at least 4.0 and back to 1.0V. 7, Perform EEC-IV Quick Test. Refer to Powertrain Management/Computers and Control Systems/System Diagnosis Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Camshaft Position Sensor: Diagram Information and Instructions Symbol Identification Wire Color Code Identification Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 614 NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Crankshaft Position Sensor: Diagram Information and Instructions Symbol Identification Wire Color Code Identification Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 619 NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Description and Operation Hall Effect Sensor: Description and Operation Profile Ignition Pickup The PIP signal is created in the Hall Effect and Stator assembly and indicates crankshaft position and engine RPM Fig. 21. The PIP signal is fed to both the TFI module and the ECA. PIP Sensor COMPONENTS The Hall Effect device is made up of a voltage regulator, a Hall voltage generator, Darlington amplifier, Schmitt trigger, and an open collector output stage integrated in a single monolithic silicon chip Fig. 22. A signal is produced when a ferrous material is passed through the opening and the flux lines decrease. The Hall generator (Hall device) sends a sine wave signal to the Darlington amplifier. The Darlington amplifier inverts the signal. When the signal is low the output is high. When the signal is high the output is low. This output then goes to the Schmitt trigger. The Schmitt trigger shapes the signal into a square wave (digital high) signal. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Description and Operation > Page 623 PIP Signal Operation OPERATION The output signal to the Darlington amplifier is high when the window (on the armature) allows the magnetic field to reach the Hall device (switch off) Fig. 23. When the TAB shunts the magnetic field (closes) away from the Hall device the signal is low to the Darlington amplifier (switch on). Hall Effect Sensor In other words when one of the windows or openings is in the gap between the Hall device and the permanent magnet, the field stays strong and the voltage is high since the magnetic path is complete from the magnet, through the Hall device, and back to the magnet. In this case the switch is off and the Hall Effect does not send a signal. When the TAB enters the gap, the armature cuts off the magnetic path to the Hall device and its voltage drops. In this case the switch is on and the Hall Effect device sends a signal. The signal is switched On and Off as long as the armature is rotating (distributor is turning) and opening and closing the magnetic path. This is the signal used by the ECA to interpret crankshaft position and engine RPM. The signal can also be used by the TFI module if the SPOUT signal from the ECA is lost. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Description and Operation > Page 624 Signature PIP SIGNATURE PIP Some Electronic Engine Control (EEC) vehicles are equipped with a signature profile ignition pickup signal. The regular type armature used for the PIP signal has the same size tabs and windows. In a signature PIP signal armature, one of the tabs is narrower than the others Fig. 25. The narrower tab provides a different signal to the ECA when it passes through the Hall Effect switch. When the ECA sees the narrow tab it knows when to properly pulse the fuel injectors. This system is used on cars and trucks where the ECA needs to know when to pulse certain injectors. For example, on sequential electronic fuel injection (SEFI) systems, each injector is pulsed to coincide with its intake valve opening. With the signature PIP, the ECA knows when the No. 1 cylinder needs to be supplied with fuel. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Description and Operation > Page 625 Hall Effect Sensor: Service and Repair Removal Do not attempt to replace stator without an arbor press. 1. Remove distributor. Remove rotor, then the TFI module. 2. If distributor uses push on type rotor, remove two retaining screws holding armature, then the armature. Hold gear to loosen armature screws, do not hold armature. 3. Mark stator, armature, gear and collar with felt tip pen to aid in reassembly. 4. Remove and discard pins in gear and collar if equipped. 5. Invert distributor and place in Axle Bearing Seal Plate and press off gear using Bearing Removal Tool. 6. Deburr and polish shaft with emery paper and wipe clean so that shaft slides out freely from distributor base. 7. Remove shaft assembly, then the thrust washer from shaft. Next remove octane rod. 8. Remove stator assembly screws, then the stator assembly from top of bowl. 9. Inspect base bushing for wear of signs of excess heat concentration, replace distributor assembly if damaged. 10. Inspect base O-ring for cuts or damage and replace as necessary. 11. Inspect base for cracks and wear, replace distributor assembly if damage is found. Installation 1. Place stator assembly over bushing and press down to seat. 2. Place stator connector in position, tab should fit in notch on base with fastening eyelets aligned with screw holes. 3. Install stator screws and Torque to 15-35 inch lbs. Next install octane rod. 4. Install thrust washer on top of bushing, then apply lubricant to distributor shaft below armature. Do not over lubricate. 5. Insert shaft through base bushing, then place collar, if equipped, over shaft and line up mark on armature and collar to aid alignment with original drill hole. Use a suitable drift punch to assure proper alignment. 6. Drill holes through shaft and collar should align on both sides of shaft. If holes do not align, collar may be 180 degrees out of alignment on shaft. Rotate collar on shaft one half rotation, then check. 7. Insert new roll pin through collar and shaft, pin should be flush with both sides of collar when seated. 8. If distributor uses push on type rotor, place a 1/2 inch deep well socket over shaft, invert and place on arbor plate. 9. If distributor uses screw down type rotor, invert and place on arbor plate. 10. Place distributor gear on shaft and line up marks on armature and gear. Hole in shaft and gear must line up as accurately as possible to assure ease of roll pin insertion. 11. Place a 5/8 inch deep well socket over shaft and gear, then press gear to align with original drill hole. 12. If gear holes do not align, gear must be removed and repressed on. Drift punch will not align holes, as in collar, holes should align. 13. Insert new roll pin through gear and shaft, pin should extrude evenly on both sides. 14. Install armature, if removed, and Torque screws to 25-35 inch lbs. 15. Install TFI module, rotor, then distributor. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Technical Service Bulletins > Customer Interest for Ignition Switch: > 932410 > Nov > 93 > Instrument Cluster Warning Lights - Dimly Lit Ignition Switch: Customer Interest Instrument Cluster Warning Lights - Dimly Lit Article No. 93-24-10 11/24/93 ^ LAMP - MALFUNCTION OF FOUR PIN LOW OIL LEVEL RELAY - VEHICLES BUILT AFTER 8/1/92 OR 1983-1993 VEHICLES THAT HAVE HAD SERVICE REPLACEMENT IGNITION SWITCHES AFTER 8/1/92 ^ LAMPS - INSTRUMENT CLUSTER WARNING LIGHTS DIMLY LIT - VEHICLES BUILT AFTER 8/1/92 OR 1983-1993 VEHICLES THAT HAVE HAD SERVICE REPLACEMENT IGNITION SWITCHES AFTER 8/1/92 FORD: 1983 FAIRMONT 1983-89 CROWN VICTORIA, ESCORT 1983-93 MUSTANG, THUNDERBIRD 1983-94 PROBE 1984-86 LTD 1984-94 TEMPO LINCOLN-MERCURY: 1983 LN7, ZEPHYR 1983-87 CONTINENTAL, LYNX 1983-89 GRAND MARQUIS, TOWN CAR 1983-93 COUGAR 1984-86 CAPRI, MARQUIS 1984-94 TOPAZ LIGHT TRUCK: 1983-91 BRONCO 1983-93 ECONOLINE, F-150-350 SERIES, RANGER 1986-91 AEROSTAR 1991-93 EXPLORER ISSUE: The instrument cluster warning light(s) may be dimly lit or there may be a malfunction of the four pin low oil relay on vehicles so equipped. This could be due to the ignition switch. ACTION: If the vehicle displays the subject symptoms and meets the following conditions, replace the ignition switch. Refer to the appropriate Car or Light Truck Service Manual (Section 13-04 for 1983-1990 Cars, Section 11-04 for 1991-1993 Cars and Section 13-05 for 1983-1990 Light Trucks, Section 11-05 for 1991-1993 Light Trucks) for removal and installation procedures. Refer to the Parts Block in this article for correct parts usage. CONDITIONS ^ The vehicle has 14401 wiring attached to the P2 terminal of the ignition switch. Refer to the wiring schematic and/or Electrical And Vacuum Troubleshooting Manual (EVTM) for the concern vehicle. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Technical Service Bulletins > Customer Interest for Ignition Switch: > 932410 > Nov > 93 > Instrument Cluster Warning Lights - Dimly Lit > Page 634 ^ The vehicle is equipped with one of the ignition switches identified in the Ignition Switch Part Number Chart. NOTE: THE SERVICE PART NUMBERS FOR THE REPLACEMENT IGNITION SWITCHES WILL HAVE THE SAME PART NUMBERS AS THOSE REPLACED. THE NEW SWITCH HAS BEEN IMPROVED TO CORRECT THE SUBJECT ISSUE. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of The Bumper To Bumper For 1992/93 Models, Basic Warranty Coverage For All Other Models Except Lincolns. Major Component Warranty Coverage For Lincolns OPERATION DESCRIPTION TIME 932410A Replace Ignition Switch - 0.5 Hr. All Light and Compact Trucks DEALER CODING BASIC PART NO. CONDITION CODE 11572 X1 OASIS CODES: 201000, 201100, 206000 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch: > 932410 > Nov > 93 > Instrument Cluster Warning Lights - Dimly Lit Ignition Switch: All Technical Service Bulletins Instrument Cluster Warning Lights - Dimly Lit Article No. 93-24-10 11/24/93 ^ LAMP - MALFUNCTION OF FOUR PIN LOW OIL LEVEL RELAY - VEHICLES BUILT AFTER 8/1/92 OR 1983-1993 VEHICLES THAT HAVE HAD SERVICE REPLACEMENT IGNITION SWITCHES AFTER 8/1/92 ^ LAMPS - INSTRUMENT CLUSTER WARNING LIGHTS DIMLY LIT - VEHICLES BUILT AFTER 8/1/92 OR 1983-1993 VEHICLES THAT HAVE HAD SERVICE REPLACEMENT IGNITION SWITCHES AFTER 8/1/92 FORD: 1983 FAIRMONT 1983-89 CROWN VICTORIA, ESCORT 1983-93 MUSTANG, THUNDERBIRD 1983-94 PROBE 1984-86 LTD 1984-94 TEMPO LINCOLN-MERCURY: 1983 LN7, ZEPHYR 1983-87 CONTINENTAL, LYNX 1983-89 GRAND MARQUIS, TOWN CAR 1983-93 COUGAR 1984-86 CAPRI, MARQUIS 1984-94 TOPAZ LIGHT TRUCK: 1983-91 BRONCO 1983-93 ECONOLINE, F-150-350 SERIES, RANGER 1986-91 AEROSTAR 1991-93 EXPLORER ISSUE: The instrument cluster warning light(s) may be dimly lit or there may be a malfunction of the four pin low oil relay on vehicles so equipped. This could be due to the ignition switch. ACTION: If the vehicle displays the subject symptoms and meets the following conditions, replace the ignition switch. Refer to the appropriate Car or Light Truck Service Manual (Section 13-04 for 1983-1990 Cars, Section 11-04 for 1991-1993 Cars and Section 13-05 for 1983-1990 Light Trucks, Section 11-05 for 1991-1993 Light Trucks) for removal and installation procedures. Refer to the Parts Block in this article for correct parts usage. CONDITIONS ^ The vehicle has 14401 wiring attached to the P2 terminal of the ignition switch. Refer to the wiring schematic and/or Electrical And Vacuum Troubleshooting Manual (EVTM) for the concern vehicle. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch: > 932410 > Nov > 93 > Instrument Cluster Warning Lights - Dimly Lit > Page 640 ^ The vehicle is equipped with one of the ignition switches identified in the Ignition Switch Part Number Chart. NOTE: THE SERVICE PART NUMBERS FOR THE REPLACEMENT IGNITION SWITCHES WILL HAVE THE SAME PART NUMBERS AS THOSE REPLACED. THE NEW SWITCH HAS BEEN IMPROVED TO CORRECT THE SUBJECT ISSUE. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of The Bumper To Bumper For 1992/93 Models, Basic Warranty Coverage For All Other Models Except Lincolns. Major Component Warranty Coverage For Lincolns OPERATION DESCRIPTION TIME 932410A Replace Ignition Switch - 0.5 Hr. All Light and Compact Trucks DEALER CODING BASIC PART NO. CONDITION CODE 11572 X1 OASIS CODES: 201000, 201100, 206000 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Technical Service Bulletins > Page 641 Ignition Switch: Service and Repair Fig. 3 Ignition switch replacement 1. Disconnect battery ground cable. 2. Remove steering column shroud and lower the steering column. 3. Disconnect electrical connector from switch, then remove 2 switch attaching nuts. 4. Lift switch up to disengage actuator rod, then remove switch from vehicle, Fig. 3. 5. Reverse procedure to install. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Description and Operation Knock Sensor: Description and Operation The Knock Sensor, is a piezoelectric accelerometer with the sensor designed to resonate at approximately the same frequency as the engine knock frequency. The sensor uses the resonant frequency to mechanically amplify the vibrations. This method allows relatively large signals to be achieved without electrical amplification and with small package size. The sensor has a thin circular piezoelectric ceramic disk which is bonded to a metal diaphragm. Electrical connections are made through a two pin integral connector. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Description and Operation > Page 645 Knock Sensor: Testing and Inspection Ford provides trouble code/symptom driven diagnostics for this component. For complete diagnosis and pinpoint testing, refer to Computers and Control Systems, Testing and Inspection. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Locations Seat Belt Buckle Switch: Locations In Driver's Seatbelt Buckle Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Clutch Pedal Position Switch <--> [Clutch Switch] > Component Information > Testing and Inspection Clutch Pedal Position Switch: Testing and Inspection Manual Transmission Vehicles Only This switch functions magnetically. Do not use magnetized tools near this switch. 1. If the switch is open when the clutch pedal is released, speed control will not operate. This must be corrected before making any other tests. Use only a multimeter of 5000 ohm/volt rating or higher when performing the clutch switch test. 2. Disconnect switch pigtail connector from speed control harness connector and connect an ohmmeter to the two switch connector terminals. 3. With clutch pedal in the fully released position, the resistance should be less than 5 ohms. With clutch pedal fully depressed, the circuit should be open. 4. If switch does not function as described, remove and replace switch. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Technical Service Bulletins > Customer Interest for Ignition Switch: > 932410 > Nov > 93 > Instrument Cluster Warning Lights - Dimly Lit Ignition Switch: Customer Interest Instrument Cluster Warning Lights - Dimly Lit Article No. 93-24-10 11/24/93 ^ LAMP - MALFUNCTION OF FOUR PIN LOW OIL LEVEL RELAY - VEHICLES BUILT AFTER 8/1/92 OR 1983-1993 VEHICLES THAT HAVE HAD SERVICE REPLACEMENT IGNITION SWITCHES AFTER 8/1/92 ^ LAMPS - INSTRUMENT CLUSTER WARNING LIGHTS DIMLY LIT - VEHICLES BUILT AFTER 8/1/92 OR 1983-1993 VEHICLES THAT HAVE HAD SERVICE REPLACEMENT IGNITION SWITCHES AFTER 8/1/92 FORD: 1983 FAIRMONT 1983-89 CROWN VICTORIA, ESCORT 1983-93 MUSTANG, THUNDERBIRD 1983-94 PROBE 1984-86 LTD 1984-94 TEMPO LINCOLN-MERCURY: 1983 LN7, ZEPHYR 1983-87 CONTINENTAL, LYNX 1983-89 GRAND MARQUIS, TOWN CAR 1983-93 COUGAR 1984-86 CAPRI, MARQUIS 1984-94 TOPAZ LIGHT TRUCK: 1983-91 BRONCO 1983-93 ECONOLINE, F-150-350 SERIES, RANGER 1986-91 AEROSTAR 1991-93 EXPLORER ISSUE: The instrument cluster warning light(s) may be dimly lit or there may be a malfunction of the four pin low oil relay on vehicles so equipped. This could be due to the ignition switch. ACTION: If the vehicle displays the subject symptoms and meets the following conditions, replace the ignition switch. Refer to the appropriate Car or Light Truck Service Manual (Section 13-04 for 1983-1990 Cars, Section 11-04 for 1991-1993 Cars and Section 13-05 for 1983-1990 Light Trucks, Section 11-05 for 1991-1993 Light Trucks) for removal and installation procedures. Refer to the Parts Block in this article for correct parts usage. CONDITIONS ^ The vehicle has 14401 wiring attached to the P2 terminal of the ignition switch. Refer to the wiring schematic and/or Electrical And Vacuum Troubleshooting Manual (EVTM) for the concern vehicle. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Technical Service Bulletins > Customer Interest for Ignition Switch: > 932410 > Nov > 93 > Instrument Cluster Warning Lights - Dimly Lit > Page 662 ^ The vehicle is equipped with one of the ignition switches identified in the Ignition Switch Part Number Chart. NOTE: THE SERVICE PART NUMBERS FOR THE REPLACEMENT IGNITION SWITCHES WILL HAVE THE SAME PART NUMBERS AS THOSE REPLACED. THE NEW SWITCH HAS BEEN IMPROVED TO CORRECT THE SUBJECT ISSUE. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of The Bumper To Bumper For 1992/93 Models, Basic Warranty Coverage For All Other Models Except Lincolns. Major Component Warranty Coverage For Lincolns OPERATION DESCRIPTION TIME 932410A Replace Ignition Switch - 0.5 Hr. All Light and Compact Trucks DEALER CODING BASIC PART NO. CONDITION CODE 11572 X1 OASIS CODES: 201000, 201100, 206000 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch: > 932410 > Nov > 93 > Instrument Cluster Warning Lights - Dimly Lit Ignition Switch: All Technical Service Bulletins Instrument Cluster Warning Lights - Dimly Lit Article No. 93-24-10 11/24/93 ^ LAMP - MALFUNCTION OF FOUR PIN LOW OIL LEVEL RELAY - VEHICLES BUILT AFTER 8/1/92 OR 1983-1993 VEHICLES THAT HAVE HAD SERVICE REPLACEMENT IGNITION SWITCHES AFTER 8/1/92 ^ LAMPS - INSTRUMENT CLUSTER WARNING LIGHTS DIMLY LIT - VEHICLES BUILT AFTER 8/1/92 OR 1983-1993 VEHICLES THAT HAVE HAD SERVICE REPLACEMENT IGNITION SWITCHES AFTER 8/1/92 FORD: 1983 FAIRMONT 1983-89 CROWN VICTORIA, ESCORT 1983-93 MUSTANG, THUNDERBIRD 1983-94 PROBE 1984-86 LTD 1984-94 TEMPO LINCOLN-MERCURY: 1983 LN7, ZEPHYR 1983-87 CONTINENTAL, LYNX 1983-89 GRAND MARQUIS, TOWN CAR 1983-93 COUGAR 1984-86 CAPRI, MARQUIS 1984-94 TOPAZ LIGHT TRUCK: 1983-91 BRONCO 1983-93 ECONOLINE, F-150-350 SERIES, RANGER 1986-91 AEROSTAR 1991-93 EXPLORER ISSUE: The instrument cluster warning light(s) may be dimly lit or there may be a malfunction of the four pin low oil relay on vehicles so equipped. This could be due to the ignition switch. ACTION: If the vehicle displays the subject symptoms and meets the following conditions, replace the ignition switch. Refer to the appropriate Car or Light Truck Service Manual (Section 13-04 for 1983-1990 Cars, Section 11-04 for 1991-1993 Cars and Section 13-05 for 1983-1990 Light Trucks, Section 11-05 for 1991-1993 Light Trucks) for removal and installation procedures. Refer to the Parts Block in this article for correct parts usage. CONDITIONS ^ The vehicle has 14401 wiring attached to the P2 terminal of the ignition switch. Refer to the wiring schematic and/or Electrical And Vacuum Troubleshooting Manual (EVTM) for the concern vehicle. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch: > 932410 > Nov > 93 > Instrument Cluster Warning Lights - Dimly Lit > Page 668 ^ The vehicle is equipped with one of the ignition switches identified in the Ignition Switch Part Number Chart. NOTE: THE SERVICE PART NUMBERS FOR THE REPLACEMENT IGNITION SWITCHES WILL HAVE THE SAME PART NUMBERS AS THOSE REPLACED. THE NEW SWITCH HAS BEEN IMPROVED TO CORRECT THE SUBJECT ISSUE. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of The Bumper To Bumper For 1992/93 Models, Basic Warranty Coverage For All Other Models Except Lincolns. Major Component Warranty Coverage For Lincolns OPERATION DESCRIPTION TIME 932410A Replace Ignition Switch - 0.5 Hr. All Light and Compact Trucks DEALER CODING BASIC PART NO. CONDITION CODE 11572 X1 OASIS CODES: 201000, 201100, 206000 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Technical Service Bulletins > Page 669 Ignition Switch: Service and Repair Fig. 3 Ignition switch replacement 1. Disconnect battery ground cable. 2. Remove steering column shroud and lower the steering column. 3. Disconnect electrical connector from switch, then remove 2 switch attaching nuts. 4. Lift switch up to disengage actuator rod, then remove switch from vehicle, Fig. 3. 5. Reverse procedure to install. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Service and Repair Neutral Safety Switch: Service and Repair Fig. 8 Neutral safety switch replacement. Exc. automatic overdrive transmission EXC. AUTOMATIC OVERDRIVE TRANSMISSION 1. Disconnect battery ground cable. 2. Remove downshift linkage rod return spring from low-reverse servo cover. 3. Apply penetrating oil to outer lever attaching nut, then remove transmission downshift outer lever attaching nut and lever. 4. Remove neutral safety switch attaching bolts, then disconnect electrical connectors and remove switch from vehicle. 5. To install, position switch on transmission and secure with attaching bolts. Do not tighten bolts at this time. 6. Place transmission manual lever in neutral position, then insert a .091 inch gauge pin through gauge pin holes, Fig. 8. 7. Tighten switch attaching bolts, then remove gauge pin. 8. Install outer downshift lever and retaining nut. 9. Install downshift linkage rod return spring between lever and retaining clip on low-reverse servo cover. 10. Reconnect electrical connectors, then check operation of switch. W/AUTOMATIC OVERDRIVE TRANSMISSION 1. Disconnect battery ground cable. 2. Raise and support vehicle. 3. Disconnect electrical connector at neutral safety switch, lifting connector straight up. 4. Using suitable socket, remove neutral safety switch and O-ring seal. 5. Reverse procedure to install, installing new O-ring seal. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Locations Power Steering Pressure Switch: Locations In Power Steering Hose, Near Steering Gear Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Locations > Page 678 Power Steering Pressure Switch: Testing and Inspection Ford provides trouble code/symptom driven diagnostics for this component. For complete diagnosis and pinpoint testing, refer to Computers and Control Systems, Testing and Inspection. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Diagram Information and Instructions Windshield Washer Switch: Diagram Information and Instructions Symbol Identification Wire Color Code Identification Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 684 NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 685 Windshield Washer Switch: Electrical Diagrams Fig. 52 Windshield Wiper/Washer Wiring Circuit (L/Interval Wipers) Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 686 Fig. 53 Windshield Wiper/Washer Wiring Circuit (W/Interval Wipers) Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Locations Wiper Switch: Locations Back View Of I/P On LH Side Of I/P Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Diagram Information and Instructions Wiper Switch: Diagram Information and Instructions Symbol Identification Wire Color Code Identification Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 692 NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 693 Wiper Switch: Electrical Diagrams Fig. 52 Windshield Wiper/Washer Wiring Circuit (L/Interval Wipers) Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 694 Fig. 53 Windshield Wiper/Washer Wiring Circuit (W/Interval Wipers) Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Page 695 Wiper Switch: Testing and Inspection Fig. 4 Wiper Switch Continuity Test Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Page 696 Fig. 5 Testing wiper switch continuity. 1980 Bronco & F-100---350 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Page 697 Fig. 5 Wiper Switch Continuity Test 1. Check continuity between switch terminals, Figs. 4 through 6. 2. To detect marginal operation of switch, rotate or slide switch control knob while each reading is being taken. 3. If switch does not show continuity or if poor continuity exists at any switch position, replace switch. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Page 698 Wiper Switch: Service and Repair F-100---350 & BRONCO 1. Disconnect battery ground cable. 2. Remove wiper switch knob, bezel nut and bezel. 3. Pull switch down from under instrument panel, then disconnect electrical connector and remove switch from vehicle. 4. Reverse procedure to install. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Customer Interest: > 892110 > Oct > 89 > Steering - Pull or Drift Alignment: Customer Interest Steering - Pull or Drift Article No. 89-21-10 ^ STEERING - PULL OR DRIFT - CASTER SPLIT - NEW SERVICE ADJUSTERS - 4X4 MODELS ^ SUSPENSION - FRONT - NEW SERVICE CASTER ADJUSTERS - 4X4 MODELS LIGHT TRUCK: 1980-89 BRONCO, F-150, F-250, F-350 1983-89 RANGER 1984-89 BRONCO II Figure 1 This TSB article is being republished in its entirety to correct the service parts for the Caster Adjusters. ISSUE: Two new alignment adjusters are now available for service. These new parts provide one degree of caster adjustment along with one degree of camber. Steering pull may be caused by caster split. The affected trucks are 4x4 Twin Traction Beam vehicles. ACTION: Use the following procedure to determine the position of the service adjuster sleeve. Refer to the appropriate Light Truck Shop Manual, Section 14-21 for installation details. The new alignment adjusters are similiar to the current camber adjusters. The one exception is the rotational position of the adjuster sleeve to obtain the desired adjustment. ADJUSTER SLEEVE APPLICATION FOR RANGER BRONCO II, BRONCO, AND F-150 1. Measure and record the alignment readings. 2. Determine what alignment adjuster sleeves are on the truck. NOTE: IF AFTERMARKET ADJUSTER SLEEVES HAVE BEEN INSTALLED, IT WILL BE NECESSARY TO FIND OUT WHAT CASTER AND CAMBER SLEEVES WERE USED. If the adjuster sleeve is not marked or cannot be identified, install a 0 degree adjuster sleeve to use as a reference point. 3. Determine what adjuster sleeve change is required. Take your desired alignment (what you want to end up with) and compare it to the readings taken in Step 1 to determine the change. 4. Pick the adjuster sleeve that will get you the closest to the desired alignment. 5. Install and position the adjuster sleeve, Figure 1. Refer to the appropriate Light Truck Shop Manual, Section 14-21 for service details. See the following caster adjuster sleeve chart and camber adjuster sleeve chart for the correct service parts. CAMBER ADJUSTER SLEEVE APPLICATION CHART Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Customer Interest: > 892110 > Oct > 89 > Steering - Pull or Drift > Page 708 SERVICE PART APPLICATION VALUE NUMBER F Series/Bronco - 0~ E0TZ-3B440-A 4x4 1/2~ E0TZ-3B440-B 1~ E0TZ-3B440-C 1-1/2~ E0TZ-3B440-D Ranger/ Bronco II - 0~ E3TZ-3B440-A 4x4 1/2~ E3TZ-3B440-B 1~ E3TZ-3B440-C 1-1/2~ E3TZ-3B440-D ADJUSTER ORIENTATION CHART CAMBER CASTER CAMBER CASTER POSITION LEFT LEFT RIGHT RIGHT OF SLOT SIDE SIDE SIDE SIDE 45~ +1~ -1~ -1~ -1~ 135~ -1~ -1~ + 1~ -1~ 225~ -1~ +1~ +1~ +1~ 315~ +1~ +1~ -1~ +1~ 6. Recheck the alignment to make sure you arrived at the desired values. CASTER WEDGE APPLICATION: F-250/350 4X4 The caster angle on the F-250 4x4 can be adjusted by inserting a wedge between the spring and the axle. Refer to the appropriate model year Light Truck Shop Manual, page 14-01-14 for installation details. See the following application chart for the correct service part. CASTER WEDGE APPLICATION CHART SERVICE PART APPLICATION VALUE NUMBER F-250/350 - 0~ E0TZ-5A313-A 4x4 1~ E0TZ-5A313-C 2~ E0TZ-5A313-B NOTE: F-350 4X4 TWIN TRACTION BEAM - CASTER AND CASTER SPLITS ARE ADJUSTABLE USING WEDGES. F-350 4X4 MONOBEAM - CASTER SPLITS ARE NOT ADJUSTABLE. A CASTER CHANGE FOR BOTH WHEELS IS ACCOMPLISHED USING WEDGES. PART NUMBER PART NAME CLASS E9TZ-3B440-F Caster Adjuster - B F-Series/Bronco E9TZ-3B440-G Caster Adjuster - B Ranger/Bronco II E0TZ-3B440-A Camber Adjuster - AM F-Series/Bronco E0TZ-3B440-B Camber Adjuster - AM Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Customer Interest: > 892110 > Oct > 89 > Steering - Pull or Drift > Page 709 F-Series/Bronco E0TZ-3B440-C Camber Adjuster - AM F-Series/Bronco E0TZ-3B440-D Camber Adjuster - AM F-Series/Bronco E3TZ-3B440-A Camber Adjuster - BM Ranger/Bronco II E3TZ-3B440-B Camber Adjuster - AM Ranger/Bronco II E3TZ-3B440-C Camber Adjuster - AM Ranger/Bronco II E3TZ-3B440-D Camber Adjuster - AM Ranger/Bronco II E0TZ-5A313-A Caster Wedge C E0TZ-5A313-B Caster Wedge BM E0TZ-5A313-C Caster Wedge RM OTHER APPLICABLE ARTICLES: 87-4-16 SUPERSEDES: 89-19-13, date 9/20 89 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 3100, 3200, 3300 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Customer Interest: > 87416 > Feb > 87 > Steering - Pulling or Drifting Alignment: Customer Interest Steering - Pulling or Drifting ^ STEERING - PULL OR DRIFT - CASTER Article No. ADJUSTMENT SERVICE KIT 87-4-16 ^ SUSPENSION - FRONT - CASTER ADJUSTMENT SERVICE KIT LIGHT TRUCK 1980-86 F-150 (4x4), BRONCO ISSUE: A steering drift or pull may be caused by excessive front wheel side-to-side caster angle differences. ACTION: If a front axle alignment check shows excessive (more than 3/4 degree split) side-to-side caster angle difference causing the vehicle to drift or pull, install a new caster adjustment kit (E0TZ-3K064-A) which allows the front axle side-to-side caster angles to be changed up to 2-1/2 degrees in 1/2 degree increments. New front axle to radius arm brackets must also be replaced when the caster kit is installed. Refer to the following service procedure for step-by-step instructions. NOTE THE FOLLOWING INFORMATION BEFORE DOING WORK ON THE VEHICLE. To correct caster side-to-side difference of up to 1- 1/2 degrees, install a caster adjuster plate on the radius arm that has the lower caster reading. Adjuster plates are identified R.H. and L.H. To correct caster side-to-side difference more than 1-1/2 degrees, install the caster plate on both radius arms. Installing both plates will allow a caster split change of 2-1/2 degrees (+1-1/2 degrees on the low caster side, -1 degree on the high caster side). 1. Remove radius arm from vehicle. Figure 14 - Article 87-4-16 2. Locate the template, included in the kit, on the bottom flange of radius arm over the existing holes, as shown in Figure 14. NOTE: Right arm adjustment is shown. One template is used to modify both right and left hand arms. When modifying right arm, position template with printed side down (printed side up for left arm). Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Customer Interest: > 87416 > Feb > 87 > Steering - Pulling or Drifting > Page 714 Figure 14 - Article 87-4-16 Figure 15 - Article 87-4-16 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Customer Interest: > 87416 > Feb > 87 > Steering - Pulling or Drifting > Page 715 Figure 16 - Article 87-4-16 3. With template secure, punch mark radius arm at the small hole in the template, as shown in Figures 14 and 15. Mark radius arm, and diegrind a slot at the axle attaching hole the same size as the slot in the template, see Figure 16. De-burr the surface; avoid rounding the edges of the slot. Figure 13 - Article 87-4-16 4. Use a No. 6 drill to make a .204 inch diameter through hole at the punch mark. Line up the caster adjuster plate on the radius arm to obtain the required change in caster, see Figure 13. Figure 17 - Article 87-4-16 NOTE: Each hole changes caster approximately 1/2 degree + or - from the "0" index hole. 5. Install the tap screw to 120 in.lbs. (13 N-m) torque. 6. Reinstall radius arm with a new bracket (front axle to radius arm). The new bracket has a larger "jaw" spacing to fit over caster adjuster plate. ^ For non-quad shock vehicles, install bracket E7TZ-3B446-A. ^ For quad shock vehicles, install bracket E7TZ-18112-A, R.H. or E7TZ-18113-A, L.H. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Customer Interest: > 87416 > Feb > 87 > Steering - Pulling or Drifting > Page 716 Figure 18 - Article 87-4-16 7. Tighten upper stud/bolt to 240-260 ft.lbs. (325-352 N-m) torque, Figure 18. 8. Tighten lower bolt to 320-340 ft.lbs. (434-461 N-m) torque, Figure 18. 9. Tighten front axle radius arm bracket bolts to 20-26 ft.lbs. (27-35 N-m) torque, Figure 18. 10. Arc weld caster adjuster plate to radius arm with a 1/4 inch-long bead along two sides of the plate. 11. Reset toe to specification. PART NUMBER PART NAME CLASS E0TZ-3K064-A Caster Kit CG E7TZ-3B446-A Bracket - Radius Arm C E7TZ-18112-A Bracket - Radius Arm CG E7TZ-18113-A Bracket - Radius Arm CG OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual OPERATION: SP870416A - Caster kit one side TIME: 2.1 Hrs. OPERATION: SP870416B - Caster kit both sides TIME: 3.5 Hrs. DLR. CODING: Basic Part No. FRONT - Code: 07 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Customer Interest: > 86622 > Mar > 86 > Steering - Vehicle Drifting/Pulling Alignment: Customer Interest Steering - Vehicle Drifting/Pulling Article No. 86-6-22 STEERING - DRIFT/PULL - RUBBER BALL SOCKET LINKAGE WIND-UP LIGHT TRUCK 1985-86 E, F SERIES, BRONCO Complaints of drifts and pulls on certain 1985-86 E, F Series and Bronco models may be caused by the installation procedure of the steering linkage. BECAUSE THE RUBBER TENDS TO RETURN TO ITS INSTALLED POSITION, IT IS IMPERATIVE THAT THE INSTALLATION BE ACCOMPLISHED WITH THE FRONT WHEELS AND THE PITMAN ARM IN THE STRAIGHT AHEAD POSITION, AND THE STUD SEATED IN THE TAPERED HOLE PRIOR TO TIGHTENING THE NUTS. Care should be taken with the installation to prevent a drift condition. To diagnose if a preload in the rubber is causing the drift, the following procedure is recommended: 1. Loosen the studs in the tapered holes at the pitman arm and the left and right spindles (i.e., disengage the stud from the hole so that it is no longer seated). 2. Hand install the nuts so that the stud is free to turn inside the tapered hole. 3. INSTALL COTTER PINS IN ALL THE STUDS. 4. Drive the vehicle. If it no longer drifts, then it can be assumed that the rubber was causing the drift. If it continues to drift, the condition is NOT being caused by the rubber ball sockets. 5. In either case, do not replace the steering linkage. Reinstall the linkage as follows: F Series and Bronco 1. Ensure the pitman arm and wheels are in the straight ahead position. (The pitman arm is exactly straight ahead when the clear vision is at 0~.) 2. Lock the steering wheel straight ahead and loose assemble the steering linkage to the pitman arm and then to the spindles. 3. Being careful not to change the position of the pitman arm, torque the steering linkage nuts to 65 ft.lbs. (88.1 N-m) The recommended sequence for tightening is: 1) the pitman arm, 2) the right side spindle and 3) the left side spindle. 4. Install all the cotter pins by advancing the nut to the next castellation. 5. Adjust the toe-in if necessary. Econoline 1. Ensure that the wheels are in the straight ahead position. 2. Loose assemble the steering linkage to the spindles and the pitman arm. 3. Being careful not to move the wheels from the straight ahead position, torque the steering linkage nuts to 65 ft.lbs. The recommended tightening sequence is: 1) the right side spindle, 2) the pitman arm and 3) the left side spindle. 4. Install all the cotter pins by advancing the nut to the next castellation. 5. Adjust the toe-in and reset the clear vision if necessary. The above procedure will eliminate any of the drift being caused by the rubber ball sockets. If the vehicle still drifts, refer to Section 19 of the Light Truck Shop Manual for further diagnosis. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION: SP3008A86A - F Series and Bronco TIME: 1.4 Hrs. OPERATION: SP3008A86B - Econoline TIME: 1.5 Hrs. DLR. CODING: Basic Part No. 3304 - Code: 36 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Customer Interest: > 851915 > Sep > 85 > Steering - Drift/Pull Alignment: Customer Interest Steering - Drift/Pull Article No. 85-19-15 STEERING - DRIFT/PULL CASTER SPLIT ADJUSTMENT LIGHT TRUCK 1980-86 F250-350 4x2; 1976-86 E100-350 A side-to-side front wheel caster difference greater than 3/4 degree can contribute to a vehicle drift or pull in the direction of the side with less caster. The service kit (E5TZ-3K064-A) can be used to increase the front wheel caster angle on either or both wheels to balance the caster split to correct a vehicle drift/pull concern. The kit contains complete parts and instructions needed to modify the front radius arm and mount a metal cam on the bottom flange of the radius arm. The kit can increase caster from 1/2 degree to 3 degrees, in 1/2 degree increments. It is not designed to decrease caster. To increase front wheel caster angle of subject vehicles and/or to balance a caster split, the following procedure is suggested: 1. Remove the radius arm from the vehicle as shown in Section 14-21 of the Reference Shop Manual and choose the appropriate paper template applicable to the vehicle model. Figure 8 - POSITIONING TEMPLATE TO LOWER FLANGE OF RADIUS ARM 2. Locate the template (3B474) on the bottom flange of the radius arm. Refer to Figure 8 for a typical arm modification for the right hand radius arm. One template per vehicle model is used to modify both the right and left hand radius arms. When modifying the right hand arm, position the Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Customer Interest: > 851915 > Sep > 85 > Steering - Drift/Pull > Page 725 template with the printed side downward. The template locates off of one of two existing holes in the radius arm. The E100-350 template is shaped to match the contours of the radius arm. Figure 9 - HOLE DRILLING INSTRUCTIONS - CAM ATTACHMENT TO LOWER FLANGE RADIUS ARM 3. With template secure, make a punch mark at the center of the small hole inside the printed circle. Scribe the slot printed/cut-out on the template and die-grind out the slot at the axle-attaching hole the same size as the slot in the template and de-burr the surface avoiding rounding the edges of the slot. Refer to Figure 9. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Customer Interest: > 851915 > Sep > 85 > Steering - Drift/Pull > Page 726 Figure 10 - ATTACHMENT OF ADJUSTING CAM TO RADIUS ARM 4. Drill a 0.228 inch diameter hole at the punch mark. Use this hole to mount the adjusting cam with the 1/4-20 self-tapping screw supplied. Refer to Figure 10. 5. Figure 10 shows a typical cam installation. Each hole in the cam represents a 1/2 degree caster increase. A caster increase of approximately 2 degrees for the E100-350, for example, will be obtained by mounting the cam with the selftapping screw in the No. 2 hole of the cam to the lower flange of the radius arm. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Customer Interest: > 851915 > Sep > 85 > Steering - Drift/Pull > Page 727 Figure 11 - TYPICAL INSTALLATION - FRONT AND RADIUS ARM 6. Figure 11 shows a typical vehicle installation. TORQUE BOLT "A" AND NUT "B" TO 270-330 FT. LBS. When increasing caster 2 degrees or more, the ears of the radius arm should be bent upward slightly to help install and seat the axles. Do not use heat to bend. 7. Reset front wheel toe after installation is complete. AFTER THE DESIRED ALIGNMENT IS ASSURED THE CAM MUST BE WELDED TO THE ARM ARC WELD ONE INCH MINIMUM LENGTH ALONG TWO SIDES OF THE CAM. NOTE: The metal adjusting cam plate has a Ford logo stamped on it to identify it for E100- 150 and F250-350 4x2 vehicles only on vehicles with a front stabilizer bar. The bar mounting bracket may be reworked to provide clearance for the self-tapping screw. Do not use parts from kit E4TZ3K064-A on these vehicles. PART NUMBER PART NAME CLASS E5TZ-3K064-A Kit Caster Adjustment C OTHER APPLICABLE ARTICLES: 85-13-12 WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION: SP3360B85L TIME: Left - F Series: 2.4 Hrs. Econoline: 2.8 Hrs. OPERATION: SP3360B85R TIME: Right - F Series: 2.4 Hrs. Econoline: 2.8 Hrs. OPERATION: SP3360B85T TIME: Both - F Series: 3.8 Hrs. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Customer Interest: > 851915 > Sep > 85 > Steering - Drift/Pull > Page 728 Econoline: 4.6 Hrs. OPERATION: 3001A TIME: 0.5 Hr. - Check caster camber and toe-in DLR. CODING: Basic Part No. 3A360 - Code: 36 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 892110 > Oct > 89 > Steering - Pull or Drift Alignment: All Technical Service Bulletins Steering - Pull or Drift Article No. 89-21-10 ^ STEERING - PULL OR DRIFT - CASTER SPLIT - NEW SERVICE ADJUSTERS - 4X4 MODELS ^ SUSPENSION - FRONT - NEW SERVICE CASTER ADJUSTERS - 4X4 MODELS LIGHT TRUCK: 1980-89 BRONCO, F-150, F-250, F-350 1983-89 RANGER 1984-89 BRONCO II Figure 1 This TSB article is being republished in its entirety to correct the service parts for the Caster Adjusters. ISSUE: Two new alignment adjusters are now available for service. These new parts provide one degree of caster adjustment along with one degree of camber. Steering pull may be caused by caster split. The affected trucks are 4x4 Twin Traction Beam vehicles. ACTION: Use the following procedure to determine the position of the service adjuster sleeve. Refer to the appropriate Light Truck Shop Manual, Section 14-21 for installation details. The new alignment adjusters are similiar to the current camber adjusters. The one exception is the rotational position of the adjuster sleeve to obtain the desired adjustment. ADJUSTER SLEEVE APPLICATION FOR RANGER BRONCO II, BRONCO, AND F-150 1. Measure and record the alignment readings. 2. Determine what alignment adjuster sleeves are on the truck. NOTE: IF AFTERMARKET ADJUSTER SLEEVES HAVE BEEN INSTALLED, IT WILL BE NECESSARY TO FIND OUT WHAT CASTER AND CAMBER SLEEVES WERE USED. If the adjuster sleeve is not marked or cannot be identified, install a 0 degree adjuster sleeve to use as a reference point. 3. Determine what adjuster sleeve change is required. Take your desired alignment (what you want to end up with) and compare it to the readings taken in Step 1 to determine the change. 4. Pick the adjuster sleeve that will get you the closest to the desired alignment. 5. Install and position the adjuster sleeve, Figure 1. Refer to the appropriate Light Truck Shop Manual, Section 14-21 for service details. See the following caster adjuster sleeve chart and camber adjuster sleeve chart for the correct service parts. CAMBER ADJUSTER SLEEVE APPLICATION CHART Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 892110 > Oct > 89 > Steering - Pull or Drift > Page 734 SERVICE PART APPLICATION VALUE NUMBER F Series/Bronco - 0~ E0TZ-3B440-A 4x4 1/2~ E0TZ-3B440-B 1~ E0TZ-3B440-C 1-1/2~ E0TZ-3B440-D Ranger/ Bronco II - 0~ E3TZ-3B440-A 4x4 1/2~ E3TZ-3B440-B 1~ E3TZ-3B440-C 1-1/2~ E3TZ-3B440-D ADJUSTER ORIENTATION CHART CAMBER CASTER CAMBER CASTER POSITION LEFT LEFT RIGHT RIGHT OF SLOT SIDE SIDE SIDE SIDE 45~ +1~ -1~ -1~ -1~ 135~ -1~ -1~ + 1~ -1~ 225~ -1~ +1~ +1~ +1~ 315~ +1~ +1~ -1~ +1~ 6. Recheck the alignment to make sure you arrived at the desired values. CASTER WEDGE APPLICATION: F-250/350 4X4 The caster angle on the F-250 4x4 can be adjusted by inserting a wedge between the spring and the axle. Refer to the appropriate model year Light Truck Shop Manual, page 14-01-14 for installation details. See the following application chart for the correct service part. CASTER WEDGE APPLICATION CHART SERVICE PART APPLICATION VALUE NUMBER F-250/350 - 0~ E0TZ-5A313-A 4x4 1~ E0TZ-5A313-C 2~ E0TZ-5A313-B NOTE: F-350 4X4 TWIN TRACTION BEAM - CASTER AND CASTER SPLITS ARE ADJUSTABLE USING WEDGES. F-350 4X4 MONOBEAM - CASTER SPLITS ARE NOT ADJUSTABLE. A CASTER CHANGE FOR BOTH WHEELS IS ACCOMPLISHED USING WEDGES. PART NUMBER PART NAME CLASS E9TZ-3B440-F Caster Adjuster - B F-Series/Bronco E9TZ-3B440-G Caster Adjuster - B Ranger/Bronco II E0TZ-3B440-A Camber Adjuster - AM F-Series/Bronco E0TZ-3B440-B Camber Adjuster - AM Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 892110 > Oct > 89 > Steering - Pull or Drift > Page 735 F-Series/Bronco E0TZ-3B440-C Camber Adjuster - AM F-Series/Bronco E0TZ-3B440-D Camber Adjuster - AM F-Series/Bronco E3TZ-3B440-A Camber Adjuster - BM Ranger/Bronco II E3TZ-3B440-B Camber Adjuster - AM Ranger/Bronco II E3TZ-3B440-C Camber Adjuster - AM Ranger/Bronco II E3TZ-3B440-D Camber Adjuster - AM Ranger/Bronco II E0TZ-5A313-A Caster Wedge C E0TZ-5A313-B Caster Wedge BM E0TZ-5A313-C Caster Wedge RM OTHER APPLICABLE ARTICLES: 87-4-16 SUPERSEDES: 89-19-13, date 9/20 89 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 3100, 3200, 3300 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 87416 > Feb > 87 > Steering - Pulling or Drifting Alignment: All Technical Service Bulletins Steering - Pulling or Drifting ^ STEERING - PULL OR DRIFT - CASTER Article No. ADJUSTMENT SERVICE KIT 87-4-16 ^ SUSPENSION - FRONT - CASTER ADJUSTMENT SERVICE KIT LIGHT TRUCK 1980-86 F-150 (4x4), BRONCO ISSUE: A steering drift or pull may be caused by excessive front wheel side-to-side caster angle differences. ACTION: If a front axle alignment check shows excessive (more than 3/4 degree split) side-to-side caster angle difference causing the vehicle to drift or pull, install a new caster adjustment kit (E0TZ-3K064-A) which allows the front axle side-to-side caster angles to be changed up to 2-1/2 degrees in 1/2 degree increments. New front axle to radius arm brackets must also be replaced when the caster kit is installed. Refer to the following service procedure for step-by-step instructions. NOTE THE FOLLOWING INFORMATION BEFORE DOING WORK ON THE VEHICLE. To correct caster side-to-side difference of up to 1- 1/2 degrees, install a caster adjuster plate on the radius arm that has the lower caster reading. Adjuster plates are identified R.H. and L.H. To correct caster side-to-side difference more than 1-1/2 degrees, install the caster plate on both radius arms. Installing both plates will allow a caster split change of 2-1/2 degrees (+1-1/2 degrees on the low caster side, -1 degree on the high caster side). 1. Remove radius arm from vehicle. Figure 14 - Article 87-4-16 2. Locate the template, included in the kit, on the bottom flange of radius arm over the existing holes, as shown in Figure 14. NOTE: Right arm adjustment is shown. One template is used to modify both right and left hand arms. When modifying right arm, position template with printed side down (printed side up for left arm). Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 87416 > Feb > 87 > Steering - Pulling or Drifting > Page 740 Figure 14 - Article 87-4-16 Figure 15 - Article 87-4-16 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 87416 > Feb > 87 > Steering - Pulling or Drifting > Page 741 Figure 16 - Article 87-4-16 3. With template secure, punch mark radius arm at the small hole in the template, as shown in Figures 14 and 15. Mark radius arm, and diegrind a slot at the axle attaching hole the same size as the slot in the template, see Figure 16. De-burr the surface; avoid rounding the edges of the slot. Figure 13 - Article 87-4-16 4. Use a No. 6 drill to make a .204 inch diameter through hole at the punch mark. Line up the caster adjuster plate on the radius arm to obtain the required change in caster, see Figure 13. Figure 17 - Article 87-4-16 NOTE: Each hole changes caster approximately 1/2 degree + or - from the "0" index hole. 5. Install the tap screw to 120 in.lbs. (13 N-m) torque. 6. Reinstall radius arm with a new bracket (front axle to radius arm). The new bracket has a larger "jaw" spacing to fit over caster adjuster plate. ^ For non-quad shock vehicles, install bracket E7TZ-3B446-A. ^ For quad shock vehicles, install bracket E7TZ-18112-A, R.H. or E7TZ-18113-A, L.H. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 87416 > Feb > 87 > Steering - Pulling or Drifting > Page 742 Figure 18 - Article 87-4-16 7. Tighten upper stud/bolt to 240-260 ft.lbs. (325-352 N-m) torque, Figure 18. 8. Tighten lower bolt to 320-340 ft.lbs. (434-461 N-m) torque, Figure 18. 9. Tighten front axle radius arm bracket bolts to 20-26 ft.lbs. (27-35 N-m) torque, Figure 18. 10. Arc weld caster adjuster plate to radius arm with a 1/4 inch-long bead along two sides of the plate. 11. Reset toe to specification. PART NUMBER PART NAME CLASS E0TZ-3K064-A Caster Kit CG E7TZ-3B446-A Bracket - Radius Arm C E7TZ-18112-A Bracket - Radius Arm CG E7TZ-18113-A Bracket - Radius Arm CG OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual OPERATION: SP870416A - Caster kit one side TIME: 2.1 Hrs. OPERATION: SP870416B - Caster kit both sides TIME: 3.5 Hrs. DLR. CODING: Basic Part No. FRONT - Code: 07 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 862427 > Dec > 86 > Front Tires - Irregular Wear Pattern Alignment: All Technical Service Bulletins Front Tires - Irregular Wear Pattern Article No. 86-24-27 TIRE WEAR - FRONT - IRREGULAR PATTERN LIGHT TRUCK 1985-87 ALL LIGHT TRUCKS Vehicles may experience front tire wear with all season/all terrain tires described as irregular, heel and toe, or diagonal. The condition may be related to alignment settings, vehicle usage, and tire tread/ carcass/compound design. Tires with minimal wear conditions should be crossrotated to the rear and alignment checked and set to Shop Manual preferred settings for toe. In cases of severe wear, obtain the complete alignment readings and tire information. Contact both your Ford Representative and Tire Manufacturer's Representative for their assistance and participation in resolving the customer's concern. Contacting the "local" tire store may not obtain the assistance which may be available from the tire manufacturer. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 862428 > Dec > 86 > Tire Wear - Toe Set Prior Vehicle Service Alignment: All Technical Service Bulletins Tire Wear - Toe Set Prior Vehicle Service Article No. 86-24-28 TIRE WEAR - TOE SET PRIOR TO VEHICLE PLACEMENT INTO SERVICE VEHICLES WITH SNOWPLOW SCHOOL BUSES, AMBULANCES LIGHT TRUCK 1985-86 RANGER, F-SERIES, BRONCO, ECONOLINE Certain model vehicles have a significant weight change on the front axle between manufacture by Ford and placement into service. This occurs when incomplete vehicles are completed by a body company or when equipment is added to a complete vehicle (i.e., winches, plows, tool boxes, etc.). This weight change can affect toe setting so these vehicles require that toe be reset. Figure 25 The tag shown in Figure 25 is attached to the steering column of vehicles originally built with the intent to add additional equipment. These vehicles require toe reset. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 86622 > Mar > 86 > Steering - Vehicle Drifting/Pulling Alignment: All Technical Service Bulletins Steering - Vehicle Drifting/Pulling Article No. 86-6-22 STEERING - DRIFT/PULL - RUBBER BALL SOCKET LINKAGE WIND-UP LIGHT TRUCK 1985-86 E, F SERIES, BRONCO Complaints of drifts and pulls on certain 1985-86 E, F Series and Bronco models may be caused by the installation procedure of the steering linkage. BECAUSE THE RUBBER TENDS TO RETURN TO ITS INSTALLED POSITION, IT IS IMPERATIVE THAT THE INSTALLATION BE ACCOMPLISHED WITH THE FRONT WHEELS AND THE PITMAN ARM IN THE STRAIGHT AHEAD POSITION, AND THE STUD SEATED IN THE TAPERED HOLE PRIOR TO TIGHTENING THE NUTS. Care should be taken with the installation to prevent a drift condition. To diagnose if a preload in the rubber is causing the drift, the following procedure is recommended: 1. Loosen the studs in the tapered holes at the pitman arm and the left and right spindles (i.e., disengage the stud from the hole so that it is no longer seated). 2. Hand install the nuts so that the stud is free to turn inside the tapered hole. 3. INSTALL COTTER PINS IN ALL THE STUDS. 4. Drive the vehicle. If it no longer drifts, then it can be assumed that the rubber was causing the drift. If it continues to drift, the condition is NOT being caused by the rubber ball sockets. 5. In either case, do not replace the steering linkage. Reinstall the linkage as follows: F Series and Bronco 1. Ensure the pitman arm and wheels are in the straight ahead position. (The pitman arm is exactly straight ahead when the clear vision is at 0~.) 2. Lock the steering wheel straight ahead and loose assemble the steering linkage to the pitman arm and then to the spindles. 3. Being careful not to change the position of the pitman arm, torque the steering linkage nuts to 65 ft.lbs. (88.1 N-m) The recommended sequence for tightening is: 1) the pitman arm, 2) the right side spindle and 3) the left side spindle. 4. Install all the cotter pins by advancing the nut to the next castellation. 5. Adjust the toe-in if necessary. Econoline 1. Ensure that the wheels are in the straight ahead position. 2. Loose assemble the steering linkage to the spindles and the pitman arm. 3. Being careful not to move the wheels from the straight ahead position, torque the steering linkage nuts to 65 ft.lbs. The recommended tightening sequence is: 1) the right side spindle, 2) the pitman arm and 3) the left side spindle. 4. Install all the cotter pins by advancing the nut to the next castellation. 5. Adjust the toe-in and reset the clear vision if necessary. The above procedure will eliminate any of the drift being caused by the rubber ball sockets. If the vehicle still drifts, refer to Section 19 of the Light Truck Shop Manual for further diagnosis. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION: SP3008A86A - F Series and Bronco TIME: 1.4 Hrs. OPERATION: SP3008A86B - Econoline TIME: 1.5 Hrs. DLR. CODING: Basic Part No. 3304 - Code: 36 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 851915 > Sep > 85 > Steering - Drift/Pull Alignment: All Technical Service Bulletins Steering - Drift/Pull Article No. 85-19-15 STEERING - DRIFT/PULL CASTER SPLIT ADJUSTMENT LIGHT TRUCK 1980-86 F250-350 4x2; 1976-86 E100-350 A side-to-side front wheel caster difference greater than 3/4 degree can contribute to a vehicle drift or pull in the direction of the side with less caster. The service kit (E5TZ-3K064-A) can be used to increase the front wheel caster angle on either or both wheels to balance the caster split to correct a vehicle drift/pull concern. The kit contains complete parts and instructions needed to modify the front radius arm and mount a metal cam on the bottom flange of the radius arm. The kit can increase caster from 1/2 degree to 3 degrees, in 1/2 degree increments. It is not designed to decrease caster. To increase front wheel caster angle of subject vehicles and/or to balance a caster split, the following procedure is suggested: 1. Remove the radius arm from the vehicle as shown in Section 14-21 of the Reference Shop Manual and choose the appropriate paper template applicable to the vehicle model. Figure 8 - POSITIONING TEMPLATE TO LOWER FLANGE OF RADIUS ARM 2. Locate the template (3B474) on the bottom flange of the radius arm. Refer to Figure 8 for a typical arm modification for the right hand radius arm. One template per vehicle model is used to modify both the right and left hand radius arms. When modifying the right hand arm, position the Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 851915 > Sep > 85 > Steering - Drift/Pull > Page 759 template with the printed side downward. The template locates off of one of two existing holes in the radius arm. The E100-350 template is shaped to match the contours of the radius arm. Figure 9 - HOLE DRILLING INSTRUCTIONS - CAM ATTACHMENT TO LOWER FLANGE RADIUS ARM 3. With template secure, make a punch mark at the center of the small hole inside the printed circle. Scribe the slot printed/cut-out on the template and die-grind out the slot at the axle-attaching hole the same size as the slot in the template and de-burr the surface avoiding rounding the edges of the slot. Refer to Figure 9. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 851915 > Sep > 85 > Steering - Drift/Pull > Page 760 Figure 10 - ATTACHMENT OF ADJUSTING CAM TO RADIUS ARM 4. Drill a 0.228 inch diameter hole at the punch mark. Use this hole to mount the adjusting cam with the 1/4-20 self-tapping screw supplied. Refer to Figure 10. 5. Figure 10 shows a typical cam installation. Each hole in the cam represents a 1/2 degree caster increase. A caster increase of approximately 2 degrees for the E100-350, for example, will be obtained by mounting the cam with the selftapping screw in the No. 2 hole of the cam to the lower flange of the radius arm. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 851915 > Sep > 85 > Steering - Drift/Pull > Page 761 Figure 11 - TYPICAL INSTALLATION - FRONT AND RADIUS ARM 6. Figure 11 shows a typical vehicle installation. TORQUE BOLT "A" AND NUT "B" TO 270-330 FT. LBS. When increasing caster 2 degrees or more, the ears of the radius arm should be bent upward slightly to help install and seat the axles. Do not use heat to bend. 7. Reset front wheel toe after installation is complete. AFTER THE DESIRED ALIGNMENT IS ASSURED THE CAM MUST BE WELDED TO THE ARM ARC WELD ONE INCH MINIMUM LENGTH ALONG TWO SIDES OF THE CAM. NOTE: The metal adjusting cam plate has a Ford logo stamped on it to identify it for E100- 150 and F250-350 4x2 vehicles only on vehicles with a front stabilizer bar. The bar mounting bracket may be reworked to provide clearance for the self-tapping screw. Do not use parts from kit E4TZ3K064-A on these vehicles. PART NUMBER PART NAME CLASS E5TZ-3K064-A Kit Caster Adjustment C OTHER APPLICABLE ARTICLES: 85-13-12 WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION: SP3360B85L TIME: Left - F Series: 2.4 Hrs. Econoline: 2.8 Hrs. OPERATION: SP3360B85R TIME: Right - F Series: 2.4 Hrs. Econoline: 2.8 Hrs. OPERATION: SP3360B85T TIME: Both - F Series: 3.8 Hrs. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 851915 > Sep > 85 > Steering - Drift/Pull > Page 762 Econoline: 4.6 Hrs. OPERATION: 3001A TIME: 0.5 Hr. - Check caster camber and toe-in DLR. CODING: Basic Part No. 3A360 - Code: 36 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 862427 > Dec > 86 > Front Tires - Irregular Wear Pattern Alignment: All Technical Service Bulletins Front Tires - Irregular Wear Pattern Article No. 86-24-27 TIRE WEAR - FRONT - IRREGULAR PATTERN LIGHT TRUCK 1985-87 ALL LIGHT TRUCKS Vehicles may experience front tire wear with all season/all terrain tires described as irregular, heel and toe, or diagonal. The condition may be related to alignment settings, vehicle usage, and tire tread/ carcass/compound design. Tires with minimal wear conditions should be crossrotated to the rear and alignment checked and set to Shop Manual preferred settings for toe. In cases of severe wear, obtain the complete alignment readings and tire information. Contact both your Ford Representative and Tire Manufacturer's Representative for their assistance and participation in resolving the customer's concern. Contacting the "local" tire store may not obtain the assistance which may be available from the tire manufacturer. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 862428 > Dec > 86 > Tire Wear - Toe Set Prior Vehicle Service Alignment: All Technical Service Bulletins Tire Wear - Toe Set Prior Vehicle Service Article No. 86-24-28 TIRE WEAR - TOE SET PRIOR TO VEHICLE PLACEMENT INTO SERVICE VEHICLES WITH SNOWPLOW SCHOOL BUSES, AMBULANCES LIGHT TRUCK 1985-86 RANGER, F-SERIES, BRONCO, ECONOLINE Certain model vehicles have a significant weight change on the front axle between manufacture by Ford and placement into service. This occurs when incomplete vehicles are completed by a body company or when equipment is added to a complete vehicle (i.e., winches, plows, tool boxes, etc.). This weight change can affect toe setting so these vehicles require that toe be reset. Figure 25 The tag shown in Figure 25 is attached to the steering column of vehicles originally built with the intent to add additional equipment. These vehicles require toe reset. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 772 Alignment: By Symptom Technical Service Bulletin # 892110 Date: 891018 Steering - Pull or Drift Article No. 89-21-10 ^ STEERING - PULL OR DRIFT - CASTER SPLIT - NEW SERVICE ADJUSTERS - 4X4 MODELS ^ SUSPENSION - FRONT - NEW SERVICE CASTER ADJUSTERS - 4X4 MODELS LIGHT TRUCK: 1980-89 BRONCO, F-150, F-250, F-350 1983-89 RANGER 1984-89 BRONCO II Figure 1 This TSB article is being republished in its entirety to correct the service parts for the Caster Adjusters. ISSUE: Two new alignment adjusters are now available for service. These new parts provide one degree of caster adjustment along with one degree of camber. Steering pull may be caused by caster split. The affected trucks are 4x4 Twin Traction Beam vehicles. ACTION: Use the following procedure to determine the position of the service adjuster sleeve. Refer to the appropriate Light Truck Shop Manual, Section 14-21 for installation details. The new alignment adjusters are similiar to the current camber adjusters. The one exception is the rotational position of the adjuster sleeve to obtain the desired adjustment. ADJUSTER SLEEVE APPLICATION FOR RANGER BRONCO II, BRONCO, AND F-150 1. Measure and record the alignment readings. 2. Determine what alignment adjuster sleeves are on the truck. NOTE: IF AFTERMARKET ADJUSTER SLEEVES HAVE BEEN INSTALLED, IT WILL BE NECESSARY TO FIND OUT WHAT CASTER AND CAMBER SLEEVES WERE USED. If the adjuster sleeve is not marked or cannot be identified, install a 0 degree adjuster sleeve to use as a reference point. 3. Determine what adjuster sleeve change is required. Take your desired alignment (what you want to end up with) and compare it to the readings taken in Step 1 to determine the change. 4. Pick the adjuster sleeve that will get you the closest to the desired alignment. 5. Install and position the adjuster sleeve, Figure 1. Refer to the appropriate Light Truck Shop Manual, Section 14-21 for service details. See the following caster adjuster sleeve chart and camber adjuster sleeve chart for the correct service parts. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 773 CAMBER ADJUSTER SLEEVE APPLICATION CHART SERVICE PART APPLICATION VALUE NUMBER F Series/Bronco - 0~ E0TZ-3B440-A 4x4 1/2~ E0TZ-3B440-B 1~ E0TZ-3B440-C 1-1/2~ E0TZ-3B440-D Ranger/ Bronco II - 0~ E3TZ-3B440-A 4x4 1/2~ E3TZ-3B440-B 1~ E3TZ-3B440-C 1-1/2~ E3TZ-3B440-D ADJUSTER ORIENTATION CHART CAMBER CASTER CAMBER CASTER POSITION LEFT LEFT RIGHT RIGHT OF SLOT SIDE SIDE SIDE SIDE 45~ +1~ -1~ -1~ -1~ 135~ -1~ -1~ + 1~ -1~ 225~ -1~ +1~ +1~ +1~ 315~ +1~ +1~ -1~ +1~ 6. Recheck the alignment to make sure you arrived at the desired values. CASTER WEDGE APPLICATION: F-250/350 4X4 The caster angle on the F-250 4x4 can be adjusted by inserting a wedge between the spring and the axle. Refer to the appropriate model year Light Truck Shop Manual, page 14-01-14 for installation details. See the following application chart for the correct service part. CASTER WEDGE APPLICATION CHART SERVICE PART APPLICATION VALUE NUMBER F-250/350 - 0~ E0TZ-5A313-A 4x4 1~ E0TZ-5A313-C 2~ E0TZ-5A313-B NOTE: F-350 4X4 TWIN TRACTION BEAM - CASTER AND CASTER SPLITS ARE ADJUSTABLE USING WEDGES. F-350 4X4 MONOBEAM - CASTER SPLITS ARE NOT ADJUSTABLE. A CASTER CHANGE FOR BOTH WHEELS IS ACCOMPLISHED USING WEDGES. PART NUMBER PART NAME CLASS E9TZ-3B440-F Caster Adjuster - B F-Series/Bronco E9TZ-3B440-G Caster Adjuster - B Ranger/Bronco II E0TZ-3B440-A Camber Adjuster - AM Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 774 F-Series/Bronco E0TZ-3B440-B Camber Adjuster - AM F-Series/Bronco E0TZ-3B440-C Camber Adjuster - AM F-Series/Bronco E0TZ-3B440-D Camber Adjuster - AM F-Series/Bronco E3TZ-3B440-A Camber Adjuster - BM Ranger/Bronco II E3TZ-3B440-B Camber Adjuster - AM Ranger/Bronco II E3TZ-3B440-C Camber Adjuster - AM Ranger/Bronco II E3TZ-3B440-D Camber Adjuster - AM Ranger/Bronco II E0TZ-5A313-A Caster Wedge C E0TZ-5A313-B Caster Wedge BM E0TZ-5A313-C Caster Wedge RM OTHER APPLICABLE ARTICLES: 87-4-16 SUPERSEDES: 89-19-13, date 9/20 89 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 3100, 3200, 3300 Technical Service Bulletin # 87416 Date: 870225 Steering - Pulling or Drifting ^ STEERING - PULL OR DRIFT - CASTER Article No. ADJUSTMENT SERVICE KIT 87-4-16 ^ SUSPENSION - FRONT - CASTER ADJUSTMENT SERVICE KIT LIGHT TRUCK 1980-86 F-150 (4x4), BRONCO ISSUE: A steering drift or pull may be caused by excessive front wheel side-to-side caster angle differences. ACTION: If a front axle alignment check shows excessive (more than 3/4 degree split) side-to-side caster angle difference causing the vehicle to drift or pull, install a new caster adjustment kit (E0TZ-3K064-A) which allows the front axle side-to-side caster angles to be changed up to 2-1/2 degrees in 1/2 degree increments. New front axle to radius arm brackets must also be replaced when the caster kit is installed. Refer to the following service procedure for step-by-step instructions. NOTE THE FOLLOWING INFORMATION BEFORE DOING WORK ON THE VEHICLE. To correct caster side-to-side difference of up to 1- 1/2 degrees, install a caster adjuster plate on the radius arm that has the lower caster reading. Adjuster plates are identified R.H. and L.H. To correct caster side-to-side difference more than 1-1/2 degrees, install the caster plate on both radius arms. Installing both plates will allow a caster split change of 2-1/2 degrees (+1-1/2 degrees on the low caster side, -1 degree on the high caster side). 1. Remove radius arm from vehicle. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 775 Figure 14 - Article 87-4-16 2. Locate the template, included in the kit, on the bottom flange of radius arm over the existing holes, as shown in Figure 14. NOTE: Right arm adjustment is shown. One template is used to modify both right and left hand arms. When modifying right arm, position template with printed side down (printed side up for left arm). Figure 14 - Article 87-4-16 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 776 Figure 15 - Article 87-4-16 Figure 16 - Article 87-4-16 3. With template secure, punch mark radius arm at the small hole in the template, as shown in Figures 14 and 15. Mark radius arm, and diegrind a slot at the axle attaching hole the same size as the slot in the template, see Figure 16. De-burr the surface; avoid rounding the edges of the slot. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 777 Figure 13 - Article 87-4-16 4. Use a No. 6 drill to make a .204 inch diameter through hole at the punch mark. Line up the caster adjuster plate on the radius arm to obtain the required change in caster, see Figure 13. Figure 17 - Article 87-4-16 NOTE: Each hole changes caster approximately 1/2 degree + or - from the "0" index hole. 5. Install the tap screw to 120 in.lbs. (13 N-m) torque. 6. Reinstall radius arm with a new bracket (front axle to radius arm). The new bracket has a larger "jaw" spacing to fit over caster adjuster plate. ^ For non-quad shock vehicles, install bracket E7TZ-3B446-A. ^ For quad shock vehicles, install bracket E7TZ-18112-A, R.H. or E7TZ-18113-A, L.H. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 778 Figure 18 - Article 87-4-16 7. Tighten upper stud/bolt to 240-260 ft.lbs. (325-352 N-m) torque, Figure 18. 8. Tighten lower bolt to 320-340 ft.lbs. (434-461 N-m) torque, Figure 18. 9. Tighten front axle radius arm bracket bolts to 20-26 ft.lbs. (27-35 N-m) torque, Figure 18. 10. Arc weld caster adjuster plate to radius arm with a 1/4 inch-long bead along two sides of the plate. 11. Reset toe to specification. PART NUMBER PART NAME CLASS E0TZ-3K064-A Caster Kit CG E7TZ-3B446-A Bracket - Radius Arm C E7TZ-18112-A Bracket - Radius Arm CG E7TZ-18113-A Bracket - Radius Arm CG OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual OPERATION: SP870416A - Caster kit one side TIME: 2.1 Hrs. OPERATION: SP870416B - Caster kit both sides TIME: 3.5 Hrs. DLR. CODING: Basic Part No. FRONT - Code: 07 Technical Service Bulletin # 86622 Date: 860326 Steering - Vehicle Drifting/Pulling Article No. 86-6-22 STEERING - DRIFT/PULL - RUBBER BALL SOCKET LINKAGE WIND-UP LIGHT TRUCK 1985-86 E, F SERIES, BRONCO Complaints of drifts and pulls on certain 1985-86 E, F Series and Bronco models may be caused by the installation procedure of the steering linkage. BECAUSE THE RUBBER TENDS TO RETURN TO ITS INSTALLED POSITION, IT IS IMPERATIVE THAT THE INSTALLATION BE ACCOMPLISHED WITH THE FRONT WHEELS AND THE PITMAN ARM IN THE STRAIGHT AHEAD POSITION, AND THE STUD SEATED IN THE TAPERED HOLE PRIOR TO TIGHTENING THE NUTS. Care should be taken with the installation to prevent a drift condition. To diagnose if a preload in the rubber is causing the drift, the following procedure is recommended: 1. Loosen the studs in the tapered holes at the pitman arm and the left and right spindles (i.e., disengage the stud from the hole so that it is no longer seated). 2. Hand install the nuts so that the stud is free to turn inside the tapered hole. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 779 3. INSTALL COTTER PINS IN ALL THE STUDS. 4. Drive the vehicle. If it no longer drifts, then it can be assumed that the rubber was causing the drift. If it continues to drift, the condition is NOT being caused by the rubber ball sockets. 5. In either case, do not replace the steering linkage. Reinstall the linkage as follows: F Series and Bronco 1. Ensure the pitman arm and wheels are in the straight ahead position. (The pitman arm is exactly straight ahead when the clear vision is at 0~.) 2. Lock the steering wheel straight ahead and loose assemble the steering linkage to the pitman arm and then to the spindles. 3. Being careful not to change the position of the pitman arm, torque the steering linkage nuts to 65 ft.lbs. (88.1 N-m) The recommended sequence for tightening is: 1) the pitman arm, 2) the right side spindle and 3) the left side spindle. 4. Install all the cotter pins by advancing the nut to the next castellation. 5. Adjust the toe-in if necessary. Econoline 1. Ensure that the wheels are in the straight ahead position. 2. Loose assemble the steering linkage to the spindles and the pitman arm. 3. Being careful not to move the wheels from the straight ahead position, torque the steering linkage nuts to 65 ft.lbs. The recommended tightening sequence is: 1) the right side spindle, 2) the pitman arm and 3) the left side spindle. 4. Install all the cotter pins by advancing the nut to the next castellation. 5. Adjust the toe-in and reset the clear vision if necessary. The above procedure will eliminate any of the drift being caused by the rubber ball sockets. If the vehicle still drifts, refer to Section 19 of the Light Truck Shop Manual for further diagnosis. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION: SP3008A86A - F Series and Bronco TIME: 1.4 Hrs. OPERATION: SP3008A86B - Econoline TIME: 1.5 Hrs. DLR. CODING: Basic Part No. 3304 - Code: 36 Technical Service Bulletin # 851915 Date: 850926 Steering - Drift/Pull Article No. 85-19-15 STEERING - DRIFT/PULL CASTER SPLIT ADJUSTMENT LIGHT TRUCK 1980-86 F250-350 4x2; 1976-86 E100-350 A side-to-side front wheel caster difference greater than 3/4 degree can contribute to a vehicle drift or pull in the direction of the side with less caster. The service kit (E5TZ-3K064-A) can be used to increase the front wheel caster angle on either or both wheels to balance the caster split to correct a vehicle drift/pull concern. The kit contains complete parts and instructions needed to modify the front radius arm and mount a metal cam on the bottom flange of the radius arm. The kit can increase caster from 1/2 degree to 3 degrees, in 1/2 degree increments. It is not designed to decrease caster. To increase front wheel caster angle of subject vehicles and/or to balance a caster split, the following procedure is suggested: 1. Remove the radius arm from the vehicle as shown in Section 14-21 of the Reference Shop Manual and choose the appropriate paper template applicable to the vehicle model. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 780 Figure 8 - POSITIONING TEMPLATE TO LOWER FLANGE OF RADIUS ARM 2. Locate the template (3B474) on the bottom flange of the radius arm. Refer to Figure 8 for a typical arm modification for the right hand radius arm. One template per vehicle model is used to modify both the right and left hand radius arms. When modifying the right hand arm, position the template with the printed side downward. The template locates off of one of two existing holes in the radius arm. The E100-350 template is shaped to match the contours of the radius arm. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 781 Figure 9 - HOLE DRILLING INSTRUCTIONS - CAM ATTACHMENT TO LOWER FLANGE RADIUS ARM 3. With template secure, make a punch mark at the center of the small hole inside the printed circle. Scribe the slot printed/cut-out on the template and die-grind out the slot at the axle-attaching hole the same size as the slot in the template and de-burr the surface avoiding rounding the edges of the slot. Refer to Figure 9. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 782 Figure 10 - ATTACHMENT OF ADJUSTING CAM TO RADIUS ARM 4. Drill a 0.228 inch diameter hole at the punch mark. Use this hole to mount the adjusting cam with the 1/4-20 self-tapping screw supplied. Refer to Figure 10. 5. Figure 10 shows a typical cam installation. Each hole in the cam represents a 1/2 degree caster increase. A caster increase of approximately 2 degrees for the E100-350, for example, will be obtained by mounting the cam with the selftapping screw in the No. 2 hole of the cam to the lower flange of the radius arm. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 783 Figure 11 - TYPICAL INSTALLATION - FRONT AND RADIUS ARM 6. Figure 11 shows a typical vehicle installation. TORQUE BOLT "A" AND NUT "B" TO 270-330 FT. LBS. When increasing caster 2 degrees or more, the ears of the radius arm should be bent upward slightly to help install and seat the axles. Do not use heat to bend. 7. Reset front wheel toe after installation is complete. AFTER THE DESIRED ALIGNMENT IS ASSURED THE CAM MUST BE WELDED TO THE ARM ARC WELD ONE INCH MINIMUM LENGTH ALONG TWO SIDES OF THE CAM. NOTE: The metal adjusting cam plate has a Ford logo stamped on it to identify it for E100- 150 and F250-350 4x2 vehicles only on vehicles with a front stabilizer bar. The bar mounting bracket may be reworked to provide clearance for the self-tapping screw. Do not use parts from kit E4TZ3K064-A on these vehicles. PART NUMBER PART NAME CLASS E5TZ-3K064-A Kit Caster Adjustment C OTHER APPLICABLE ARTICLES: 85-13-12 WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION: SP3360B85L TIME: Left - F Series: 2.4 Hrs. Econoline: 2.8 Hrs. OPERATION: SP3360B85R TIME: Right - F Series: 2.4 Hrs. Econoline: 2.8 Hrs. OPERATION: SP3360B85T TIME: Both - F Series: 3.8 Hrs. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 784 Econoline: 4.6 Hrs. OPERATION: 3001A TIME: 0.5 Hr. - Check caster camber and toe-in DLR. CODING: Basic Part No. 3A360 - Code: 36 Technical Service Bulletin # 851915 Date: 850926 Steering - Drift/Pull Article No. 85-19-15 STEERING - DRIFT/PULL CASTER SPLIT ADJUSTMENT LIGHT TRUCK 1980-86 F250-350 4x2; 1976-86 E100-350 A side-to-side front wheel caster difference greater than 3/4 degree can contribute to a vehicle drift or pull in the direction of the side with less caster. The service kit (E5TZ-3K064-A) can be used to increase the front wheel caster angle on either or both wheels to balance the caster split to correct a vehicle drift/pull concern. The kit contains complete parts and instructions needed to modify the front radius arm and mount a metal cam on the bottom flange of the radius arm. The kit can increase caster from 1/2 degree to 3 degrees, in 1/2 degree increments. It is not designed to decrease caster. To increase front wheel caster angle of subject vehicles and/or to balance a caster split, the following procedure is suggested: 1. Remove the radius arm from the vehicle as shown in Section 14-21 of the Reference Shop Manual and choose the appropriate paper template applicable to the vehicle model. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 785 Figure 8 - POSITIONING TEMPLATE TO LOWER FLANGE OF RADIUS ARM 2. Locate the template (3B474) on the bottom flange of the radius arm. Refer to Figure 8 for a typical arm modification for the right hand radius arm. One template per vehicle model is used to modify both the right and left hand radius arms. When modifying the right hand arm, position the template with the printed side downward. The template locates off of one of two existing holes in the radius arm. The E100-350 template is shaped to match the contours of the radius arm. Figure 9 - HOLE DRILLING INSTRUCTIONS - CAM ATTACHMENT TO LOWER FLANGE RADIUS ARM 3. With template secure, make a punch mark at the center of the small hole inside the printed circle. Scribe the slot printed/cut-out on the template and die-grind out the slot at the axle-attaching hole the same size as the slot in the template and de-burr the surface avoiding rounding the edges of the slot. Refer to Figure 9. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 786 Figure 10 - ATTACHMENT OF ADJUSTING CAM TO RADIUS ARM 4. Drill a 0.228 inch diameter hole at the punch mark. Use this hole to mount the adjusting cam with the 1/4-20 self-tapping screw supplied. Refer to Figure 10. 5. Figure 10 shows a typical cam installation. Each hole in the cam represents a 1/2 degree caster increase. A caster increase of approximately 2 degrees for the E100-350, for example, will be obtained by mounting the cam with the selftapping screw in the No. 2 hole of the cam to the lower flange of the radius arm. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 787 Figure 11 - TYPICAL INSTALLATION - FRONT AND RADIUS ARM 6. Figure 11 shows a typical vehicle installation. TORQUE BOLT "A" AND NUT "B" TO 270-330 FT. LBS. When increasing caster 2 degrees or more, the ears of the radius arm should be bent upward slightly to help install and seat the axles. Do not use heat to bend. 7. Reset front wheel toe after installation is complete. AFTER THE DESIRED ALIGNMENT IS ASSURED THE CAM MUST BE WELDED TO THE ARM ARC WELD ONE INCH MINIMUM LENGTH ALONG TWO SIDES OF THE CAM. NOTE: The metal adjusting cam plate has a Ford logo stamped on it to identify it for E100- 150 and F250-350 4x2 vehicles only on vehicles with a front stabilizer bar. The bar mounting bracket may be reworked to provide clearance for the self-tapping screw. Do not use parts from kit E4TZ3K064-A on these vehicles. PART NUMBER PART NAME CLASS E5TZ-3K064-A Kit Caster Adjustment C OTHER APPLICABLE ARTICLES: 85-13-12 WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION: SP3360B85L TIME: Left - F Series: 2.4 Hrs. Econoline: 2.8 Hrs. OPERATION: SP3360B85R TIME: Right - F Series: 2.4 Hrs. Econoline: 2.8 Hrs. OPERATION: SP3360B85T TIME: Both - F Series: 3.8 Hrs. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 788 Econoline: 4.6 Hrs. OPERATION: 3001A TIME: 0.5 Hr. - Check caster camber and toe-in DLR. CODING: Basic Part No. 3A360 - Code: 36 Technical Service Bulletin # 892110 Date: 891018 Steering - Pull or Drift Article No. 89-21-10 ^ STEERING - PULL OR DRIFT - CASTER SPLIT - NEW SERVICE ADJUSTERS - 4X4 MODELS ^ SUSPENSION - FRONT - NEW SERVICE CASTER ADJUSTERS - 4X4 MODELS LIGHT TRUCK: 1980-89 BRONCO, F-150, F-250, F-350 1983-89 RANGER 1984-89 BRONCO II Figure 1 This TSB article is being republished in its entirety to correct the service parts for the Caster Adjusters. ISSUE: Two new alignment adjusters are now available for service. These new parts provide one degree of caster adjustment along with one degree of camber. Steering pull may be caused by caster split. The affected trucks are 4x4 Twin Traction Beam vehicles. ACTION: Use the following procedure to determine the position of the service adjuster sleeve. Refer to the appropriate Light Truck Shop Manual, Section 14-21 for installation details. The new alignment adjusters are similiar to the current camber adjusters. The one exception is the rotational position of the adjuster sleeve to obtain the desired adjustment. ADJUSTER SLEEVE APPLICATION FOR RANGER BRONCO II, BRONCO, AND F-150 1. Measure and record the alignment readings. 2. Determine what alignment adjuster sleeves are on the truck. NOTE: IF AFTERMARKET ADJUSTER SLEEVES HAVE BEEN INSTALLED, IT WILL BE NECESSARY TO FIND OUT WHAT CASTER AND CAMBER SLEEVES WERE USED. If the adjuster sleeve is not marked or cannot be identified, install a 0 degree adjuster sleeve to use as a reference point. 3. Determine what adjuster sleeve change is required. Take your desired alignment (what you want to end up with) and compare it to the readings taken in Step 1 to determine the change. 4. Pick the adjuster sleeve that will get you the closest to the desired alignment. 5. Install and position the adjuster sleeve, Figure Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 789 1. Refer to the appropriate Light Truck Shop Manual, Section 14-21 for service details. See the following caster adjuster sleeve chart and camber adjuster sleeve chart for the correct service parts. CAMBER ADJUSTER SLEEVE APPLICATION CHART SERVICE PART APPLICATION VALUE NUMBER F Series/Bronco - 0~ E0TZ-3B440-A 4x4 1/2~ E0TZ-3B440-B 1~ E0TZ-3B440-C 1-1/2~ E0TZ-3B440-D Ranger/ Bronco II - 0~ E3TZ-3B440-A 4x4 1/2~ E3TZ-3B440-B 1~ E3TZ-3B440-C 1-1/2~ E3TZ-3B440-D ADJUSTER ORIENTATION CHART CAMBER CASTER CAMBER CASTER POSITION LEFT LEFT RIGHT RIGHT OF SLOT SIDE SIDE SIDE SIDE 45~ +1~ -1~ -1~ -1~ 135~ -1~ -1~ + 1~ -1~ 225~ -1~ +1~ +1~ +1~ 315~ +1~ +1~ -1~ +1~ 6. Recheck the alignment to make sure you arrived at the desired values. CASTER WEDGE APPLICATION: F-250/350 4X4 The caster angle on the F-250 4x4 can be adjusted by inserting a wedge between the spring and the axle. Refer to the appropriate model year Light Truck Shop Manual, page 14-01-14 for installation details. See the following application chart for the correct service part. CASTER WEDGE APPLICATION CHART SERVICE PART APPLICATION VALUE NUMBER F-250/350 - 0~ E0TZ-5A313-A 4x4 1~ E0TZ-5A313-C 2~ E0TZ-5A313-B NOTE: F-350 4X4 TWIN TRACTION BEAM - CASTER AND CASTER SPLITS ARE ADJUSTABLE USING WEDGES. F-350 4X4 MONOBEAM - CASTER SPLITS ARE NOT ADJUSTABLE. A CASTER CHANGE FOR BOTH WHEELS IS ACCOMPLISHED USING WEDGES. PART NUMBER PART NAME CLASS E9TZ-3B440-F Caster Adjuster - B F-Series/Bronco E9TZ-3B440-G Caster Adjuster - B Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 790 Ranger/Bronco II E0TZ-3B440-A Camber Adjuster - AM F-Series/Bronco E0TZ-3B440-B Camber Adjuster - AM F-Series/Bronco E0TZ-3B440-C Camber Adjuster - AM F-Series/Bronco E0TZ-3B440-D Camber Adjuster - AM F-Series/Bronco E3TZ-3B440-A Camber Adjuster - BM Ranger/Bronco II E3TZ-3B440-B Camber Adjuster - AM Ranger/Bronco II E3TZ-3B440-C Camber Adjuster - AM Ranger/Bronco II E3TZ-3B440-D Camber Adjuster - AM Ranger/Bronco II E0TZ-5A313-A Caster Wedge C E0TZ-5A313-B Caster Wedge BM E0TZ-5A313-C Caster Wedge RM OTHER APPLICABLE ARTICLES: 87-4-16 SUPERSEDES: 89-19-13, date 9/20 89 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 3100, 3200, 3300 Technical Service Bulletin # 87416 Date: 870225 Steering - Pulling or Drifting ^ STEERING - PULL OR DRIFT - CASTER Article No. ADJUSTMENT SERVICE KIT 87-4-16 ^ SUSPENSION - FRONT - CASTER ADJUSTMENT SERVICE KIT LIGHT TRUCK 1980-86 F-150 (4x4), BRONCO ISSUE: A steering drift or pull may be caused by excessive front wheel side-to-side caster angle differences. ACTION: If a front axle alignment check shows excessive (more than 3/4 degree split) side-to-side caster angle difference causing the vehicle to drift or pull, install a new caster adjustment kit (E0TZ-3K064-A) which allows the front axle side-to-side caster angles to be changed up to 2-1/2 degrees in 1/2 degree increments. New front axle to radius arm brackets must also be replaced when the caster kit is installed. Refer to the following service procedure for step-by-step instructions. NOTE THE FOLLOWING INFORMATION BEFORE DOING WORK ON THE VEHICLE. To correct caster side-to-side difference of up to 1- 1/2 degrees, install a caster adjuster plate on the radius arm that has the lower caster reading. Adjuster plates are identified R.H. and L.H. To correct caster side-to-side difference more than 1-1/2 degrees, install the caster plate on both radius arms. Installing both plates will allow a caster split change of 2-1/2 degrees (+1-1/2 degrees on the low caster side, -1 degree on the high caster side). 1. Remove radius arm from vehicle. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 791 Figure 14 - Article 87-4-16 2. Locate the template, included in the kit, on the bottom flange of radius arm over the existing holes, as shown in Figure 14. NOTE: Right arm adjustment is shown. One template is used to modify both right and left hand arms. When modifying right arm, position template with printed side down (printed side up for left arm). Figure 14 - Article 87-4-16 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 792 Figure 15 - Article 87-4-16 Figure 16 - Article 87-4-16 3. With template secure, punch mark radius arm at the small hole in the template, as shown in Figures 14 and 15. Mark radius arm, and diegrind a slot at the axle attaching hole the same size as the slot in the template, see Figure 16. De-burr the surface; avoid rounding the edges of the slot. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 793 Figure 13 - Article 87-4-16 4. Use a No. 6 drill to make a .204 inch diameter through hole at the punch mark. Line up the caster adjuster plate on the radius arm to obtain the required change in caster, see Figure 13. Figure 17 - Article 87-4-16 NOTE: Each hole changes caster approximately 1/2 degree + or - from the "0" index hole. 5. Install the tap screw to 120 in.lbs. (13 N-m) torque. 6. Reinstall radius arm with a new bracket (front axle to radius arm). The new bracket has a larger "jaw" spacing to fit over caster adjuster plate. ^ For non-quad shock vehicles, install bracket E7TZ-3B446-A. ^ For quad shock vehicles, install bracket E7TZ-18112-A, R.H. or E7TZ-18113-A, L.H. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 794 Figure 18 - Article 87-4-16 7. Tighten upper stud/bolt to 240-260 ft.lbs. (325-352 N-m) torque, Figure 18. 8. Tighten lower bolt to 320-340 ft.lbs. (434-461 N-m) torque, Figure 18. 9. Tighten front axle radius arm bracket bolts to 20-26 ft.lbs. (27-35 N-m) torque, Figure 18. 10. Arc weld caster adjuster plate to radius arm with a 1/4 inch-long bead along two sides of the plate. 11. Reset toe to specification. PART NUMBER PART NAME CLASS E0TZ-3K064-A Caster Kit CG E7TZ-3B446-A Bracket - Radius Arm C E7TZ-18112-A Bracket - Radius Arm CG E7TZ-18113-A Bracket - Radius Arm CG OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual OPERATION: SP870416A - Caster kit one side TIME: 2.1 Hrs. OPERATION: SP870416B - Caster kit both sides TIME: 3.5 Hrs. DLR. CODING: Basic Part No. FRONT - Code: 07 Technical Service Bulletin # 86622 Date: 860326 Steering - Vehicle Drifting/Pulling Article No. 86-6-22 STEERING - DRIFT/PULL - RUBBER BALL SOCKET LINKAGE WIND-UP LIGHT TRUCK 1985-86 E, F SERIES, BRONCO Complaints of drifts and pulls on certain 1985-86 E, F Series and Bronco models may be caused by the installation procedure of the steering linkage. BECAUSE THE RUBBER TENDS TO RETURN TO ITS INSTALLED POSITION, IT IS IMPERATIVE THAT THE INSTALLATION BE ACCOMPLISHED WITH THE FRONT WHEELS AND THE PITMAN ARM IN THE STRAIGHT AHEAD POSITION, AND THE STUD SEATED IN THE TAPERED HOLE PRIOR TO TIGHTENING THE NUTS. Care should be taken with the installation to prevent a drift condition. To diagnose if a preload in the rubber is causing the drift, the following procedure is recommended: 1. Loosen the studs in the tapered holes at the pitman arm and the left and right spindles (i.e., disengage the stud from the hole so that it is no longer seated). 2. Hand install the nuts so that the stud is free to turn inside the tapered hole. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 795 3. INSTALL COTTER PINS IN ALL THE STUDS. 4. Drive the vehicle. If it no longer drifts, then it can be assumed that the rubber was causing the drift. If it continues to drift, the condition is NOT being caused by the rubber ball sockets. 5. In either case, do not replace the steering linkage. Reinstall the linkage as follows: F Series and Bronco 1. Ensure the pitman arm and wheels are in the straight ahead position. (The pitman arm is exactly straight ahead when the clear vision is at 0~.) 2. Lock the steering wheel straight ahead and loose assemble the steering linkage to the pitman arm and then to the spindles. 3. Being careful not to change the position of the pitman arm, torque the steering linkage nuts to 65 ft.lbs. (88.1 N-m) The recommended sequence for tightening is: 1) the pitman arm, 2) the right side spindle and 3) the left side spindle. 4. Install all the cotter pins by advancing the nut to the next castellation. 5. Adjust the toe-in if necessary. Econoline 1. Ensure that the wheels are in the straight ahead position. 2. Loose assemble the steering linkage to the spindles and the pitman arm. 3. Being careful not to move the wheels from the straight ahead position, torque the steering linkage nuts to 65 ft.lbs. The recommended tightening sequence is: 1) the right side spindle, 2) the pitman arm and 3) the left side spindle. 4. Install all the cotter pins by advancing the nut to the next castellation. 5. Adjust the toe-in and reset the clear vision if necessary. The above procedure will eliminate any of the drift being caused by the rubber ball sockets. If the vehicle still drifts, refer to Section 19 of the Light Truck Shop Manual for further diagnosis. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION: SP3008A86A - F Series and Bronco TIME: 1.4 Hrs. OPERATION: SP3008A86B - Econoline TIME: 1.5 Hrs. DLR. CODING: Basic Part No. 3304 - Code: 36 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Camber Alignment: Specifications Camber Note: Side to side camber readings must be within 7 (degrees), when truck frame to axle riding height is such that right-hand side is from 0-.4 inch less than left-hand side. Ride Height 3-3.2 in -1 to +1/4 deg 3.2-3.4 in -3/4 to +3/4 deg 3.4-3.6 in -1/4 to +1 1/4 deg 3.6-3.8 in +1/4 to + 1 3/4 deg 3.8-4 in +3/4 to +2 deg 4-4.2 in +1 to +2 1/2 deg 4.2-4.74 in +1 1/2 to +3 deg 4.4-4.6 in +2 to +3 1/2 1/4 deg 4.6-4.8 in +2 1/2 to +4 deg Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Camber > Page 798 Alignment: Specifications Caster Note: Side to side caster readings must be wintin 1 1/2 (degrees), when truck frame to axle riding height is such that right hand side is from 0 to .4 inch than left hand side. Ride Height 3-3.2 in +5 1/4 to 7 1/4 deg 3.2-3.4 in +5 to 7 deg 3.4-3.6 in 4 1/2 to 6 1/2 deg 3.6-3.8 in +4 1/4 to 6 1/4 deg 3.8-4.0 in +3 3/4 to 5 3/4 deg 4.0-4.2 in +3 1/4 to 5 1/4 deg 4.2-4.4 in +2 3/4 to 4 3/4 deg 4.4-4.6 in +2 1/2 to 4 1/2 deg 4.6-4.8 in +2 to 4 deg 4.8-5.0 in +1 1/2 to 3 1/2 deg Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Page 799 Alignment: Service and Repair Fig. 1 Measuring Ride Height Fig. 7 Measuring riding height. 1980---85 F-100---350 & Bronco Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Page 800 Fig. 8 Measuring Riding Height Prior to checking caster and camber, ensure vehicle front ride height is within {1/8} inch side to side 1980-87 E-100-350. On 1980-87 F-100-350 models, the left side ride height should be within 0-{3/8} inch higher than the right side ride height. On 1980-87 F-150-350 (4x4) and Bronco, the front ride heights should be within {3/16} inch side to side. Refer to Figs. 6, 7 and 8. If the vehicle ride heights are not within specifications, redistribute load on loaded vehicles or slightly load empty vehicles on one side. If the ride heights cannot be brought within specifications, verify correct spring installation. The ride height variations stated, are for checking purposes only. The vehicle does not have to operate within these specifications. Check and correct as necessary all tire inflation pressures, then check front tires for the same size, ply rating and load range. Check front wheel bearings and adjust as necessary. If all the above checks have been made, check wheel alignment with suitable alignment equipment. Using the ride heights obtained earlier, compare caster and camber readings to those listed in the ``Wheel Alignment Specifications Chart''. If the caster and camber angles exceed the specifications, inspect front end for damaged suspension components. Replace as necessary. Alignment equipment indicates a true reading only when the vehicle's frame is horizontal. Therefore, if the frame is not level (due to tire, spring or load differences), the caster angle reading must be modified to compensate for the frame angles. If the front is higher than the rear, subtract the amount of angle from the reading. If the front is lower than the rear, add the angle. To check frame angle, use a spirit protractor, and take the frame angle measurement on the lower frame flange at the flat area immediately adjacent to the rear spring front hanger. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Page 801 Fig. 3 Camber Adjustment Fig. 4 Removing Caster/Camber Adjustment Sleeve Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Page 802 Fig. 5 Caster/Camber Adjustment 1980-87 F-150-350 4 X 4 & BRONCO, 1982-87 F-100-350 4 X 2 W/BALL JOINTS The caster angle on 1981-87 F-250-350 4 x 4 models with leaf spring front suspension can be adjusted by inserting a shim between the spring and axle. Shims are available in increments of 0°, 1° and 2°. The 0° shim is used to adjust side to side ride height when an angled shim is installed on the opposite side of the axle. On all other models, the caster angle is designed into the axle and is not adjustable. The camber angle may be adjusted by means of mounting sleeves placed on the upper ball joint, Figs. 9, 10 and 11. Four sleeves are available in {1/2}° camber increments to allow a 3° range of adjustment from - 1 {1/2}° to +1 {1/2}°. TOE-IN, ADJUST Check the steering wheel spoke position when the front wheels are in the straight ahead position. If the spokes are not in the normal position, they can be adjusted while toe-in is being adjusted. 1. Loosen clamp bolts on each tie rod end sleeve. 2. Adjust toe-in. If steering wheel spokes are in their normal position, lengthen or shorten both rods equally to obtain correct toe-in. If spokes are not in normal position, make necessary rod adjustments to obtain correct toe-in and steering wheel spoke alignment. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Technical Service Bulletins > By Symptom Fuel Pressure: By Symptom Technical Service Bulletin # 911211 Date: 910612 Engine - Lack of Power/No Start Diagnosis Article No. 91-12-11 06/12/91 LACK OF POWER 7.5L, 5.8L, 5.0L, 4.9L - CATALYTIC CONVERTER DIAGNOSTIC TIPS LIGHT TRUCK: 1986-91 BRONCO, ECONOLINE, F-150-350 SERIES 1988-91 F SUPER DUTY, F47 ISSUE: Lack of power or a no start condition may be diagnosed as an exhaust restriction caused by a plugged catalytic converter. A plugged catalytic converter (internal deterioration) is usually caused by abnormal engine operation. ACTION: Diagnose the catalytic converter to confirm internal failure. Refer to the Catalyst and Exhaust System Diagnostic Section, in the Engine/Emissions Diagnostic Shop Manual and the following procedures for service details. 1. Lack of proper HEGO operation may cause, or be the result of a rich or lean fuel condition, which could cause additional heat in the catalyst. Perform self test KOEO and KOER, service any codes. NOTE: IF TWO DIGIT CODES 41, 42, 85 OR THREE DIGIT CODES 171, 172, 173, 179, 181, 182, 183 AND 565 ARE RECEIVED, CHECK FOR PROPER HEGO GROUND. If the HEGO ground is good, the following areas may be at fault: ^ Ignition Coil ^ Distributor Cap ^ Distributor Rotor ^ Fouled Spark Plug ^ Spark Plug Wires ^ Air Filter ^ Stuck Open Injector ^ Fuel Contamination Engine OIL ^ Manifold Leaks Intake/ Exhaust ^ Fuel Pressure ^ Poor Power Ground ^ Engine Not At Normal Operating Temperature ^ HEGO Sensor 2. Spark timing that is retarded from specification may increase exhaust gas temperature and shorten catalyst life. Refer to the following procedure for service details. a. Check spark timing. Check base timing with spout disconnected. Set base timing to the specification on the vehicle emission decal. b. Check computed timing with spout connected. NOTE: COMPUTED TIMING IS EQUAL TO BASE TIMING PLUS 20~ BTDC +/- 3~. 3. Misfiring spark plugs may cause an unburned fuel air mixture to pass through the catalyst, which could cause higher than normal catalyst Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Technical Service Bulletins > By Symptom > Page 808 temperatures. Refer to the following procedure for service details. a. Check secondary ignition, hook the vehicle up to an engine analyzer and check for a secondary ignition misfire. NOTE: SERVICE ANY ITEM THAT IS NOT PERFORMING AT PROPER SPECIFICATIONS BEFORE CONTINUING. 4. Fuel pressure that is too high may cause rich air fuel mixtures to pass through the catalyst which could cause higher than normal catalyst temperatures. Refer to the following procedure for service details. a. Check fuel pressure, install fuel pressure gauge, start and run the engine at idle. Fuel pressures between 28 and 34 PSI are typical (4.9L typically is 15 PSI higher). b. Disconnect the vacuum line going to the fuel pressure regulator. Fuel pressure typically jumps to 40 PSI +/- 3 PSI (4.9L typically is 15 PSI higher). Visually inspect vacuum line for raw fuel. NOTE: FUEL PRESSURES ABOVE THESE VALUES SHOULD BE CORRECTED. HOWEVER, THIS MAY NOT BE THE CAUSE OF THE CONCERN. SERVICE AS NECESSARY. 5. Throttle plates in the throttle body not returning to the proper closed position may cause excessive catalyst temperatures during downhill grades. Refer to the following procedure for service details. a. Visually inspect the throttle body and linkage for: ^ Binding or sticking throttle linkage. ^ Tight speed control linkage or cable. ^ Vacuum line interference. ^ Electrical harness interference. NOTE: AFTERMARKET GOVERNORS, THROTTLE LINKAGE AND CABLES ASSOCIATED WITH POWER TAKE-OFF UNITS, MAY ALSO INTERFERE WITH PROPER THROTTLE RETURN. SERVICE AS NECESSARY. 6. It is extremely important that all systems related to the engine and emission systems operate properly. a. Visually inspect the engine compartment to make sure all vacuum hoses and spark plug wires are properly routed and securely connected. b. Inspect all wiring harnesses and connectors for insulation damage, burned, overheated, loose or broken conditions. c. Verify proper operation of the thermactor system. Thermactor systems that fail to dump thermactor air to the atmosphere properly or at the correct time can cause high catalyst temperatures. d. Visually inspect thermactor system for damaged or kinked hoses and perform a function test on following components: air control valve, check valve, silencer, filter and the air bypass solenoid. e. Verify proper operation of the engine cooling system thermostat. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under Basic Warranty Coverage, Emissions Warranty Coverage OPERATION DESCRIPTION TIME 911211A Diagnostics - Perform 0.5 Hrs. KOEO And KOER Self Tests 911211B Timing - Check Or Adjust 0.5 Hrs. Spark Timing, Check Computed Timing And Check Secondary Ignition System With Engine Analyzer. 911211C Check - Fuel Pressure And 0.2 Hrs. Inspect Vacuum Line For Raw Fuel. 911211D Inspect - Throttle Body And 0.1 Hrs. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Technical Service Bulletins > By Symptom > Page 809 Linkage. 911211E Inspect - Vacuum Hoses, 0.1 Hrs. Electrical Harnesses, Connectors And Spark Plug Wires For Routing Damage. 911211F Thermactor System - 0.3 Hrs. Inspect For Proper Operation And Damaged Component. Includes Function Check Of Air Control Valve, Thermactor Air Bypass Solenoid, Check Valves, Silencer And Filter. 911211G Thermostat - Check For 0.2 Hrs. Proper Operation. DEALER CODING BASIC PART NO. CONDITION CODE 5E212 25 OASIS CODES: 403000, 603300, 614000 Technical Service Bulletin # 911211 Date: 910612 Engine - Lack of Power/No Start Diagnosis Article No. 91-12-11 06/12/91 LACK OF POWER 7.5L, 5.8L, 5.0L, 4.9L - CATALYTIC CONVERTER DIAGNOSTIC TIPS LIGHT TRUCK: 1986-91 BRONCO, ECONOLINE, F-150-350 SERIES 1988-91 F SUPER DUTY, F47 ISSUE: Lack of power or a no start condition may be diagnosed as an exhaust restriction caused by a plugged catalytic converter. A plugged catalytic converter (internal deterioration) is usually caused by abnormal engine operation. ACTION: Diagnose the catalytic converter to confirm internal failure. Refer to the Catalyst and Exhaust System Diagnostic Section, in the Engine/Emissions Diagnostic Shop Manual and the following procedures for service details. 1. Lack of proper HEGO operation may cause, or be the result of a rich or lean fuel condition, which could cause additional heat in the catalyst. Perform self test KOEO and KOER, service any codes. NOTE: IF TWO DIGIT CODES 41, 42, 85 OR THREE DIGIT CODES 171, 172, 173, 179, 181, 182, 183 AND 565 ARE RECEIVED, CHECK FOR PROPER HEGO GROUND. If the HEGO ground is good, the following areas may be at fault: ^ Ignition Coil ^ Distributor Cap ^ Distributor Rotor ^ Fouled Spark Plug ^ Spark Plug Wires ^ Air Filter ^ Stuck Open Injector ^ Fuel Contamination Engine OIL ^ Manifold Leaks Intake/ Exhaust Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Technical Service Bulletins > By Symptom > Page 810 ^ Fuel Pressure ^ Poor Power Ground ^ Engine Not At Normal Operating Temperature ^ HEGO Sensor 2. Spark timing that is retarded from specification may increase exhaust gas temperature and shorten catalyst life. Refer to the following procedure for service details. a. Check spark timing. Check base timing with spout disconnected. Set base timing to the specification on the vehicle emission decal. b. Check computed timing with spout connected. NOTE: COMPUTED TIMING IS EQUAL TO BASE TIMING PLUS 20~ BTDC +/- 3~. 3. Misfiring spark plugs may cause an unburned fuel air mixture to pass through the catalyst, which could cause higher than normal catalyst temperatures. Refer to the following procedure for service details. a. Check secondary ignition, hook the vehicle up to an engine analyzer and check for a secondary ignition misfire. NOTE: SERVICE ANY ITEM THAT IS NOT PERFORMING AT PROPER SPECIFICATIONS BEFORE CONTINUING. 4. Fuel pressure that is too high may cause rich air fuel mixtures to pass through the catalyst which could cause higher than normal catalyst temperatures. Refer to the following procedure for service details. a. Check fuel pressure, install fuel pressure gauge, start and run the engine at idle. Fuel pressures between 28 and 34 PSI are typical (4.9L typically is 15 PSI higher). b. Disconnect the vacuum line going to the fuel pressure regulator. Fuel pressure typically jumps to 40 PSI +/- 3 PSI (4.9L typically is 15 PSI higher). Visually inspect vacuum line for raw fuel. NOTE: FUEL PRESSURES ABOVE THESE VALUES SHOULD BE CORRECTED. HOWEVER, THIS MAY NOT BE THE CAUSE OF THE CONCERN. SERVICE AS NECESSARY. 5. Throttle plates in the throttle body not returning to the proper closed position may cause excessive catalyst temperatures during downhill grades. Refer to the following procedure for service details. a. Visually inspect the throttle body and linkage for: ^ Binding or sticking throttle linkage. ^ Tight speed control linkage or cable. ^ Vacuum line interference. ^ Electrical harness interference. NOTE: AFTERMARKET GOVERNORS, THROTTLE LINKAGE AND CABLES ASSOCIATED WITH POWER TAKE-OFF UNITS, MAY ALSO INTERFERE WITH PROPER THROTTLE RETURN. SERVICE AS NECESSARY. 6. It is extremely important that all systems related to the engine and emission systems operate properly. a. Visually inspect the engine compartment to make sure all vacuum hoses and spark plug wires are properly routed and securely connected. b. Inspect all wiring harnesses and connectors for insulation damage, burned, overheated, loose or broken conditions. c. Verify proper operation of the thermactor system. Thermactor systems that fail to dump thermactor air to the atmosphere properly or at the correct time can cause high catalyst temperatures. d. Visually inspect thermactor system for damaged or kinked hoses and perform a function test on following components: air control valve, check valve, silencer, filter and the air bypass solenoid. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Technical Service Bulletins > By Symptom > Page 811 e. Verify proper operation of the engine cooling system thermostat. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under Basic Warranty Coverage, Emissions Warranty Coverage OPERATION DESCRIPTION TIME 911211A Diagnostics - Perform 0.5 Hrs. KOEO And KOER Self Tests 911211B Timing - Check Or Adjust 0.5 Hrs. Spark Timing, Check Computed Timing And Check Secondary Ignition System With Engine Analyzer. 911211C Check - Fuel Pressure And 0.2 Hrs. Inspect Vacuum Line For Raw Fuel. 911211D Inspect - Throttle Body And 0.1 Hrs. Linkage. 911211E Inspect - Vacuum Hoses, 0.1 Hrs. Electrical Harnesses, Connectors And Spark Plug Wires For Routing Damage. 911211F Thermactor System - 0.3 Hrs. Inspect For Proper Operation And Damaged Component. Includes Function Check Of Air Control Valve, Thermactor Air Bypass Solenoid, Check Valves, Silencer And Filter. 911211G Thermostat - Check For 0.2 Hrs. Proper Operation. DEALER CODING BASIC PART NO. CONDITION CODE 5E212 25 OASIS CODES: 403000, 603300, 614000 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Pressure: > 911211 > Jun > 91 > Engine - Lack of Power/No Start Diagnosis Fuel Pressure: All Technical Service Bulletins Engine - Lack of Power/No Start Diagnosis Article No. 91-12-11 06/12/91 LACK OF POWER 7.5L, 5.8L, 5.0L, 4.9L - CATALYTIC CONVERTER DIAGNOSTIC TIPS LIGHT TRUCK: 1986-91 BRONCO, ECONOLINE, F-150-350 SERIES 1988-91 F SUPER DUTY, F47 ISSUE: Lack of power or a no start condition may be diagnosed as an exhaust restriction caused by a plugged catalytic converter. A plugged catalytic converter (internal deterioration) is usually caused by abnormal engine operation. ACTION: Diagnose the catalytic converter to confirm internal failure. Refer to the Catalyst and Exhaust System Diagnostic Section, in the Engine/Emissions Diagnostic Shop Manual and the following procedures for service details. 1. Lack of proper HEGO operation may cause, or be the result of a rich or lean fuel condition, which could cause additional heat in the catalyst. Perform self test KOEO and KOER, service any codes. NOTE: IF TWO DIGIT CODES 41, 42, 85 OR THREE DIGIT CODES 171, 172, 173, 179, 181, 182, 183 AND 565 ARE RECEIVED, CHECK FOR PROPER HEGO GROUND. If the HEGO ground is good, the following areas may be at fault: ^ Ignition Coil ^ Distributor Cap ^ Distributor Rotor ^ Fouled Spark Plug ^ Spark Plug Wires ^ Air Filter ^ Stuck Open Injector ^ Fuel Contamination Engine OIL ^ Manifold Leaks Intake/ Exhaust ^ Fuel Pressure ^ Poor Power Ground ^ Engine Not At Normal Operating Temperature ^ HEGO Sensor 2. Spark timing that is retarded from specification may increase exhaust gas temperature and shorten catalyst life. Refer to the following procedure for service details. a. Check spark timing. Check base timing with spout disconnected. Set base timing to the specification on the vehicle emission decal. b. Check computed timing with spout connected. NOTE: COMPUTED TIMING IS EQUAL TO BASE TIMING PLUS 20~ BTDC +/- 3~. 3. Misfiring spark plugs may cause an unburned fuel air mixture to pass through the catalyst, which could cause higher than normal catalyst temperatures. Refer to the following procedure for service details. a. Check secondary ignition, hook the vehicle up to an engine analyzer and check for a secondary ignition misfire. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Pressure: > 911211 > Jun > 91 > Engine - Lack of Power/No Start Diagnosis > Page 817 NOTE: SERVICE ANY ITEM THAT IS NOT PERFORMING AT PROPER SPECIFICATIONS BEFORE CONTINUING. 4. Fuel pressure that is too high may cause rich air fuel mixtures to pass through the catalyst which could cause higher than normal catalyst temperatures. Refer to the following procedure for service details. a. Check fuel pressure, install fuel pressure gauge, start and run the engine at idle. Fuel pressures between 28 and 34 PSI are typical (4.9L typically is 15 PSI higher). b. Disconnect the vacuum line going to the fuel pressure regulator. Fuel pressure typically jumps to 40 PSI +/- 3 PSI (4.9L typically is 15 PSI higher). Visually inspect vacuum line for raw fuel. NOTE: FUEL PRESSURES ABOVE THESE VALUES SHOULD BE CORRECTED. HOWEVER, THIS MAY NOT BE THE CAUSE OF THE CONCERN. SERVICE AS NECESSARY. 5. Throttle plates in the throttle body not returning to the proper closed position may cause excessive catalyst temperatures during downhill grades. Refer to the following procedure for service details. a. Visually inspect the throttle body and linkage for: ^ Binding or sticking throttle linkage. ^ Tight speed control linkage or cable. ^ Vacuum line interference. ^ Electrical harness interference. NOTE: AFTERMARKET GOVERNORS, THROTTLE LINKAGE AND CABLES ASSOCIATED WITH POWER TAKE-OFF UNITS, MAY ALSO INTERFERE WITH PROPER THROTTLE RETURN. SERVICE AS NECESSARY. 6. It is extremely important that all systems related to the engine and emission systems operate properly. a. Visually inspect the engine compartment to make sure all vacuum hoses and spark plug wires are properly routed and securely connected. b. Inspect all wiring harnesses and connectors for insulation damage, burned, overheated, loose or broken conditions. c. Verify proper operation of the thermactor system. Thermactor systems that fail to dump thermactor air to the atmosphere properly or at the correct time can cause high catalyst temperatures. d. Visually inspect thermactor system for damaged or kinked hoses and perform a function test on following components: air control valve, check valve, silencer, filter and the air bypass solenoid. e. Verify proper operation of the engine cooling system thermostat. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under Basic Warranty Coverage, Emissions Warranty Coverage OPERATION DESCRIPTION TIME 911211A Diagnostics - Perform 0.5 Hrs. KOEO And KOER Self Tests 911211B Timing - Check Or Adjust 0.5 Hrs. Spark Timing, Check Computed Timing And Check Secondary Ignition System With Engine Analyzer. 911211C Check - Fuel Pressure And 0.2 Hrs. Inspect Vacuum Line For Raw Fuel. 911211D Inspect - Throttle Body And 0.1 Hrs. Linkage. 911211E Inspect - Vacuum Hoses, 0.1 Hrs. Electrical Harnesses, Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Pressure: > 911211 > Jun > 91 > Engine - Lack of Power/No Start Diagnosis > Page 818 Connectors And Spark Plug Wires For Routing Damage. 911211F Thermactor System - 0.3 Hrs. Inspect For Proper Operation And Damaged Component. Includes Function Check Of Air Control Valve, Thermactor Air Bypass Solenoid, Check Valves, Silencer And Filter. 911211G Thermostat - Check For 0.2 Hrs. Proper Operation. DEALER CODING BASIC PART NO. CONDITION CODE 5E212 25 OASIS CODES: 403000, 603300, 614000 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Technical Service Bulletins > Page 819 Fuel Pressure: Specifications FUEL PRESSURE Pump Pressure .................................................................................................................................... ...................................................................... 6 - 8 psi Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Test Fuel Pressure: Testing and Inspection Fuel Pressure Test NOTE: Perform Fuel System Capacity Test prior to performing Pressure Test. See: Fuel System Capacity Test PRESSURE TEST 1. Connect a suitable pressure gauge (0-15 PSI) to the carburetor end of the fuel line. WARNING: Use care to prevent combustion of spilled fuel. 2. Start the engine (it should be able to run for over 30 seconds on the fuel in the carburetor bowl) and read the pressure after 10 seconds. If pump pressure is too low or too high install a new fuel pump. Fuel Pump Pressure ............................................................................................................................ ................................................. 6.0-8.0 PSI 3. Reconnect fuel line at filter and install air cleaner. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Test > Page 822 Fuel Pressure: Testing and Inspection Fuel System Capacity Test FUEL CAPACITY (VOLUME) TEST - Remove the carburetor air cleaner. - Slowly (fuel line is pressurized) disconnect the fuel line at the fuel filter. WARNING: Use care to prevent combustion of spilled fuel. - Place a suitable non-breakable container (1/2 liter or 1 pint minimum) at the end of the disconnected fuel line (a piece of hose may be needed on the fuel line end). - Disconnect high tension wire from coil. - Crank engine 10 seconds, the fuel pump should deliver 0.158 liters (1/3 pint) of fuel or more. - If fuel flow is to specification perform pressure test. See: Fuel Pressure Test - If fuel flow is low repeat procedure using a non-breakable container of gasoline connected to the fuel pump inlet. If fuel pressure is to specification, the problem is either a plugged in-tank filter, or a kinked or leaking fuel pump inlet hose. - If fuel flow is still below specification, replace fuel pump. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air/Fuel Mixture > System Information > Technical Service Bulletins > Idle Fuel Mixture - Manual Revision Technical Service Bulletin # 8912A26 Date: 890627 Idle Fuel Mixture - Manual Revision ENGINE EMISSIONS DIAGNOSIS SHOP MANUAL- 1986-SECTION 4-IDLE FUEL MIXTURE-PROPANE ENRICHMENT METHOD ENGINE EMISSIONS DIAGNOSIS SHOP MANUAL- 1987-SECTION 4-IDLE FUEL MIXTURE-PROPANE ENRICHMENT METHOD Article No. 89-12A-26 FORD: 1986 ESCORT, LTD, MUSTANG 1986-87 TEMPO 1986 THUNDERBIRD LINCOLN-MERCURY: 1986 CAPRI, COUGAR, MARQUIS 1986-87 TOPAZ LIGHT TRUCK: 1986 AEROSTAR 1986-87 BRONCO, ECONOLINE, F-150, F-250, F-350, RANGER ISSUE: The tachometer reference "or equivalent" as shown in procedure I.-B in both 1986 and 1987 Engine Emissions Diagnosis Manuals is incorrect. This also applies to procedure I.-H in the 1986 Engine Emissions Diagnosis Manual. ACTION: Refer to the pages following this TSB article for the revised Volume H pages which show the correct tachometer designation as: "Connect an analog tachometer, Rotunda 059-000010 or an equivalent analog tachometer." This information should be inserted in your 1986 Engine Emissions Diagnosis Manual, pages 4-83, 4-87, 4-90, 4-93 and the 1987 Manual, pages 4-66 and 4-69. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 680000 Pages 4-83, 4-84 1986 Carburetors, Fuel Charging Assemblies and Throttle Bodies 4-83 Idle Mixture Setting Procedures IDLE FUEL MIXTURE-PROPANE ENRICHMENT METHOD Passenger Car. 1.9L w/740-2V, 2.3L OHC w/YFA-IV FB, 2.3L HSC w/1949-IV, 3.8L w/2150-A-2V and 5.0L w/4180C-4V. Truck, Under 8500 GVW: 5.8L w/4180C-4V. NOTE: This procedure is applicable to the above engines only. If CO and HC are not within specification, perform appropriate electrical diagnostic procedure in Section 15. I. Vehicle Preparation: All Carburetors as noted above. A. Apply the parking brake, and block the wheels. Disconnect the automatic brake release, if so equipped, and plug the vacuum connection. B. Connect an analog tachometer, Rotunda 059-000010 or an equivalent analog tachometer. C. If so equipped, insure that the hot idle compensator is in a closed position and remains so throughout the test. Idle vehicle on kickdown step of fast idle cam for three to five minutes to insure that HIC valve is closed. D. If so equipped, disconnect the fuel evaporative purge hose at the engine or the carburetor, (1.9L engines) and plug the connection. (Not applicable to 5.0L and 5.8L Truck and 5.0L Passenger Car engines). E. If so equipped, disconnect the fuel evaporative purge hose at the air cleaner and plug the nipple. (Not applicable to 5.0L and 5.8L Truck and 5.0L Passenger car engines). F. Disconnect the flexible fresh air tube from the air cleaner duct or adaptor. Using propane enrichment Tool T75L-9600-A or equivalent, insert the tool hose approximately 3/4 of the way into the duct or fresh air tube. If necessary, secure the hose with tape. G. For vehicles equipped with thermactor systems, revise the dump valve vacuum hoses as follows: (Not applicable to 1.9L engines). 1. For dump valves with two vacuum fittings, disconnect and plug the hose(s). Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air/Fuel Mixture > System Information > Technical Service Bulletins > Idle Fuel Mixture - Manual Revision > Page 827 2. For dump valves with one fitting or combination air bypass/air control valve, remove the hose at the dump valve and plug it. Connect a slave hose from the dump valve vacuum fitting to an intake manifold vacuum fitting. (Not applicable to 5.0L and 5.8L Truck engines with 2150A-2VFB). 3. For 2.3L OHC engines: a. Equipped with a dump valve with two vacuum fittings: Disconnect and plug the hoses. b. Equipped with a combination dump valve and air diverter valve: Disconnect and plug the hoses (2-port) from the dump valve portion. c. Equipped with feedback carburetor: Disconnect electric lead wire from electric PVS. 4. On 3.8L engine Canadian 2150A-2V applications, do not make any thermactor system modifications. 5. For 5.8L 4180C-4V Truck Disconnect and Plug Vacuum Hose to Dump Valve. 1986 4-84 Carburetors, Fuel Charging Assemblies and Throttle Bodies Idle Mixture Setting Procedures H. For 1.9L ATX/MTX vehicles equipped with (Mechanical Vacuum) Idle Speed Control (ISC): 1. With engine off: a. Disconnect and plug the vacuum hose at the MVISC. b. Connect an alternate vacuum source (hand vacuum pump) capable of maintaining 22 inches Hg. to the ISC diaphragm on carburetor, and apply vacuum (retracting ISC plunger clear of throttle linkage). 2. With engine running and transmission in Drive (ATX) or Neutral (MTX): ^ Idle speed should be equal to the ISC retracted speed specified on the emission decal, if not readjust throttle stop adjustment screw under choke housing to specification, (fan On, A/C Off). I. When the above Steps have been completed, proceed to Section II. II. Propane Enrichment Method (Except as Noted) NOTE: Leave all vacuum signal hoses attached to the air cleaner assembly when relocating the assembly to perform carburetor adjustments. The air cleaner assembly must be in place however, when measuring engine speeds. CAUTION: Prolonged engine idling can result in catalyst overheating and excessive underbody temperatures. A. Verify that the timing is set to specification; reset if necessary, Section 15. B. Check engine curb idle rpm or A/C-off rpm, and, if necessary, reset to specification, Section 4. NOTE: Even If the vehicle has less than 160.9 km (100 miles) of operation, set the speed to the normal engine specification. NOTE: Remove PCV valve from grommet, and allow PCV valve to draw underhood air during idle fuel mixture check. (PCV should remain in vertical position). NOTE: Escort/Lynx, has an in-line fixed orifice crankcase vent, not a conventional PCV valve. The fixed orifice is located in the crankcase vent hose located between the vacuum fitting on the intake manifold and the plastic fitting attached to the air cleaner tray. Locate the crankcase vent hose and disconnect at the air cleaner end, allowing the hose to vent to underhood air during idle fuel/air mixture check. C. With the transmission in Neutral, run the engine at approximately 2500 rpm for 15 seconds before each mixture check. NOTE: On Escort/Lynx and Tempo/Topaz, run engine until electric fan comes On. Pages 4-87 Thru 4-90 1986 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air/Fuel Mixture > System Information > Technical Service Bulletins > Idle Fuel Mixture - Manual Revision > Page 828 Carburetors, Fuel Charging Assemblies and Throttle Bodies 4-87 Idle Mixture Setting Procedures IDLE FUEL MIXTURE-PROPANE ENRICHMENT METHOD 2.0L TRUCK UNDER 8600 GVW w/YFA-IV NOTE: This procedure is for 2.0L Truck engines only, it is not for trucks over 8500 GVW. Propane specifications are not listed for these applications. If CO and HC are not within specification, perform appropriate electrical diagnostic procedure, Section 15. I. Vehicle Preparation A. Apply the parking brake and block the wheels. B. Connect an analog tachometer, Rotunda 059-000010 or an equivalent analog tachometer. C. Disconnect the flexible fresh air tube from the air cleaner duct or adaptor. Using propane enrichment Tool T75L-9600-A or equivalent, insert the tool hose approximately 3/4 of the way into the duct or fresh air tube. If necessary, secure the hose with tape. D. Disconnect and plug the hose at the air bypass valve. E. Disconnect and plug the hose between the purge valve and the spacer at the purge valve. F. When the above Steps have been completed, proceed to Section II. II. Propane Enrichment Method (Except as Noted) NOTE: Leave all vacuum signal hoses attached to the air cleaner assembly when relocating the assembly to perform carburetor adjustments. The air cleaner assembly must be in place, however, when measuring engine speeds. CAUTION: Prolonged engine idling can result in catalyst overheating and excessive underbody temperatures. A. Verify engine timing is set to specification - reset if necessary, Section 15. B. Verify that the curb idle speed is being controlled to specification. Then, electrically disconnect idle speed control (ISC) motor from wiring harness. C. Place A/C-heat selector in the Off position and verify that lamps are Off. NOTE: Remove PCV valve from grommet, locate the crankcase closure hose and disconnect at the air cleaner end (allowing the PCV valve and closure hose to vent to underhood air during idle fuel mixture check). D. With the transmission in Neutral, run the engine at approximately 2500 rpm for 15 seconds before each mixture check. If check is not completed within 60 seconds, repeat this cleanout Step. 1986 4-88 Carburetors, Fuel Charging Assemblies and Throttle Bodies Idle Mixture Setting Procedures E. With the engine idling at normal operating temperature gradually open the propane tool valve and watch for engine speed gain, on the tachometer. When the engine speed reaches a maximum and then begins to drop off, note the amount of speed gain. (Propane cartridge must be in vertical position). NOTE: If the engine speed will not drop off check the propane cartridge gas supply. If necessary repeat Steps D & E with a new propane cartridge gas supply. F. Compare measured speed gain to specified speed gain.* 1. If the measured speed gain is within specification, proceed to Step H. NOTE: The carburetor assembly is equipped with a tamper-resistant idle adjustment feature, the carburetor must be removed from the vehicle. Refer to Shop Manual, Group 24 for removal of the above feature. NOTE: If it is determined that idle fuel mixture adjustment will be necessary, adjust the mixture according to the reset rpm specification. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air/Fuel Mixture > System Information > Technical Service Bulletins > Idle Fuel Mixture - Manual Revision > Page 829 2. If the measured speed gain is higher than the speed gain specification:* Turn the mixture screw counterclockwise (rich) and simultaneously repeat Steps D and E until the measured speed rise meets the reset rpm specification.* After final adjustment, proceed to Step G. 3. If the measured speed gain is lower than the speed gain specification:* Turn the mixture screw clockwise (lean) and simultaneously repeat Steps D and E until the measured speed rise meets the reset rpm specification.* After final adjustment, proceed to Step G. 4. If there is no rpm rise and the minimum speed gain specification is "0" rpm, perform the following speed drop test: NOTE: Speed drop test information is specified with the artificial enrichment requirements whenever the minimum speed gain specification is "0" rpm. * a. While watching the tachometer, adjust the mixture screw 1/4 turn clockwise (lean). Note the drop in engine speed. b. If the measured speed drop is greater "0" and less than or equal to 30 rpm, proceed to Step G. c. If the measured speed drop is more than 30 rpm, return the mixture screw to the position before adjustment. Proceed to Step G. d. If the measured speed drop is still "0" rpm repeat steps a, b, and c. G. The carburetor fuel air adjustment must have the tamper-resistant feature reinstalled, see Section III. *Refer to the Special Specifications Issue TSB Publications. 1986 Carburetors, Fuel Charging Assemblies and Throttle Bodies 4-89 Idle Mixture Setting Procedures H. Reinstall PCV valve in grommet. Reconnect air bypass valve, purge valve and crankcase closure hose. Reconnect ISC motor to wiring harness. I. Remove all test equipment. Reconnect all system components, reinstall air cleaner, and tighten the air cleaner wing nut(s) to specification. III. Removal and Installation for Tamper-Resistant Fuel Air Adjustment Feature: A. See appropriate carburetor disassembly instructions in Shop Manual, Group 24. 1986 4-90 Carburetors, Fuel Charging Assemblies and Throttle Bodies Idle Mixture Setting Procedures IDLE FUEL MIXTURE-PROPANE ENRICHMENT METHOD 2.8L AEROSTAR w/2150A FB NOTE: This procedure is for the 2.8L engine only. It is not for trucks over 8500 GVW. I. Vehicle Preparation A. Apply the parking brake and block the wheels. B. Verify that timing is set to specification. C. Remove the air cleaner assembly. D. Disconnect wiring harness from carburetor feedback solenoid, located in the rear of carburetor. E. Remove the PCV valve from the rocker cover grommet and move away from the crankcase vapors. F. Disconnect the fuel evaporating purge line (from the intake manifold spacer at the purge solenoid). Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air/Fuel Mixture > System Information > Technical Service Bulletins > Idle Fuel Mixture - Manual Revision > Page 830 G. Install purge line tester (Tool T84T-9600-A) into the end of purge line that is still connected to the intake manifold spacer. H. Disconnect ISC motor from wiring harness as follows: Simultaneously: 1. Connect tachometer, Rotunda Model 059-00001, 099-00001 or equivalent. 2. Start engine. 3. Manually hold throttle above 1000 rpm. 4. Push ISC plunger until it retracts fully. 5. After plunger retracts, release throttle and quickly unplug the connection. NOTE: Before proceeding, verify that the throttle lever is resting on the speed screw and that the engine idles at specification for anti-dieseling rpm (750 rpm in neutral). I. Install air cleaner assembly, but do not connect the flexible fresh air tube to the air cleaner duct and valve assembly. Using a propane enrichment Tool T75L-9600-A or equivalent, insert the tool hose approximately 3/4 of the way into the duct and valve assembly. If necessary, secure the hose with tape. J. When the above Steps have been completed, proceed to Section II. Pages 4-93 & 4-94 1986 Carburetors, Fuel Charging Assemblies and Throttle Bodies 4-93 Idle Mixture Setting Procedures IDLE FUEL MIXTURE-PROPANE ENRICHMENT METHOD 4.9L TRUCK UNDER 8500 GVW w/YFA-IV FB NOTE: This procedure is for the 4.9L engine only. It is not for trucks over 8600 GVW. Propane specifications are not listed for these applications. If CO and HC are not within specification, perform appropriate electrical diagnostic procedure, Section 15. I. Vehicle Preparation A. Apply the parking brake and block the wheels. Disconnect the automatic brake release (if so equipped), and plug the vacuum connection. B. Connect an analog tachometer, Rotunda 059-000010 or an equivalent analog tachometer. C. Disconnect the flexible fresh air tube from the air cleaner duct or adapter. Using propane enrichment Tool T75L-9600-A or equivalent, insert the tool hose approximately 3/4 of the way into the duct or fresh air tube. If necessary, secure the hose with tape. D. When the above Steps have been completed, proceed to Section II. II. Propane Enrichment Method (Except as Noted) NOTE: Leave all vacuum signal hoses attached to the air cleaner assembly when relocating the assembly to perform carburetor adjustments. The air cleaner assembly must be in place, however, when measuring engine speeds. CAUTION: Prolonged engine idling can result in catalyst overheating and excessive underbody temperatures. A. Verify engine timing is set to specification-reset if necessary, Section 15. B. Place A/C-heat selector in the Off position and verify that all accessories (lamps, defrost, etc.) are Off. 1986 4-94 Carburetors, Fuel Charging Assemblies and Throttle Bodies Idle Mixture Setting Procedures Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air/Fuel Mixture > System Information > Technical Service Bulletins > Idle Fuel Mixture - Manual Revision > Page 831 Figure 1 - In-Line Base Timing Connector NOTE: Remove PCV valve from grommet locate the crankcase closure hose and disconnect at the air cleaner end (allowing the PCV valve and closure hose to vent to underhood air during idle fuel mixture check). C. Verify that the idle speed control motor and the single wire connector near the distributor (sometimes called the In-Line Base timing connector, Figure 1) are connected electrically. With the transmission in Neutral, run the engine at approximately 2500 rpm for 15 seconds before each mixture check. If check is not completed within 60 seconds, repeat this cleanout Step. D. Return engine to idle and disconnect idle speed control motor from wiring harness. Disconnect single wire connector near the distributor (Fig. 1). With the engine idling at normal operating temperature, place the transmission selector in the position specified for the idle fuel mixture check. Gradually open the propane tool valve and watch for engine speed gain, on the tachometer. When the engine speed reaches a maximum and then begins to drop off, note the amount of speed gain. (Propane cartridge must be in vertical position). NOTE: If the engine speed will not drop off check the propane cartridge gas supply. If necessary repeat Steps C and D with a new propane cartridge gas supply. E. Compare measured speed gain to specified speed gain.* 1. If the measured speed gain is within specification, proceed to Step G. NOTE: The carburetor assembly is equipped with a tamper-resistant idle adjustment feature, the carburetor must be removed from the vehicle. Refer to Group 24, Powertrain Shop manual for removal of the above feature. NOTE: If it is determined that idle fuel mixture adjustment will be necessary, adjust the mixture according to the reset rpm specification. 2. If the measured speed gain is higher than the speed gain specification:* Turn the mixture screw counterclockwise (rich) and simultaneously repeat Steps C and D until the measured speed rise meets the reset rpm specification,* After final adjustment, proceed to Step F. 3. If the measured speed gain is lower than the speed gain specification:* Turn the mixture screw clockwise (lean) and simultaneously repeat Steps C and D until the measured speed rise meets the reset rpm specification.* After final adjustment, proceed to Step F. F. The carburetor fuel air adjustment must have the tamper-resistant feature reinstalled. Refer to appropriate carburetor assembly instructions in Shop Manual, Group 24. G. Reinstall PCV valve in grommet. Reconnect idle speed control motor and crankcase closure system, and the single wire connector near the distributor. H. Remove all test equipment. Reconnect all system components, reinstall air cleaner, and tighten the air cleaner wing nut(s) to specification, *Specified speed gain is 10 to 70 rpm, specified reset is 30 rpm. Pages 4-65 & 4-66 1987 Carburetors, Fuel Charging Assemblies and Throttle Bodies 4-65 Idle Mixture Setting Procedures Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air/Fuel Mixture > System Information > Technical Service Bulletins > Idle Fuel Mixture - Manual Revision > Page 832 IDLE FUEL MIXTURE-PROPANE ENRICHMENT METHOD Propane Enrichment Procedures Are Not Applicable For The Following: ^ CFI Applications. ^ EFI Applications. ^ Truck Over 8500 GVW Applications. ^ 5.8L MCU Police and Trailer Tow Vehicles w/7200 Carburetors. 1987 4-66 Carburetors, Fuel Charging Assemblies and Throttle Bodies Idle Mixture Setting Procedures IDLE FUEL MIXTURE-PROPANE ENRICHMENT METHOD Passenger Car. 2.3L HSC w/1949-IV Truck, Under 8500 GVW: 5.8L w/418OC-4V. NOTE: This procedure is applicable to the above engines only. If CO and HC are not within specificatlon, perform appropriate electrical diagnostic procedure in Section 15. I. Vehicle Preparation: All Carburetors as noted above. A. Apply the parking brake, and block the wheels, Disconnect the automatic brake release, If so equipped, and plug the vacuum connection. B. Connect an analog tachometer, Rotunda 059-000010 or equivalent analog tachometer. C. If so equipped, ensure that the hot idle compensator is in a closed position and remains so throughout the test. Idle vehicle on kickdown step of fast idle cam for three to five minutes to ensure that HIC valve is closed. D. If so equipped, disconnect the fuel evaporative purge hose at the engine or the carburetor, (1.9L engines) and plug the connection. (Not applicable to 5.8L Truck engines). E. If so equipped, disconnect the fuel evaporative purge hose at the air cleaner and plug the nipple. (Not applicable 5.8L Truck engines.) F. Disconnect the flexible fresh air tube from the air cleaner duct or adaptor. Using propane enrichment Tool T75L-9600-A or equivalent, insert the tool hose approximately 3/4 of the way into the duct or fresh air tube. If necessary, secure the hose with tape. G. For vehicles equipped with Thermactor systems, revise the dump valve vacuum hoses as follows: 1. For dump valves with two vacuum fittings, disconnect and plug the hose(s). 2. For dump valves with one fitting or combination air bypass/air control valve, remove the hose at the dump valve and plug it. Connect a slave hose from the dump valve vacuum fitting to an intake manifold vacuum fitting. (Not applicable to 5.0L and 5.8L Truck engines with 2150A-2VFB). 3. For 5.8L 4180C-4V Truck Disconnect and Plug Vacuum Hose to Dump Valve. H. When the above Steps have been completed, proceed to Section II. Pages 4-69 & 4-70 1987 Carburetors, Fuel Charging Assemblies and Throttle Bodies 4-69 Idle Mixture Setting Procedures IDLE FUEL MIXTURE-PROPANE ENRICHMENT METHOD 2.0L TRUCK UNDER 8500 GVW w/Aisan Carburetor NOTE: This procedure is for 2.0L Truck engines only, it is not for trucks over 8500 GVW. Propane specifications are not listed for these applications. If CO and HC are not within specification, perform appropriate electrical diagnostic procedure, Section 15. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air/Fuel Mixture > System Information > Technical Service Bulletins > Idle Fuel Mixture - Manual Revision > Page 833 I. Vehicle Preparation A. Apply the parking brake and block the wheels. B. Connect an analog tachometer, Rotunda 059-000010 or an equivalent analog tachometer. C. Disconnect the flexible fresh air tube from the air cleaner duct or adaptor. Using propane enrichment Tool T75L-9600-A or equivalent, insert the tool hose approximately 3/4 of the way into the duct or fresh air tube. If necessary, secure the hose with tape. D. Disconnect and plug the hose at the air bypass valve. E. Disconnect and plug the hose between the purge valve and the spacer at the purge valve. F. When the above Steps have been completed, proceed to Section II. II. Propane Enrichment Method (Except as Noted) NOTE: Leave all vacuum signal hoses attached to the air cleaner assembly when relocating the assembly to perform carburetor adjustments. The air cleaner assembly must be in place, however, when measuring engine speeds. CAUTION: Prolonged engine idling can result in catalyst overheating and excessive underbody temperatures. A. Verify engine timing is set to specification-reset if necessary, Section 15. B. Verify that the curb idle speed is being controlled to specification. Then, electrically disconnect idle speed control (ISC) motor from wiring harness. C. Place A/C-heat selector in the Off position and verify that lamps are Off. NOTE: Remove PCV valve from grommet, locate the crankcase closure hose and disconnect at the air cleaner end (allowing the PCV valve and closure hose to vent to underhood air during idle fuel mixture check). D. With the transmission in Neutral, run the engine at approximately 2500 rpm for 15 seconds before each mixture check. If check is not completed within 60 seconds, repeat this cleanout Step. 1987 4-70 Carburetors, Fuel Charging Assemblies and Throttle Bodies Idle Mixture Setting Procedures E. With the engine idling at normal operating temperature gradually open the propane tool valve and watch for engine speed gain, on the tachometer. When the engine speed reaches a maximum and then begins to drop off, note the amount of speed gain. (Propane cartridge must be in vertical position). NOTE: If the engine speed will not drop off check the propane cartridge gas supply. If necessary repeat Steps D & E with a new propane cartridge gas supply. F. Compare measured speed gain to specified speed gain.* 1. If the measured speed gain is within specification, proceed to Step H. NOTE: The carburetor assembly is equipped with a tamper-resistant idle adjustment feature, the carburetor must be removed from the vehicle. Refer to Shop Manual, Group 24 for removal of the above feature. NOTE: If it is determined that idle fuel mixture adjustment will be necessary, adjust the mixture according to the reset rpm specification. 2. If the measured speed gain is higher than the speed gain specification:* Turn the mixture screw counterclockwise (rich) and simultaneously repeat Steps D and E until the measured speed rise meets the reset rpm specification.* After final adjustment, proceed to Step G. 3. If the measured speed gain is lower than the speed gain specification:* Turn the mixture screw clockwise (lean) and simultaneously repeat Steps D and E until the measured speed rise meets the reset rpm specification.* After final adjustment, proceed to Step G. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air/Fuel Mixture > System Information > Technical Service Bulletins > Idle Fuel Mixture - Manual Revision > Page 834 4. If there is no rpm rise and the minimum speed gain specification is "0" rpm, perform the following speed drop test: NOTE: Speed drop test information is specified with the artificial enrichment requirements whenever the minimum speed gain specification is "0" rpm.* a. While watching the tachometer, adjust the mixture screw 1/4 turn clockwise (lean). Note the drop in engine speed. b. If the measured speed drop is greater than "0" and less than or equal to 40 rpm, proceed to Step G. c. If the measured speed drop is more than 40 rpm, return the mixture screw to the position before adjustment. Proceed to Step G. d. If the measured speed drop is still "0" rpm repeat steps a, b, and c. G. The carburetor fuel air adjustment must have the tamper-resistant feature reinstalled, see Section III. *Refer to the Special Specifications Issue TSB Publications. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > Customer Interest: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up Technical Service Bulletin # 91257 Date: 911213 Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up Article No. 91-25-7 12/13/91 ^ HARD COLD START - DURING INITIAL START-UP, IDLE OR DECEL - EFI ENGINES SLUDGE IN THROTTLE BODY AND/OR IDLE AIR BY-PASS VALVE ^ HESITATION/STALLS - DURING INITIAL START-UP, IDLE OR DECEL - EFI ENGINES SLUDGE IN THROTTLE BODY AND/OR IDLE AIR BY-PASS VALVE FORD: 1983-87 EXP 1983-91 ESCORT 1984-90 MUSTANG, THUNDERBIRD 1986-90 TAURUS 1986-91 CROWN VICTORIA 1988-90 TEMPO LINCOLN-MERCURY: 1983-85 LN7 1983-87 LYNX 1984-88 CAPRI 1984-90 COUGAR 1986-90 CONTINENTAL, MARK VII, SABLE 1986-91 GRAND MARQUIS, TOWN CAR 1988-90 TOPAZ 1991 TRACER LIGHT TRUCK: 1985-90 BRONCO II, BRONCO 1985-91 ECONOLINE, F-150-350 SERIES 1985-92 RANGER 1986-91 AEROSTAR 1991 EXPLORER ISSUE: Hard cold starts, hesitation and stalls on initial start-up or during idle or decel may be caused by sludge in the throttle body and/or idle by-pass valve. Sludge deposits or oil film on the throttle body bore and plate or the idle air by-pass valve may cause one or more of the following conditions. ^ Hard Cold Start ^ Stall On Initial Start-Up ^ Stall During Idle ^ Stall During Decel ^ Rough Idle ^ Rolling Idle ^ Hesitation During Acceleration ACTION: A new idle air by-pass service kit (F2PZ-9F939-A) is now available for service use to correct sludge contamination concerns of the throttle bore and plate only. It eliminates the need to clean the majority of past model throttle body applications. Cleaning is not required on sludge tolerant throttle body designs released for 1991 and newer model years. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > Customer Interest: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 843 Figure 1 Install an idle air by-pass service kit (F2PZ-9F939-A) as applicable to provide a permanent correction for symptoms caused by throttle body sludge deposits. Refer to the instruction sheet included in the kit for installation details. Refer to Figure 1 for a specific application list of EFI (port fuel Injection) engines involved in this TSB article. The idle air by-pass service kit (F2PZ-9F939-A) includes the following items. ^ One (1) Idle Adjust Spacer ^ Two (2) Gaskets Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > Customer Interest: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 844 ^ Two (2) Attaching Bolts ^ One (1) "Attention" Sticker ^ One (1) Instruction Sheet Figure 2 Refer to Figure 2 for a pictorial of the kits components. NOTE: EFFECTIVE WITH THIS TSB, THROTTLE BODY CLEANING IS NO LONGER COVERED UNDER 5/50 EMISSIONS WARRANTY, UNLESS AS SPECIFIED IN THE FOLLOWING APPLICATION CHARTS. FAILURE TO FOLLOW THE CORRECT PROCEDURE MAY RESULT IN THE CLAIM BEING DISALLOWED. The idle air adjust spacer incorporates sludge tolerant design features that eliminate throttle body sludge related conditions. Once installed, throttle body cleaning is not allowed and periodic adjustment of the throttle body is not required. Procedures, Warranty and Labor CHECKS TO MAKE PRIOR TO SERVICE KIT INSTALLATION Confirm that the following items are not causing the idle quality concern before proceeding with the service kit installation. ^ Contamination within the idle air by-pass solenoid ^ Lack of fuel system control (excessively rich or lean) ^ Ignition timing change ^ Incorrect or malfunctioning EGR system ^ Incorrect or malfunctioning cooling system ^ Vacuum leaks (air intake manifold, vacuum hoses, vacuum reservoirs, power brake booster where applicable) ^ EEC diagnostics have been performed and vehicle malfunction indicated service output codes have been resolved and cleared. If any of the areas listed above are found to be at fault, correct them before proceeding with the service kit installation. Idle Speed Adjustment Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > Customer Interest: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 845 WARNING: BEFORE PROCEEDING WITH THE IDLE SPEED ADJUSTMENT, VERIFY THAT THE FOLLOWING ITEMS ARE TAKEN CARE OF PROPERLY. ^ The transmission is in PARK or Neutral. ^ The parking brake is applied. ^ The wheels are properly blocked. ^ The engine is at operating temperature. ^ The heater, A/C, cooling fan and other accessories are OFF. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > Customer Interest: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 846 Figure 3 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > Customer Interest: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 847 Figure 4 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > Customer Interest: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 848 Figure 5 The EFI throttle body idle speed adjustment procedures for the various model year passenger cars and light trucks are outlined in step-by-step procedures featured in Figures 3, 4 and 5. Select the appropriate procedure for the vehicle involved and adjust the throttle body idle RPM accordingly, after service kit installation. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > Customer Interest: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 849 Figure 6 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > Customer Interest: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 850 Figure 7 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > Customer Interest: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 851 Figure 8 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > Customer Interest: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 852 Figure 9 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > Customer Interest: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 853 Figure 10 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > Customer Interest: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 854 Figure 11 THROTTLE BODY AND IDLE AIR BY-PASS SOLENOID SERVICE PROCEDURE Detailed application charts for throttle body and idle air by-pass solenoid service procedures by engine VIN # /engine displacement/vehicle application and model year are shown in Figures 6 through 11. Refer to these charts to see if the service kit is to be installed and which service cleaning procedure, if any, is to be used. SERVICE CLEANING PROCEDURES The following items should be noted prior to beginning the service cleaning procedure. ^ Confirm that the correct service cleaning procedure is identified in the Application Charts, Figures 6-11, for the vehicle/engine combination being Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > Customer Interest: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 855 serviced. ^ Do not clean throttle bodies identified to accept service kit (F2PZ-9F939-A), IDLE AIR ADJUST SPACER. ^ Use a 1" (25.4 mm) to 1-1/2" (38.1 mm) wire stemmed horse hair or nylon bottle cleaner type brush. ^ Use rubber gloves and eye protection. ^ Do not clean throttle bodies identified with a yellow/black "ATTENTION" label. ^ Do not clean "Black" plastic air by-pass valves. Refer to TSB 89-13-8 for service details. ^ Do not run vehicles with air flow meters when the air duct is removed. ^ Do not use carburetor cleaner as a cleaning solvent. Use Carburetor Tune-up Cleaner (D9AZ-19579-AA). Procedure # 1 THROTTLE BODY AND IDLE AIR BY-PASS VALVE CLEANING CAUTION: DO NOT RUN VEHICLES EQUIPPED WITH AIR FLOW METERS DURING THE CLEANING PROCEDURE. IF THERE IS A YELLOW/BLACK "ATTENTION" LABEL ON THE THROTTLE BODY ADVISING NOT TO CLEAN, OR IF THE VEHICLE IS IDENTIFIED AS ACCEPTING SERVICE KIT (F2PZ-9F939-A), USE PROCEDURE # 2 FOR IDLE AIR BY-PASS VALVE CLEANING ONLY. 1. Plug the actuator into the connector in the Rotunda Cleaner/Tester, Tool 113-00009. 2. Remove the air duct to the throttle body inlet. 3. Disoonnect the idle air by-pass valve signal lead. 4. Attach the actuator harness plug to the idle air by-pass valve. 5. Start the actuator and then start the engine. Do not start engines that have air flow meters. 6. Spray just enough Carburetor Tune-up Cleaner (D9AZ-19579-AA) into the throttle bore to wet the bore and throttle plate. 7. Spray the Carburetor Tune-up Cleaner for about five (5) seconds into the idle air by-pass valve inlet passage while the actuator is operating. 8. Stop the engine and actuator. Let everything soak for fifteen (15) minutes. 9. After a fifteen (15) minute soak, saturate the cleaning brush with solvent and scrub between the throttle body bore and plate while holding the throttle wide open. NOTE: IT IS NECESSARY TO APPLY SOME PRESSURE ON THE BRUSH WHILE SCRUBBING. 10. Repeat saturating the brush and scrubbing for one (1) to two (2) minutes, making sure to reach into the corners where the throttle shaft meets the bore wall. 11. Start the actuator and the start the engine. Do not start engines that have air flow meters. 12. Spray Carburetor Tune-up Cleaner into the throttle bore for up to one (1) minute to wash away residue. Do not spray for longer than six (6) continuous seconds on engines that have air flow meters and are not running. 13. Spray Carburetor Tune-up Cleaner into the idle by-pass valve passage leading to the inlet of the valve for up to one (1) minute. Do not spray for longer than six (6) continuous seconds on engines that have air flow meters and are not running. 14. Stop actuator and stop engine, if running. NOTE: MAKE SURE THE THROTTLE PLATES OPERATE FREELY AND CLOSE PROPERLY. 15. Reinstall the air duct. 16. Start and run the engine for about one (1) minute to dry out the solvent residue. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > Customer Interest: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 856 17. Operate the actuator to make sure the solvent is purged from the idle by-pass valve. 18. Disconnect the actuator from the idle air by-pass valve. 19. Reattach the control signal lead to the air by-pass valve. 20. Check engine for normal operation. It may be necessary to reset the idle speed due to a previous adjustment for an idle concern. (Refer to the respective Powertrain/Emissions Diagnosis Service Manual, Throttle Body Section, for idle speed adjust procedure.) Procedure # 2 Idle Air By-Pass Valve Cleaning Only CAUTION: THIS CLEANING PROCEDURE MAY BE USED WITH SLUDGE TOLERANT THROTTLE BODIES WHICH ARE IDENTIFIED WITH A YELLOW/BLACK "ATTENTION" LABEL AND THOSE USING SERVICE KIT (F2PZ-9F939-A). NO ATTEMPT SHOULD BE MADE TO CLEAN THROTTLE BODY BORE/PLATE AREA BY DIRECT SPRAYING OR SCRUBBING. DO NOT RUN VEHICLES WITH AIR FLOW METERS DURING CLEANING PROCEDURE. 1. Plug the actuator into the connector in the Rotunda Air By-Pass Valve Adapter 113-00009, or equivalent. 2. Remove the air duct to the throttle body inlet. 3. Disconnect the idle air by-pass valve signal lead. 4. Attach the actuator harness plug to the idle air by-pass valve. 5. Start the actuator and then start the engine. NOTE: DO NOT START ENGINES THAT HAVE AIR FLOW METERS. 6. Spray the Carburetor Tune-up Cleaner for about five (5) seconds into the idle air by-pass valve inlet passage while the actuator is operating. CAUTION: AVOID DIRECT SPRAYING ON THROTTLE PLATE/BORE AREA. 7. Stop the engine and actuator. Let everything soak for fifteen (15) minutes. 8. Start the actuator and the start the engine. CAUTION: DO NOT START ENGINES THAT HAVE AIR FLOW METERS. 9. Spray Carburetor Tune-up Cleaner into the throttle bore for up to one (1) minute. CAUTION: DO NOT SPRAY FOR LONGER THAN SIX (6) CONTINUOUS SECONDS ON ENGINES THAT HAVE AIR FLOW METERS AND ARE NOT RUNNING. 10. Stop actuator and stop engine if running. 11. Reinstall the air duct. 12. Start and run the engine for about one (1) minute to dry out the solvent residue. 13. Operate the actuator to make sure the solvent is purged from the idle by-pass valve. 14. Disconnect the actuator from the idle air by-pass valve. 15. Reattach the control signal lead to the air by-pass valve. 16. Check engine for normal operation. NOTE: IT SHOULD NOT BE NECESSARY TO RESET THE IDLE SPEED SINCE ONLY THE IDLE AIR BY-PASS VALVE WAS SERVICED IN THIS PROCEDURE Warranty Coverage Throttle bodies and idle air by-pass valves on all EFI (Port Fuel Injection) engines through the 1992 model year that can be cleaned (as identified in the application charts) are covered under 5/50 Emissions Warranty Coverage. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > Customer Interest: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 857 For those throttle bodies identified as having sludge tolerant designs or using service kit (F2PZ-9F939-A) where cleaning is not allowed per the application charts, the warranty claims for cleaning will not be reimbursed even within the 12/12 warranty coverage period. Cleaning is not allowed. Service kit installation (single time) is covered under 5/50 emission warranty. Labor Standards Operations The labor operations shown in the following Operation/Description/Time columns are identified by procedure number and vehicle line. Specific engines for various vehicles are identified in the sludge cleaning procedure application charts. The throttle body cleaning operations with combinations and the air by-pass valve cleaning combinations will appear in future Labor Manuals under the following operation numbers. ^ 9926 B - Throttle body and idle air by-pass valve cleaning ^ 9926 B2 - Adjust idle speed ^ 9715 A - Air by-pass valve cleaning only ^ 9715 A1 - Adjust idle speed PART NUMBER PART NAME CLASS F2PZ-9F939-A Idle Air By-pass Service Kit B D9AZ-19579-AA Carburstor Tune-Up Cleaner BG OTHER APPLICABLE ARTICLES: 89-13-8 SUPERSEDES: 88-24-5, 88-24-6, 89-16-5, 91-10-9, 91-7-4 Operation Description WARRANTY STATUS: Eligible Under Warranty Coverage As Stated In The Text Of This Article OPERATION DESCRIPTION TIME 912507A Idle Air By-Pass Valve 0.5 Hr. Cleaning - 1983-85 Escort, EXP, LN7, LYNX 1.6L EFI. 912507B Idle Air By-Pass Valve 0.5 Hr. Cleaning - 1986-91 Escort 1.9L EFI, 1986/87 EXP, Lynx 1.9L EFI, 1991 Tracer 1.9L EFI. 912507C Idle Air By Pass Valve 0.5 Hr. Cleaning - 1984-87 Mustang 2.3L T/C, 1986/87 Capri, Cougar 2.3L T/C, 1984-88 T-Bird 2.3L T/C, 1987/92 Mustang 2.3L EFI. 912507D Idle By-Pass Valve Cleaning 0.6 Hr. - 1988-91 Tempo, Topaz 2.3L HSC, 1985-92 Ranger 2.3L EFI. 912507E Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1986/87 Aerostar 2.3L EFI, 1985 Bronco II 2.3L EFI. 912507F Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1986-90 Bronco II 2.9L EFI, 1986-92 Ranger 2.9L EFI. 912507G Idle Air By-Pass Valve 0.6 Hr. Cleaning - 1991/92 Probe 3.0L EFI, 1986-91 Taurus 3.0L EFI, 1987-91 Sable 3.0L EFI. 912507H Idle Air By-Pass Valve 0.7 Hr. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > Customer Interest: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 858 Cleaning - 1986-91 Aerostar 3.0L EFI, 1991 Ranger 3.0L EFI. 912507I Idle Air By-Pass Valve 0.6 Hr. Cleaning - 1988 Continental, Cougar, Taurus, T-Bird, Sable 3.8L EFI. 1988 Cougar, T-Bird 3.8L S/C. 912507J Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1990-92 Aerostar 4.0L EFI, 1990 Bronco II 4.0L EFI, 1991/92 Explorer 4.0L EFI, 1990-92 Ranger 4.0L EFI. 912507K Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1987-92 Bronco 4.9L EFI, 1987-92 F-Series 4.9L EFI, 1987/90 Econoline (Without Rear Heater) 4.9L EFI, 1991/92 Econoline (All) 4.9L EFI. 912507L Idle Air By-Pass Valve 0.6 Hr. Cleaning - 1986-88 Cougar, T-Bird 5.0L EFI, 1986-87 Continental, Mark VII 5.OL EFI, 1986/91 Crn - Victoria, Grn - Marquis 5.0L EFI, 1986-92 Mark VII 5.0L HO, 1982-92 Mustang 5.0L HO. 912507M Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1985-92 Bronco, E-Series, F-Series 5.0L EFI. 912507N Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1988-90 Bronco, F-Series 5.8L. 1991 Econo, F-Series, Bronco 5.8L (Do not Clean Solenoid, Calib; 1-64E-R10, 1-64H-R10, 1-64J-R10, 1-64K-R10, 1-64M-R10, 1-64P-R10, 1-64R-R10, 1-75A-R00, 1-76A-R00, 1-76B-R00, 1-76C-R00. 912507O Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1991/92 F And B Series, 7.0L EFI. 912507P Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1987-92 E-Series, F-Series 7.5L EFI. 912507Q Throttle Body And Idle Air 0.9 Hr. By-Pass Valve Cleaning - 1989/90 Probe 3.0L EFI. 912507R Throttle Body And Idle Air 0.8 Hr. By-Pass Valve Cleaning - 1987-90 Econoline (With Rear Heat) 4.9L EFI. 912507S Throttle Body And Idle Air 0.9 Hr. By-Pass Valve Cleaning - 1988-90 Econoline 5.8L EFI. 912507T Service Kit Install - All Cars 1.0 Hr. And Light Trucks (Except Aerostar And Econoline) - Refer To The Service Procedure Application Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > Customer Interest: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 859 Charts, For Vehicle Application. 912507U Service Kit Install - 1.2 Hr. Aerostar, Econoline - Refer To Service Procedure Application Charts - For Vehicle Application. DEALER CODING BASIC PART NO. CONDITION CODE 9E926 49 OASIS CODES: 602300, 607000, 607400, 607700, 608400, 611500, 618400 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up Technical Service Bulletin # 91257 Date: 911213 Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up Article No. 91-25-7 12/13/91 ^ HARD COLD START - DURING INITIAL START-UP, IDLE OR DECEL - EFI ENGINES SLUDGE IN THROTTLE BODY AND/OR IDLE AIR BY-PASS VALVE ^ HESITATION/STALLS - DURING INITIAL START-UP, IDLE OR DECEL - EFI ENGINES SLUDGE IN THROTTLE BODY AND/OR IDLE AIR BY-PASS VALVE FORD: 1983-87 EXP 1983-91 ESCORT 1984-90 MUSTANG, THUNDERBIRD 1986-90 TAURUS 1986-91 CROWN VICTORIA 1988-90 TEMPO LINCOLN-MERCURY: 1983-85 LN7 1983-87 LYNX 1984-88 CAPRI 1984-90 COUGAR 1986-90 CONTINENTAL, MARK VII, SABLE 1986-91 GRAND MARQUIS, TOWN CAR 1988-90 TOPAZ 1991 TRACER LIGHT TRUCK: 1985-90 BRONCO II, BRONCO 1985-91 ECONOLINE, F-150-350 SERIES 1985-92 RANGER 1986-91 AEROSTAR 1991 EXPLORER ISSUE: Hard cold starts, hesitation and stalls on initial start-up or during idle or decel may be caused by sludge in the throttle body and/or idle by-pass valve. Sludge deposits or oil film on the throttle body bore and plate or the idle air by-pass valve may cause one or more of the following conditions. ^ Hard Cold Start ^ Stall On Initial Start-Up ^ Stall During Idle ^ Stall During Decel ^ Rough Idle ^ Rolling Idle ^ Hesitation During Acceleration ACTION: A new idle air by-pass service kit (F2PZ-9F939-A) is now available for service use to correct sludge contamination concerns of the throttle bore and plate only. It eliminates the need to clean the majority of past model throttle body applications. Cleaning is not required on sludge tolerant throttle body designs released for 1991 and newer model years. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 865 Figure 1 Install an idle air by-pass service kit (F2PZ-9F939-A) as applicable to provide a permanent correction for symptoms caused by throttle body sludge deposits. Refer to the instruction sheet included in the kit for installation details. Refer to Figure 1 for a specific application list of EFI (port fuel Injection) engines involved in this TSB article. The idle air by-pass service kit (F2PZ-9F939-A) includes the following items. ^ One (1) Idle Adjust Spacer ^ Two (2) Gaskets Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 866 ^ Two (2) Attaching Bolts ^ One (1) "Attention" Sticker ^ One (1) Instruction Sheet Figure 2 Refer to Figure 2 for a pictorial of the kits components. NOTE: EFFECTIVE WITH THIS TSB, THROTTLE BODY CLEANING IS NO LONGER COVERED UNDER 5/50 EMISSIONS WARRANTY, UNLESS AS SPECIFIED IN THE FOLLOWING APPLICATION CHARTS. FAILURE TO FOLLOW THE CORRECT PROCEDURE MAY RESULT IN THE CLAIM BEING DISALLOWED. The idle air adjust spacer incorporates sludge tolerant design features that eliminate throttle body sludge related conditions. Once installed, throttle body cleaning is not allowed and periodic adjustment of the throttle body is not required. Procedures, Warranty and Labor CHECKS TO MAKE PRIOR TO SERVICE KIT INSTALLATION Confirm that the following items are not causing the idle quality concern before proceeding with the service kit installation. ^ Contamination within the idle air by-pass solenoid ^ Lack of fuel system control (excessively rich or lean) ^ Ignition timing change ^ Incorrect or malfunctioning EGR system ^ Incorrect or malfunctioning cooling system ^ Vacuum leaks (air intake manifold, vacuum hoses, vacuum reservoirs, power brake booster where applicable) ^ EEC diagnostics have been performed and vehicle malfunction indicated service output codes have been resolved and cleared. If any of the areas listed above are found to be at fault, correct them before proceeding with the service kit installation. Idle Speed Adjustment Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 867 WARNING: BEFORE PROCEEDING WITH THE IDLE SPEED ADJUSTMENT, VERIFY THAT THE FOLLOWING ITEMS ARE TAKEN CARE OF PROPERLY. ^ The transmission is in PARK or Neutral. ^ The parking brake is applied. ^ The wheels are properly blocked. ^ The engine is at operating temperature. ^ The heater, A/C, cooling fan and other accessories are OFF. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 868 Figure 3 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 869 Figure 4 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 870 Figure 5 The EFI throttle body idle speed adjustment procedures for the various model year passenger cars and light trucks are outlined in step-by-step procedures featured in Figures 3, 4 and 5. Select the appropriate procedure for the vehicle involved and adjust the throttle body idle RPM accordingly, after service kit installation. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 871 Figure 6 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 872 Figure 7 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 873 Figure 8 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 874 Figure 9 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 875 Figure 10 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 876 Figure 11 THROTTLE BODY AND IDLE AIR BY-PASS SOLENOID SERVICE PROCEDURE Detailed application charts for throttle body and idle air by-pass solenoid service procedures by engine VIN # /engine displacement/vehicle application and model year are shown in Figures 6 through 11. Refer to these charts to see if the service kit is to be installed and which service cleaning procedure, if any, is to be used. SERVICE CLEANING PROCEDURES The following items should be noted prior to beginning the service cleaning procedure. ^ Confirm that the correct service cleaning procedure is identified in the Application Charts, Figures 6-11, for the vehicle/engine combination being Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 877 serviced. ^ Do not clean throttle bodies identified to accept service kit (F2PZ-9F939-A), IDLE AIR ADJUST SPACER. ^ Use a 1" (25.4 mm) to 1-1/2" (38.1 mm) wire stemmed horse hair or nylon bottle cleaner type brush. ^ Use rubber gloves and eye protection. ^ Do not clean throttle bodies identified with a yellow/black "ATTENTION" label. ^ Do not clean "Black" plastic air by-pass valves. Refer to TSB 89-13-8 for service details. ^ Do not run vehicles with air flow meters when the air duct is removed. ^ Do not use carburetor cleaner as a cleaning solvent. Use Carburetor Tune-up Cleaner (D9AZ-19579-AA). Procedure # 1 THROTTLE BODY AND IDLE AIR BY-PASS VALVE CLEANING CAUTION: DO NOT RUN VEHICLES EQUIPPED WITH AIR FLOW METERS DURING THE CLEANING PROCEDURE. IF THERE IS A YELLOW/BLACK "ATTENTION" LABEL ON THE THROTTLE BODY ADVISING NOT TO CLEAN, OR IF THE VEHICLE IS IDENTIFIED AS ACCEPTING SERVICE KIT (F2PZ-9F939-A), USE PROCEDURE # 2 FOR IDLE AIR BY-PASS VALVE CLEANING ONLY. 1. Plug the actuator into the connector in the Rotunda Cleaner/Tester, Tool 113-00009. 2. Remove the air duct to the throttle body inlet. 3. Disoonnect the idle air by-pass valve signal lead. 4. Attach the actuator harness plug to the idle air by-pass valve. 5. Start the actuator and then start the engine. Do not start engines that have air flow meters. 6. Spray just enough Carburetor Tune-up Cleaner (D9AZ-19579-AA) into the throttle bore to wet the bore and throttle plate. 7. Spray the Carburetor Tune-up Cleaner for about five (5) seconds into the idle air by-pass valve inlet passage while the actuator is operating. 8. Stop the engine and actuator. Let everything soak for fifteen (15) minutes. 9. After a fifteen (15) minute soak, saturate the cleaning brush with solvent and scrub between the throttle body bore and plate while holding the throttle wide open. NOTE: IT IS NECESSARY TO APPLY SOME PRESSURE ON THE BRUSH WHILE SCRUBBING. 10. Repeat saturating the brush and scrubbing for one (1) to two (2) minutes, making sure to reach into the corners where the throttle shaft meets the bore wall. 11. Start the actuator and the start the engine. Do not start engines that have air flow meters. 12. Spray Carburetor Tune-up Cleaner into the throttle bore for up to one (1) minute to wash away residue. Do not spray for longer than six (6) continuous seconds on engines that have air flow meters and are not running. 13. Spray Carburetor Tune-up Cleaner into the idle by-pass valve passage leading to the inlet of the valve for up to one (1) minute. Do not spray for longer than six (6) continuous seconds on engines that have air flow meters and are not running. 14. Stop actuator and stop engine, if running. NOTE: MAKE SURE THE THROTTLE PLATES OPERATE FREELY AND CLOSE PROPERLY. 15. Reinstall the air duct. 16. Start and run the engine for about one (1) minute to dry out the solvent residue. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 878 17. Operate the actuator to make sure the solvent is purged from the idle by-pass valve. 18. Disconnect the actuator from the idle air by-pass valve. 19. Reattach the control signal lead to the air by-pass valve. 20. Check engine for normal operation. It may be necessary to reset the idle speed due to a previous adjustment for an idle concern. (Refer to the respective Powertrain/Emissions Diagnosis Service Manual, Throttle Body Section, for idle speed adjust procedure.) Procedure # 2 Idle Air By-Pass Valve Cleaning Only CAUTION: THIS CLEANING PROCEDURE MAY BE USED WITH SLUDGE TOLERANT THROTTLE BODIES WHICH ARE IDENTIFIED WITH A YELLOW/BLACK "ATTENTION" LABEL AND THOSE USING SERVICE KIT (F2PZ-9F939-A). NO ATTEMPT SHOULD BE MADE TO CLEAN THROTTLE BODY BORE/PLATE AREA BY DIRECT SPRAYING OR SCRUBBING. DO NOT RUN VEHICLES WITH AIR FLOW METERS DURING CLEANING PROCEDURE. 1. Plug the actuator into the connector in the Rotunda Air By-Pass Valve Adapter 113-00009, or equivalent. 2. Remove the air duct to the throttle body inlet. 3. Disconnect the idle air by-pass valve signal lead. 4. Attach the actuator harness plug to the idle air by-pass valve. 5. Start the actuator and then start the engine. NOTE: DO NOT START ENGINES THAT HAVE AIR FLOW METERS. 6. Spray the Carburetor Tune-up Cleaner for about five (5) seconds into the idle air by-pass valve inlet passage while the actuator is operating. CAUTION: AVOID DIRECT SPRAYING ON THROTTLE PLATE/BORE AREA. 7. Stop the engine and actuator. Let everything soak for fifteen (15) minutes. 8. Start the actuator and the start the engine. CAUTION: DO NOT START ENGINES THAT HAVE AIR FLOW METERS. 9. Spray Carburetor Tune-up Cleaner into the throttle bore for up to one (1) minute. CAUTION: DO NOT SPRAY FOR LONGER THAN SIX (6) CONTINUOUS SECONDS ON ENGINES THAT HAVE AIR FLOW METERS AND ARE NOT RUNNING. 10. Stop actuator and stop engine if running. 11. Reinstall the air duct. 12. Start and run the engine for about one (1) minute to dry out the solvent residue. 13. Operate the actuator to make sure the solvent is purged from the idle by-pass valve. 14. Disconnect the actuator from the idle air by-pass valve. 15. Reattach the control signal lead to the air by-pass valve. 16. Check engine for normal operation. NOTE: IT SHOULD NOT BE NECESSARY TO RESET THE IDLE SPEED SINCE ONLY THE IDLE AIR BY-PASS VALVE WAS SERVICED IN THIS PROCEDURE Warranty Coverage Throttle bodies and idle air by-pass valves on all EFI (Port Fuel Injection) engines through the 1992 model year that can be cleaned (as identified in the application charts) are covered under 5/50 Emissions Warranty Coverage. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 879 For those throttle bodies identified as having sludge tolerant designs or using service kit (F2PZ-9F939-A) where cleaning is not allowed per the application charts, the warranty claims for cleaning will not be reimbursed even within the 12/12 warranty coverage period. Cleaning is not allowed. Service kit installation (single time) is covered under 5/50 emission warranty. Labor Standards Operations The labor operations shown in the following Operation/Description/Time columns are identified by procedure number and vehicle line. Specific engines for various vehicles are identified in the sludge cleaning procedure application charts. The throttle body cleaning operations with combinations and the air by-pass valve cleaning combinations will appear in future Labor Manuals under the following operation numbers. ^ 9926 B - Throttle body and idle air by-pass valve cleaning ^ 9926 B2 - Adjust idle speed ^ 9715 A - Air by-pass valve cleaning only ^ 9715 A1 - Adjust idle speed PART NUMBER PART NAME CLASS F2PZ-9F939-A Idle Air By-pass Service Kit B D9AZ-19579-AA Carburstor Tune-Up Cleaner BG OTHER APPLICABLE ARTICLES: 89-13-8 SUPERSEDES: 88-24-5, 88-24-6, 89-16-5, 91-10-9, 91-7-4 Operation Description WARRANTY STATUS: Eligible Under Warranty Coverage As Stated In The Text Of This Article OPERATION DESCRIPTION TIME 912507A Idle Air By-Pass Valve 0.5 Hr. Cleaning - 1983-85 Escort, EXP, LN7, LYNX 1.6L EFI. 912507B Idle Air By-Pass Valve 0.5 Hr. Cleaning - 1986-91 Escort 1.9L EFI, 1986/87 EXP, Lynx 1.9L EFI, 1991 Tracer 1.9L EFI. 912507C Idle Air By Pass Valve 0.5 Hr. Cleaning - 1984-87 Mustang 2.3L T/C, 1986/87 Capri, Cougar 2.3L T/C, 1984-88 T-Bird 2.3L T/C, 1987/92 Mustang 2.3L EFI. 912507D Idle By-Pass Valve Cleaning 0.6 Hr. - 1988-91 Tempo, Topaz 2.3L HSC, 1985-92 Ranger 2.3L EFI. 912507E Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1986/87 Aerostar 2.3L EFI, 1985 Bronco II 2.3L EFI. 912507F Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1986-90 Bronco II 2.9L EFI, 1986-92 Ranger 2.9L EFI. 912507G Idle Air By-Pass Valve 0.6 Hr. Cleaning - 1991/92 Probe 3.0L EFI, 1986-91 Taurus 3.0L EFI, 1987-91 Sable 3.0L EFI. 912507H Idle Air By-Pass Valve 0.7 Hr. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 880 Cleaning - 1986-91 Aerostar 3.0L EFI, 1991 Ranger 3.0L EFI. 912507I Idle Air By-Pass Valve 0.6 Hr. Cleaning - 1988 Continental, Cougar, Taurus, T-Bird, Sable 3.8L EFI. 1988 Cougar, T-Bird 3.8L S/C. 912507J Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1990-92 Aerostar 4.0L EFI, 1990 Bronco II 4.0L EFI, 1991/92 Explorer 4.0L EFI, 1990-92 Ranger 4.0L EFI. 912507K Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1987-92 Bronco 4.9L EFI, 1987-92 F-Series 4.9L EFI, 1987/90 Econoline (Without Rear Heater) 4.9L EFI, 1991/92 Econoline (All) 4.9L EFI. 912507L Idle Air By-Pass Valve 0.6 Hr. Cleaning - 1986-88 Cougar, T-Bird 5.0L EFI, 1986-87 Continental, Mark VII 5.OL EFI, 1986/91 Crn - Victoria, Grn - Marquis 5.0L EFI, 1986-92 Mark VII 5.0L HO, 1982-92 Mustang 5.0L HO. 912507M Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1985-92 Bronco, E-Series, F-Series 5.0L EFI. 912507N Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1988-90 Bronco, F-Series 5.8L. 1991 Econo, F-Series, Bronco 5.8L (Do not Clean Solenoid, Calib; 1-64E-R10, 1-64H-R10, 1-64J-R10, 1-64K-R10, 1-64M-R10, 1-64P-R10, 1-64R-R10, 1-75A-R00, 1-76A-R00, 1-76B-R00, 1-76C-R00. 912507O Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1991/92 F And B Series, 7.0L EFI. 912507P Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1987-92 E-Series, F-Series 7.5L EFI. 912507Q Throttle Body And Idle Air 0.9 Hr. By-Pass Valve Cleaning - 1989/90 Probe 3.0L EFI. 912507R Throttle Body And Idle Air 0.8 Hr. By-Pass Valve Cleaning - 1987-90 Econoline (With Rear Heat) 4.9L EFI. 912507S Throttle Body And Idle Air 0.9 Hr. By-Pass Valve Cleaning - 1988-90 Econoline 5.8L EFI. 912507T Service Kit Install - All Cars 1.0 Hr. And Light Trucks (Except Aerostar And Econoline) - Refer To The Service Procedure Application Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 881 Charts, For Vehicle Application. 912507U Service Kit Install - 1.2 Hr. Aerostar, Econoline - Refer To Service Procedure Application Charts - For Vehicle Application. DEALER CODING BASIC PART NO. CONDITION CODE 9E926 49 OASIS CODES: 602300, 607000, 607400, 607700, 608400, 611500, 618400 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 861516 > Jul > 86 > Vehicle - High Altitude Modification Idle Speed: All Technical Service Bulletins Vehicle - High Altitude Modification Article No. 86-15-16 ALTITUDE (5.8L (W)) - MODIFICATION OF SEA LEVEL CALIBRATION FOR ALTITUDE APPLICATION - VEHICLES WITH 4V CARBURETORS ONLY - OVER 8500 LBS. GVWR LIGHT TRUCK 1986 E SERIES, F SERIES CALIBRATION: 5-76J-R17 (Manual Transmission) WARNING: This modification is authorized only for the listed engines. Performing this modification on other engine calibrations is unauthorized and could create liability under applicable federal or local laws. Customers who may have relocated and/or continually operate the subject vehicles in high altitude (above 4,000 ft. alt.) may have the following procedure performed to improve performance. 1. Remove existing PCV valve and replace with new PCV valve (part number D90Z-6A666-A). 2. Advance initial ignition timing 6~ from nominal setting of 8~ BTDC to 14~ BTDC. Refer to 1986 Light Truck Shop Manual, Volume B, Section 23-01. 3. Increase choke pull down hard gauge setting to .193". Refer to 1986 Light Truck Shop Manual, Volume B, Section 24-26. 4. Remove existing choke cap and replace with new choke cap 47R-776-A (part number E5PZ-9848-B). 5. Reset hi-cam and curb idle speeds to specification (refer to Vehicle Emission Control Information Decal). Obtain a Vehicle Emission Control Information Update Decal (available at all Ford or Lincoln-Mercury dealers) and fill in the appropriate information as indicated. If the vehicle is returned to continuous sea level (below 4,000 ft. alt.) operation, the above procedure should be reversed and the Vehicle Emission Control Information Update Decal should be removed from the vehicle. PART NUMBER PART NAME CLASS D90Z-6A666-A PCV Valve A E5PZ-9848-B Choke Cap C OTHER APPLICABLE ARTICLES: 85-21-16 WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION: SP9514A86 TIME: 1.3 Hrs. DLR. CODING: Basic Part No. DRIVE - Code: N4, P6, T5 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Other Service Bulletins for Idle Speed: > 861516 > Jul > 86 > Vehicle - High Altitude Modification Idle Speed: All Technical Service Bulletins Vehicle - High Altitude Modification Article No. 86-15-16 ALTITUDE (5.8L (W)) - MODIFICATION OF SEA LEVEL CALIBRATION FOR ALTITUDE APPLICATION - VEHICLES WITH 4V CARBURETORS ONLY - OVER 8500 LBS. GVWR LIGHT TRUCK 1986 E SERIES, F SERIES CALIBRATION: 5-76J-R17 (Manual Transmission) WARNING: This modification is authorized only for the listed engines. Performing this modification on other engine calibrations is unauthorized and could create liability under applicable federal or local laws. Customers who may have relocated and/or continually operate the subject vehicles in high altitude (above 4,000 ft. alt.) may have the following procedure performed to improve performance. 1. Remove existing PCV valve and replace with new PCV valve (part number D90Z-6A666-A). 2. Advance initial ignition timing 6~ from nominal setting of 8~ BTDC to 14~ BTDC. Refer to 1986 Light Truck Shop Manual, Volume B, Section 23-01. 3. Increase choke pull down hard gauge setting to .193". Refer to 1986 Light Truck Shop Manual, Volume B, Section 24-26. 4. Remove existing choke cap and replace with new choke cap 47R-776-A (part number E5PZ-9848-B). 5. Reset hi-cam and curb idle speeds to specification (refer to Vehicle Emission Control Information Decal). Obtain a Vehicle Emission Control Information Update Decal (available at all Ford or Lincoln-Mercury dealers) and fill in the appropriate information as indicated. If the vehicle is returned to continuous sea level (below 4,000 ft. alt.) operation, the above procedure should be reversed and the Vehicle Emission Control Information Update Decal should be removed from the vehicle. PART NUMBER PART NAME CLASS D90Z-6A666-A PCV Valve A E5PZ-9848-B Choke Cap C OTHER APPLICABLE ARTICLES: 85-21-16 WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION: SP9514A86 TIME: 1.3 Hrs. DLR. CODING: Basic Part No. DRIVE - Code: N4, P6, T5 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Other Service Bulletins for Idle Speed: > Page 891 Idle Speed: By Symptom Technical Service Bulletin # 91257 Date: 911213 Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up Article No. 91-25-7 12/13/91 ^ HARD COLD START - DURING INITIAL START-UP, IDLE OR DECEL - EFI ENGINES SLUDGE IN THROTTLE BODY AND/OR IDLE AIR BY-PASS VALVE ^ HESITATION/STALLS - DURING INITIAL START-UP, IDLE OR DECEL - EFI ENGINES SLUDGE IN THROTTLE BODY AND/OR IDLE AIR BY-PASS VALVE FORD: 1983-87 EXP 1983-91 ESCORT 1984-90 MUSTANG, THUNDERBIRD 1986-90 TAURUS 1986-91 CROWN VICTORIA 1988-90 TEMPO LINCOLN-MERCURY: 1983-85 LN7 1983-87 LYNX 1984-88 CAPRI 1984-90 COUGAR 1986-90 CONTINENTAL, MARK VII, SABLE 1986-91 GRAND MARQUIS, TOWN CAR 1988-90 TOPAZ 1991 TRACER LIGHT TRUCK: 1985-90 BRONCO II, BRONCO 1985-91 ECONOLINE, F-150-350 SERIES 1985-92 RANGER 1986-91 AEROSTAR 1991 EXPLORER ISSUE: Hard cold starts, hesitation and stalls on initial start-up or during idle or decel may be caused by sludge in the throttle body and/or idle by-pass valve. Sludge deposits or oil film on the throttle body bore and plate or the idle air by-pass valve may cause one or more of the following conditions. ^ Hard Cold Start ^ Stall On Initial Start-Up ^ Stall During Idle ^ Stall During Decel ^ Rough Idle ^ Rolling Idle ^ Hesitation During Acceleration ACTION: A new idle air by-pass service kit (F2PZ-9F939-A) is now available for service use to correct sludge contamination concerns of the throttle bore and plate only. It eliminates the need to clean the majority of past model throttle body applications. Cleaning is not required on sludge tolerant throttle body designs released for 1991 and newer model years. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Other Service Bulletins for Idle Speed: > Page 892 Figure 1 Install an idle air by-pass service kit (F2PZ-9F939-A) as applicable to provide a permanent correction for symptoms caused by throttle body sludge deposits. Refer to the instruction sheet included in the kit for installation details. Refer to Figure 1 for a specific application list of EFI (port fuel Injection) engines involved in this TSB article. The idle air by-pass service kit (F2PZ-9F939-A) includes the following items. ^ One (1) Idle Adjust Spacer ^ Two (2) Gaskets Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Other Service Bulletins for Idle Speed: > Page 893 ^ Two (2) Attaching Bolts ^ One (1) "Attention" Sticker ^ One (1) Instruction Sheet Figure 2 Refer to Figure 2 for a pictorial of the kits components. NOTE: EFFECTIVE WITH THIS TSB, THROTTLE BODY CLEANING IS NO LONGER COVERED UNDER 5/50 EMISSIONS WARRANTY, UNLESS AS SPECIFIED IN THE FOLLOWING APPLICATION CHARTS. FAILURE TO FOLLOW THE CORRECT PROCEDURE MAY RESULT IN THE CLAIM BEING DISALLOWED. The idle air adjust spacer incorporates sludge tolerant design features that eliminate throttle body sludge related conditions. Once installed, throttle body cleaning is not allowed and periodic adjustment of the throttle body is not required. Procedures, Warranty and Labor CHECKS TO MAKE PRIOR TO SERVICE KIT INSTALLATION Confirm that the following items are not causing the idle quality concern before proceeding with the service kit installation. ^ Contamination within the idle air by-pass solenoid ^ Lack of fuel system control (excessively rich or lean) ^ Ignition timing change ^ Incorrect or malfunctioning EGR system ^ Incorrect or malfunctioning cooling system ^ Vacuum leaks (air intake manifold, vacuum hoses, vacuum reservoirs, power brake booster where applicable) ^ EEC diagnostics have been performed and vehicle malfunction indicated service output codes have been resolved and cleared. If any of the areas listed above are found to be at fault, correct them before proceeding with the service kit installation. Idle Speed Adjustment Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Other Service Bulletins for Idle Speed: > Page 894 WARNING: BEFORE PROCEEDING WITH THE IDLE SPEED ADJUSTMENT, VERIFY THAT THE FOLLOWING ITEMS ARE TAKEN CARE OF PROPERLY. ^ The transmission is in PARK or Neutral. ^ The parking brake is applied. ^ The wheels are properly blocked. ^ The engine is at operating temperature. ^ The heater, A/C, cooling fan and other accessories are OFF. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Other Service Bulletins for Idle Speed: > Page 895 Figure 3 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Other Service Bulletins for Idle Speed: > Page 896 Figure 4 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Other Service Bulletins for Idle Speed: > Page 897 Figure 5 The EFI throttle body idle speed adjustment procedures for the various model year passenger cars and light trucks are outlined in step-by-step procedures featured in Figures 3, 4 and 5. Select the appropriate procedure for the vehicle involved and adjust the throttle body idle RPM accordingly, after service kit installation. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Other Service Bulletins for Idle Speed: > Page 898 Figure 6 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Other Service Bulletins for Idle Speed: > Page 899 Figure 7 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Other Service Bulletins for Idle Speed: > Page 900 Figure 8 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Other Service Bulletins for Idle Speed: > Page 901 Figure 9 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Other Service Bulletins for Idle Speed: > Page 902 Figure 10 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Other Service Bulletins for Idle Speed: > Page 903 Figure 11 THROTTLE BODY AND IDLE AIR BY-PASS SOLENOID SERVICE PROCEDURE Detailed application charts for throttle body and idle air by-pass solenoid service procedures by engine VIN # /engine displacement/vehicle application and model year are shown in Figures 6 through 11. Refer to these charts to see if the service kit is to be installed and which service cleaning procedure, if any, is to be used. SERVICE CLEANING PROCEDURES The following items should be noted prior to beginning the service cleaning procedure. ^ Confirm that the correct service cleaning procedure is identified in the Application Charts, Figures 6-11, for the vehicle/engine combination being Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Other Service Bulletins for Idle Speed: > Page 904 serviced. ^ Do not clean throttle bodies identified to accept service kit (F2PZ-9F939-A), IDLE AIR ADJUST SPACER. ^ Use a 1" (25.4 mm) to 1-1/2" (38.1 mm) wire stemmed horse hair or nylon bottle cleaner type brush. ^ Use rubber gloves and eye protection. ^ Do not clean throttle bodies identified with a yellow/black "ATTENTION" label. ^ Do not clean "Black" plastic air by-pass valves. Refer to TSB 89-13-8 for service details. ^ Do not run vehicles with air flow meters when the air duct is removed. ^ Do not use carburetor cleaner as a cleaning solvent. Use Carburetor Tune-up Cleaner (D9AZ-19579-AA). Procedure # 1 THROTTLE BODY AND IDLE AIR BY-PASS VALVE CLEANING CAUTION: DO NOT RUN VEHICLES EQUIPPED WITH AIR FLOW METERS DURING THE CLEANING PROCEDURE. IF THERE IS A YELLOW/BLACK "ATTENTION" LABEL ON THE THROTTLE BODY ADVISING NOT TO CLEAN, OR IF THE VEHICLE IS IDENTIFIED AS ACCEPTING SERVICE KIT (F2PZ-9F939-A), USE PROCEDURE # 2 FOR IDLE AIR BY-PASS VALVE CLEANING ONLY. 1. Plug the actuator into the connector in the Rotunda Cleaner/Tester, Tool 113-00009. 2. Remove the air duct to the throttle body inlet. 3. Disoonnect the idle air by-pass valve signal lead. 4. Attach the actuator harness plug to the idle air by-pass valve. 5. Start the actuator and then start the engine. Do not start engines that have air flow meters. 6. Spray just enough Carburetor Tune-up Cleaner (D9AZ-19579-AA) into the throttle bore to wet the bore and throttle plate. 7. Spray the Carburetor Tune-up Cleaner for about five (5) seconds into the idle air by-pass valve inlet passage while the actuator is operating. 8. Stop the engine and actuator. Let everything soak for fifteen (15) minutes. 9. After a fifteen (15) minute soak, saturate the cleaning brush with solvent and scrub between the throttle body bore and plate while holding the throttle wide open. NOTE: IT IS NECESSARY TO APPLY SOME PRESSURE ON THE BRUSH WHILE SCRUBBING. 10. Repeat saturating the brush and scrubbing for one (1) to two (2) minutes, making sure to reach into the corners where the throttle shaft meets the bore wall. 11. Start the actuator and the start the engine. Do not start engines that have air flow meters. 12. Spray Carburetor Tune-up Cleaner into the throttle bore for up to one (1) minute to wash away residue. Do not spray for longer than six (6) continuous seconds on engines that have air flow meters and are not running. 13. Spray Carburetor Tune-up Cleaner into the idle by-pass valve passage leading to the inlet of the valve for up to one (1) minute. Do not spray for longer than six (6) continuous seconds on engines that have air flow meters and are not running. 14. Stop actuator and stop engine, if running. NOTE: MAKE SURE THE THROTTLE PLATES OPERATE FREELY AND CLOSE PROPERLY. 15. Reinstall the air duct. 16. Start and run the engine for about one (1) minute to dry out the solvent residue. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Other Service Bulletins for Idle Speed: > Page 905 17. Operate the actuator to make sure the solvent is purged from the idle by-pass valve. 18. Disconnect the actuator from the idle air by-pass valve. 19. Reattach the control signal lead to the air by-pass valve. 20. Check engine for normal operation. It may be necessary to reset the idle speed due to a previous adjustment for an idle concern. (Refer to the respective Powertrain/Emissions Diagnosis Service Manual, Throttle Body Section, for idle speed adjust procedure.) Procedure # 2 Idle Air By-Pass Valve Cleaning Only CAUTION: THIS CLEANING PROCEDURE MAY BE USED WITH SLUDGE TOLERANT THROTTLE BODIES WHICH ARE IDENTIFIED WITH A YELLOW/BLACK "ATTENTION" LABEL AND THOSE USING SERVICE KIT (F2PZ-9F939-A). NO ATTEMPT SHOULD BE MADE TO CLEAN THROTTLE BODY BORE/PLATE AREA BY DIRECT SPRAYING OR SCRUBBING. DO NOT RUN VEHICLES WITH AIR FLOW METERS DURING CLEANING PROCEDURE. 1. Plug the actuator into the connector in the Rotunda Air By-Pass Valve Adapter 113-00009, or equivalent. 2. Remove the air duct to the throttle body inlet. 3. Disconnect the idle air by-pass valve signal lead. 4. Attach the actuator harness plug to the idle air by-pass valve. 5. Start the actuator and then start the engine. NOTE: DO NOT START ENGINES THAT HAVE AIR FLOW METERS. 6. Spray the Carburetor Tune-up Cleaner for about five (5) seconds into the idle air by-pass valve inlet passage while the actuator is operating. CAUTION: AVOID DIRECT SPRAYING ON THROTTLE PLATE/BORE AREA. 7. Stop the engine and actuator. Let everything soak for fifteen (15) minutes. 8. Start the actuator and the start the engine. CAUTION: DO NOT START ENGINES THAT HAVE AIR FLOW METERS. 9. Spray Carburetor Tune-up Cleaner into the throttle bore for up to one (1) minute. CAUTION: DO NOT SPRAY FOR LONGER THAN SIX (6) CONTINUOUS SECONDS ON ENGINES THAT HAVE AIR FLOW METERS AND ARE NOT RUNNING. 10. Stop actuator and stop engine if running. 11. Reinstall the air duct. 12. Start and run the engine for about one (1) minute to dry out the solvent residue. 13. Operate the actuator to make sure the solvent is purged from the idle by-pass valve. 14. Disconnect the actuator from the idle air by-pass valve. 15. Reattach the control signal lead to the air by-pass valve. 16. Check engine for normal operation. NOTE: IT SHOULD NOT BE NECESSARY TO RESET THE IDLE SPEED SINCE ONLY THE IDLE AIR BY-PASS VALVE WAS SERVICED IN THIS PROCEDURE Warranty Coverage Throttle bodies and idle air by-pass valves on all EFI (Port Fuel Injection) engines through the 1992 model year that can be cleaned (as identified in the application charts) are covered under 5/50 Emissions Warranty Coverage. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Other Service Bulletins for Idle Speed: > Page 906 For those throttle bodies identified as having sludge tolerant designs or using service kit (F2PZ-9F939-A) where cleaning is not allowed per the application charts, the warranty claims for cleaning will not be reimbursed even within the 12/12 warranty coverage period. Cleaning is not allowed. Service kit installation (single time) is covered under 5/50 emission warranty. Labor Standards Operations The labor operations shown in the following Operation/Description/Time columns are identified by procedure number and vehicle line. Specific engines for various vehicles are identified in the sludge cleaning procedure application charts. The throttle body cleaning operations with combinations and the air by-pass valve cleaning combinations will appear in future Labor Manuals under the following operation numbers. ^ 9926 B - Throttle body and idle air by-pass valve cleaning ^ 9926 B2 - Adjust idle speed ^ 9715 A - Air by-pass valve cleaning only ^ 9715 A1 - Adjust idle speed PART NUMBER PART NAME CLASS F2PZ-9F939-A Idle Air By-pass Service Kit B D9AZ-19579-AA Carburstor Tune-Up Cleaner BG OTHER APPLICABLE ARTICLES: 89-13-8 SUPERSEDES: 88-24-5, 88-24-6, 89-16-5, 91-10-9, 91-7-4 Operation Description WARRANTY STATUS: Eligible Under Warranty Coverage As Stated In The Text Of This Article OPERATION DESCRIPTION TIME 912507A Idle Air By-Pass Valve 0.5 Hr. Cleaning - 1983-85 Escort, EXP, LN7, LYNX 1.6L EFI. 912507B Idle Air By-Pass Valve 0.5 Hr. Cleaning - 1986-91 Escort 1.9L EFI, 1986/87 EXP, Lynx 1.9L EFI, 1991 Tracer 1.9L EFI. 912507C Idle Air By Pass Valve 0.5 Hr. Cleaning - 1984-87 Mustang 2.3L T/C, 1986/87 Capri, Cougar 2.3L T/C, 1984-88 T-Bird 2.3L T/C, 1987/92 Mustang 2.3L EFI. 912507D Idle By-Pass Valve Cleaning 0.6 Hr. - 1988-91 Tempo, Topaz 2.3L HSC, 1985-92 Ranger 2.3L EFI. 912507E Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1986/87 Aerostar 2.3L EFI, 1985 Bronco II 2.3L EFI. 912507F Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1986-90 Bronco II 2.9L EFI, 1986-92 Ranger 2.9L EFI. 912507G Idle Air By-Pass Valve 0.6 Hr. Cleaning - 1991/92 Probe 3.0L EFI, 1986-91 Taurus 3.0L EFI, 1987-91 Sable 3.0L EFI. 912507H Idle Air By-Pass Valve 0.7 Hr. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Other Service Bulletins for Idle Speed: > Page 907 Cleaning - 1986-91 Aerostar 3.0L EFI, 1991 Ranger 3.0L EFI. 912507I Idle Air By-Pass Valve 0.6 Hr. Cleaning - 1988 Continental, Cougar, Taurus, T-Bird, Sable 3.8L EFI. 1988 Cougar, T-Bird 3.8L S/C. 912507J Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1990-92 Aerostar 4.0L EFI, 1990 Bronco II 4.0L EFI, 1991/92 Explorer 4.0L EFI, 1990-92 Ranger 4.0L EFI. 912507K Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1987-92 Bronco 4.9L EFI, 1987-92 F-Series 4.9L EFI, 1987/90 Econoline (Without Rear Heater) 4.9L EFI, 1991/92 Econoline (All) 4.9L EFI. 912507L Idle Air By-Pass Valve 0.6 Hr. Cleaning - 1986-88 Cougar, T-Bird 5.0L EFI, 1986-87 Continental, Mark VII 5.OL EFI, 1986/91 Crn - Victoria, Grn - Marquis 5.0L EFI, 1986-92 Mark VII 5.0L HO, 1982-92 Mustang 5.0L HO. 912507M Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1985-92 Bronco, E-Series, F-Series 5.0L EFI. 912507N Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1988-90 Bronco, F-Series 5.8L. 1991 Econo, F-Series, Bronco 5.8L (Do not Clean Solenoid, Calib; 1-64E-R10, 1-64H-R10, 1-64J-R10, 1-64K-R10, 1-64M-R10, 1-64P-R10, 1-64R-R10, 1-75A-R00, 1-76A-R00, 1-76B-R00, 1-76C-R00. 912507O Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1991/92 F And B Series, 7.0L EFI. 912507P Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1987-92 E-Series, F-Series 7.5L EFI. 912507Q Throttle Body And Idle Air 0.9 Hr. By-Pass Valve Cleaning - 1989/90 Probe 3.0L EFI. 912507R Throttle Body And Idle Air 0.8 Hr. By-Pass Valve Cleaning - 1987-90 Econoline (With Rear Heat) 4.9L EFI. 912507S Throttle Body And Idle Air 0.9 Hr. By-Pass Valve Cleaning - 1988-90 Econoline 5.8L EFI. 912507T Service Kit Install - All Cars 1.0 Hr. And Light Trucks (Except Aerostar And Econoline) - Refer To The Service Procedure Application Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Other Service Bulletins for Idle Speed: > Page 908 Charts, For Vehicle Application. 912507U Service Kit Install - 1.2 Hr. Aerostar, Econoline - Refer To Service Procedure Application Charts - For Vehicle Application. DEALER CODING BASIC PART NO. CONDITION CODE 9E926 49 OASIS CODES: 602300, 607000, 607400, 607700, 608400, 611500, 618400 Technical Service Bulletin # 91257 Date: 911213 Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up Article No. 91-25-7 12/13/91 ^ HARD COLD START - DURING INITIAL START-UP, IDLE OR DECEL - EFI ENGINES SLUDGE IN THROTTLE BODY AND/OR IDLE AIR BY-PASS VALVE ^ HESITATION/STALLS - DURING INITIAL START-UP, IDLE OR DECEL - EFI ENGINES SLUDGE IN THROTTLE BODY AND/OR IDLE AIR BY-PASS VALVE FORD: 1983-87 EXP 1983-91 ESCORT 1984-90 MUSTANG, THUNDERBIRD 1986-90 TAURUS 1986-91 CROWN VICTORIA 1988-90 TEMPO LINCOLN-MERCURY: 1983-85 LN7 1983-87 LYNX 1984-88 CAPRI 1984-90 COUGAR 1986-90 CONTINENTAL, MARK VII, SABLE 1986-91 GRAND MARQUIS, TOWN CAR 1988-90 TOPAZ 1991 TRACER LIGHT TRUCK: 1985-90 BRONCO II, BRONCO 1985-91 ECONOLINE, F-150-350 SERIES 1985-92 RANGER 1986-91 AEROSTAR 1991 EXPLORER ISSUE: Hard cold starts, hesitation and stalls on initial start-up or during idle or decel may be caused by sludge in the throttle body and/or idle by-pass valve. Sludge deposits or oil film on the throttle body bore and plate or the idle air by-pass valve may cause one or more of the following conditions. ^ Hard Cold Start ^ Stall On Initial Start-Up ^ Stall During Idle ^ Stall During Decel ^ Rough Idle ^ Rolling Idle Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Other Service Bulletins for Idle Speed: > Page 909 ^ Hesitation During Acceleration ACTION: A new idle air by-pass service kit (F2PZ-9F939-A) is now available for service use to correct sludge contamination concerns of the throttle bore and plate only. It eliminates the need to clean the majority of past model throttle body applications. Cleaning is not required on sludge tolerant throttle body designs released for 1991 and newer model years. Figure 1 Install an idle air by-pass service kit (F2PZ-9F939-A) as applicable to provide a permanent correction for symptoms caused by throttle body sludge deposits. Refer to the instruction sheet included in the kit for installation details. Refer to Figure 1 for a specific application list of EFI (port fuel Injection) engines involved in this TSB article. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Other Service Bulletins for Idle Speed: > Page 910 The idle air by-pass service kit (F2PZ-9F939-A) includes the following items. ^ One (1) Idle Adjust Spacer ^ Two (2) Gaskets ^ Two (2) Attaching Bolts ^ One (1) "Attention" Sticker ^ One (1) Instruction Sheet Figure 2 Refer to Figure 2 for a pictorial of the kits components. NOTE: EFFECTIVE WITH THIS TSB, THROTTLE BODY CLEANING IS NO LONGER COVERED UNDER 5/50 EMISSIONS WARRANTY, UNLESS AS SPECIFIED IN THE FOLLOWING APPLICATION CHARTS. FAILURE TO FOLLOW THE CORRECT PROCEDURE MAY RESULT IN THE CLAIM BEING DISALLOWED. The idle air adjust spacer incorporates sludge tolerant design features that eliminate throttle body sludge related conditions. Once installed, throttle body cleaning is not allowed and periodic adjustment of the throttle body is not required. Procedures, Warranty and Labor CHECKS TO MAKE PRIOR TO SERVICE KIT INSTALLATION Confirm that the following items are not causing the idle quality concern before proceeding with the service kit installation. ^ Contamination within the idle air by-pass solenoid ^ Lack of fuel system control (excessively rich or lean) ^ Ignition timing change ^ Incorrect or malfunctioning EGR system ^ Incorrect or malfunctioning cooling system ^ Vacuum leaks (air intake manifold, vacuum hoses, vacuum reservoirs, power brake booster where applicable) ^ EEC diagnostics have been performed and vehicle malfunction indicated service output codes have been resolved and cleared. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Other Service Bulletins for Idle Speed: > Page 911 If any of the areas listed above are found to be at fault, correct them before proceeding with the service kit installation. Idle Speed Adjustment WARNING: BEFORE PROCEEDING WITH THE IDLE SPEED ADJUSTMENT, VERIFY THAT THE FOLLOWING ITEMS ARE TAKEN CARE OF PROPERLY. ^ The transmission is in PARK or Neutral. ^ The parking brake is applied. ^ The wheels are properly blocked. ^ The engine is at operating temperature. ^ The heater, A/C, cooling fan and other accessories are OFF. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Other Service Bulletins for Idle Speed: > Page 912 Figure 3 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Other Service Bulletins for Idle Speed: > Page 913 Figure 4 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Other Service Bulletins for Idle Speed: > Page 914 Figure 5 The EFI throttle body idle speed adjustment procedures for the various model year passenger cars and light trucks are outlined in step-by-step procedures featured in Figures 3, 4 and 5. Select the appropriate procedure for the vehicle involved and adjust the throttle body idle RPM accordingly, after service kit installation. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Other Service Bulletins for Idle Speed: > Page 915 Figure 6 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Other Service Bulletins for Idle Speed: > Page 916 Figure 7 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Other Service Bulletins for Idle Speed: > Page 917 Figure 8 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Other Service Bulletins for Idle Speed: > Page 918 Figure 9 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Other Service Bulletins for Idle Speed: > Page 919 Figure 10 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Other Service Bulletins for Idle Speed: > Page 920 Figure 11 THROTTLE BODY AND IDLE AIR BY-PASS SOLENOID SERVICE PROCEDURE Detailed application charts for throttle body and idle air by-pass solenoid service procedures by engine VIN # /engine displacement/vehicle application and model year are shown in Figures 6 through 11. Refer to these charts to see if the service kit is to be installed and which service cleaning procedure, if any, is to be used. SERVICE CLEANING PROCEDURES The following items should be noted prior to beginning the service cleaning procedure. ^ Confirm that the correct service cleaning procedure is identified in the Application Charts, Figures 6-11, for the vehicle/engine combination being Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Other Service Bulletins for Idle Speed: > Page 921 serviced. ^ Do not clean throttle bodies identified to accept service kit (F2PZ-9F939-A), IDLE AIR ADJUST SPACER. ^ Use a 1" (25.4 mm) to 1-1/2" (38.1 mm) wire stemmed horse hair or nylon bottle cleaner type brush. ^ Use rubber gloves and eye protection. ^ Do not clean throttle bodies identified with a yellow/black "ATTENTION" label. ^ Do not clean "Black" plastic air by-pass valves. Refer to TSB 89-13-8 for service details. ^ Do not run vehicles with air flow meters when the air duct is removed. ^ Do not use carburetor cleaner as a cleaning solvent. Use Carburetor Tune-up Cleaner (D9AZ-19579-AA). Procedure # 1 THROTTLE BODY AND IDLE AIR BY-PASS VALVE CLEANING CAUTION: DO NOT RUN VEHICLES EQUIPPED WITH AIR FLOW METERS DURING THE CLEANING PROCEDURE. IF THERE IS A YELLOW/BLACK "ATTENTION" LABEL ON THE THROTTLE BODY ADVISING NOT TO CLEAN, OR IF THE VEHICLE IS IDENTIFIED AS ACCEPTING SERVICE KIT (F2PZ-9F939-A), USE PROCEDURE # 2 FOR IDLE AIR BY-PASS VALVE CLEANING ONLY. 1. Plug the actuator into the connector in the Rotunda Cleaner/Tester, Tool 113-00009. 2. Remove the air duct to the throttle body inlet. 3. Disoonnect the idle air by-pass valve signal lead. 4. Attach the actuator harness plug to the idle air by-pass valve. 5. Start the actuator and then start the engine. Do not start engines that have air flow meters. 6. Spray just enough Carburetor Tune-up Cleaner (D9AZ-19579-AA) into the throttle bore to wet the bore and throttle plate. 7. Spray the Carburetor Tune-up Cleaner for about five (5) seconds into the idle air by-pass valve inlet passage while the actuator is operating. 8. Stop the engine and actuator. Let everything soak for fifteen (15) minutes. 9. After a fifteen (15) minute soak, saturate the cleaning brush with solvent and scrub between the throttle body bore and plate while holding the throttle wide open. NOTE: IT IS NECESSARY TO APPLY SOME PRESSURE ON THE BRUSH WHILE SCRUBBING. 10. Repeat saturating the brush and scrubbing for one (1) to two (2) minutes, making sure to reach into the corners where the throttle shaft meets the bore wall. 11. Start the actuator and the start the engine. Do not start engines that have air flow meters. 12. Spray Carburetor Tune-up Cleaner into the throttle bore for up to one (1) minute to wash away residue. Do not spray for longer than six (6) continuous seconds on engines that have air flow meters and are not running. 13. Spray Carburetor Tune-up Cleaner into the idle by-pass valve passage leading to the inlet of the valve for up to one (1) minute. Do not spray for longer than six (6) continuous seconds on engines that have air flow meters and are not running. 14. Stop actuator and stop engine, if running. NOTE: MAKE SURE THE THROTTLE PLATES OPERATE FREELY AND CLOSE PROPERLY. 15. Reinstall the air duct. 16. Start and run the engine for about one (1) minute to dry out the solvent residue. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Other Service Bulletins for Idle Speed: > Page 922 17. Operate the actuator to make sure the solvent is purged from the idle by-pass valve. 18. Disconnect the actuator from the idle air by-pass valve. 19. Reattach the control signal lead to the air by-pass valve. 20. Check engine for normal operation. It may be necessary to reset the idle speed due to a previous adjustment for an idle concern. (Refer to the respective Powertrain/Emissions Diagnosis Service Manual, Throttle Body Section, for idle speed adjust procedure.) Procedure # 2 Idle Air By-Pass Valve Cleaning Only CAUTION: THIS CLEANING PROCEDURE MAY BE USED WITH SLUDGE TOLERANT THROTTLE BODIES WHICH ARE IDENTIFIED WITH A YELLOW/BLACK "ATTENTION" LABEL AND THOSE USING SERVICE KIT (F2PZ-9F939-A). NO ATTEMPT SHOULD BE MADE TO CLEAN THROTTLE BODY BORE/PLATE AREA BY DIRECT SPRAYING OR SCRUBBING. DO NOT RUN VEHICLES WITH AIR FLOW METERS DURING CLEANING PROCEDURE. 1. Plug the actuator into the connector in the Rotunda Air By-Pass Valve Adapter 113-00009, or equivalent. 2. Remove the air duct to the throttle body inlet. 3. Disconnect the idle air by-pass valve signal lead. 4. Attach the actuator harness plug to the idle air by-pass valve. 5. Start the actuator and then start the engine. NOTE: DO NOT START ENGINES THAT HAVE AIR FLOW METERS. 6. Spray the Carburetor Tune-up Cleaner for about five (5) seconds into the idle air by-pass valve inlet passage while the actuator is operating. CAUTION: AVOID DIRECT SPRAYING ON THROTTLE PLATE/BORE AREA. 7. Stop the engine and actuator. Let everything soak for fifteen (15) minutes. 8. Start the actuator and the start the engine. CAUTION: DO NOT START ENGINES THAT HAVE AIR FLOW METERS. 9. Spray Carburetor Tune-up Cleaner into the throttle bore for up to one (1) minute. CAUTION: DO NOT SPRAY FOR LONGER THAN SIX (6) CONTINUOUS SECONDS ON ENGINES THAT HAVE AIR FLOW METERS AND ARE NOT RUNNING. 10. Stop actuator and stop engine if running. 11. Reinstall the air duct. 12. Start and run the engine for about one (1) minute to dry out the solvent residue. 13. Operate the actuator to make sure the solvent is purged from the idle by-pass valve. 14. Disconnect the actuator from the idle air by-pass valve. 15. Reattach the control signal lead to the air by-pass valve. 16. Check engine for normal operation. NOTE: IT SHOULD NOT BE NECESSARY TO RESET THE IDLE SPEED SINCE ONLY THE IDLE AIR BY-PASS VALVE WAS SERVICED IN THIS PROCEDURE Warranty Coverage Throttle bodies and idle air by-pass valves on all EFI (Port Fuel Injection) engines through the 1992 model year that can be cleaned (as identified in the application charts) are covered under 5/50 Emissions Warranty Coverage. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Other Service Bulletins for Idle Speed: > Page 923 For those throttle bodies identified as having sludge tolerant designs or using service kit (F2PZ-9F939-A) where cleaning is not allowed per the application charts, the warranty claims for cleaning will not be reimbursed even within the 12/12 warranty coverage period. Cleaning is not allowed. Service kit installation (single time) is covered under 5/50 emission warranty. Labor Standards Operations The labor operations shown in the following Operation/Description/Time columns are identified by procedure number and vehicle line. Specific engines for various vehicles are identified in the sludge cleaning procedure application charts. The throttle body cleaning operations with combinations and the air by-pass valve cleaning combinations will appear in future Labor Manuals under the following operation numbers. ^ 9926 B - Throttle body and idle air by-pass valve cleaning ^ 9926 B2 - Adjust idle speed ^ 9715 A - Air by-pass valve cleaning only ^ 9715 A1 - Adjust idle speed PART NUMBER PART NAME CLASS F2PZ-9F939-A Idle Air By-pass Service Kit B D9AZ-19579-AA Carburstor Tune-Up Cleaner BG OTHER APPLICABLE ARTICLES: 89-13-8 SUPERSEDES: 88-24-5, 88-24-6, 89-16-5, 91-10-9, 91-7-4 Operation Description WARRANTY STATUS: Eligible Under Warranty Coverage As Stated In The Text Of This Article OPERATION DESCRIPTION TIME 912507A Idle Air By-Pass Valve 0.5 Hr. Cleaning - 1983-85 Escort, EXP, LN7, LYNX 1.6L EFI. 912507B Idle Air By-Pass Valve 0.5 Hr. Cleaning - 1986-91 Escort 1.9L EFI, 1986/87 EXP, Lynx 1.9L EFI, 1991 Tracer 1.9L EFI. 912507C Idle Air By Pass Valve 0.5 Hr. Cleaning - 1984-87 Mustang 2.3L T/C, 1986/87 Capri, Cougar 2.3L T/C, 1984-88 T-Bird 2.3L T/C, 1987/92 Mustang 2.3L EFI. 912507D Idle By-Pass Valve Cleaning 0.6 Hr. - 1988-91 Tempo, Topaz 2.3L HSC, 1985-92 Ranger 2.3L EFI. 912507E Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1986/87 Aerostar 2.3L EFI, 1985 Bronco II 2.3L EFI. 912507F Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1986-90 Bronco II 2.9L EFI, 1986-92 Ranger 2.9L EFI. 912507G Idle Air By-Pass Valve 0.6 Hr. Cleaning - 1991/92 Probe 3.0L EFI, 1986-91 Taurus 3.0L EFI, 1987-91 Sable 3.0L EFI. 912507H Idle Air By-Pass Valve 0.7 Hr. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Other Service Bulletins for Idle Speed: > Page 924 Cleaning - 1986-91 Aerostar 3.0L EFI, 1991 Ranger 3.0L EFI. 912507I Idle Air By-Pass Valve 0.6 Hr. Cleaning - 1988 Continental, Cougar, Taurus, T-Bird, Sable 3.8L EFI. 1988 Cougar, T-Bird 3.8L S/C. 912507J Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1990-92 Aerostar 4.0L EFI, 1990 Bronco II 4.0L EFI, 1991/92 Explorer 4.0L EFI, 1990-92 Ranger 4.0L EFI. 912507K Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1987-92 Bronco 4.9L EFI, 1987-92 F-Series 4.9L EFI, 1987/90 Econoline (Without Rear Heater) 4.9L EFI, 1991/92 Econoline (All) 4.9L EFI. 912507L Idle Air By-Pass Valve 0.6 Hr. Cleaning - 1986-88 Cougar, T-Bird 5.0L EFI, 1986-87 Continental, Mark VII 5.OL EFI, 1986/91 Crn - Victoria, Grn - Marquis 5.0L EFI, 1986-92 Mark VII 5.0L HO, 1982-92 Mustang 5.0L HO. 912507M Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1985-92 Bronco, E-Series, F-Series 5.0L EFI. 912507N Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1988-90 Bronco, F-Series 5.8L. 1991 Econo, F-Series, Bronco 5.8L (Do not Clean Solenoid, Calib; 1-64E-R10, 1-64H-R10, 1-64J-R10, 1-64K-R10, 1-64M-R10, 1-64P-R10, 1-64R-R10, 1-75A-R00, 1-76A-R00, 1-76B-R00, 1-76C-R00. 912507O Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1991/92 F And B Series, 7.0L EFI. 912507P Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1987-92 E-Series, F-Series 7.5L EFI. 912507Q Throttle Body And Idle Air 0.9 Hr. By-Pass Valve Cleaning - 1989/90 Probe 3.0L EFI. 912507R Throttle Body And Idle Air 0.8 Hr. By-Pass Valve Cleaning - 1987-90 Econoline (With Rear Heat) 4.9L EFI. 912507S Throttle Body And Idle Air 0.9 Hr. By-Pass Valve Cleaning - 1988-90 Econoline 5.8L EFI. 912507T Service Kit Install - All Cars 1.0 Hr. And Light Trucks (Except Aerostar And Econoline) - Refer To The Service Procedure Application Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Other Service Bulletins for Idle Speed: > Page 925 Charts, For Vehicle Application. 912507U Service Kit Install - 1.2 Hr. Aerostar, Econoline - Refer To Service Procedure Application Charts - For Vehicle Application. DEALER CODING BASIC PART NO. CONDITION CODE 9E926 49 OASIS CODES: 602300, 607000, 607400, 607700, 608400, 611500, 618400 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > Page 926 IDLE SPEED SPECIFICATIONS Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Adjustments > Curb Idle Speed Idle Speed: Adjustments Curb Idle Speed CURB IDLE SPEED ADJUSTMENT - Set parking brake, block wheels and place the transmission in Neutral (manual) or Park (automatic). - Bring engine to normal operating temperature (upper radiator hose hot). - Place A/C Heat selector to "OFF" (if equipped). - Disconnect and plug vacuum hoses at air bypass valve, EGR valve, and purge control valve. - Place the transmission in the specified gear. See: Specifications - Check curb idle rpm. Adjust to specification. See: Specifications - Place the transmission in Neutral (manual) or Park (automatic). Rev the engine momentarily. Place the transmission in specified position, and recheck curb idle rpm. Readjust if required. - If vehicle is equipped with A/C, perform the following additional steps: Connect an external vacuum source providing a minimum of 33.7 kPA (10 in-Hg) to the Vacuum Operated Throttle Modulator (VOTM) kicker. - Place the transmission selector in specified position. See: Specifications - Check/adjust VOTM kicker speed. If adjustment is required, loosen kicker locknut and turn kicker to required speed, tighten locknut. - Remove plugs and reconnect vacuum hoses. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Adjustments > Curb Idle Speed > Page 929 Idle Speed: Adjustments Fast Idle Speed FAST IDLE SPEED ADJUSTMENT - Set parking brake, block wheels and place the transmission in Park (automatic) or Neutral (manual). - Bring the engine to normal operating temperature. - Disconnect the vacuum hose at the EGR valve, air bypass valve, and purge control valve and plug. - Place the fast idle adjustment mechanism on specified step of fast idle cam. Check/adjust fast idle rpm to specification. See: Specifications - Recheck for repeatability. - Remove plugs from the EGR valve, air bypass valve, and purge control valve vacuum hoses and reconnect. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Element <--> [Air Filter Element] > Component Information > Technical Service Bulletins > Engine - Lack of Power/No Start Diagnosis Air Cleaner Element: Technical Service Bulletins Engine - Lack of Power/No Start Diagnosis Article No. 91-12-11 06/12/91 LACK OF POWER 7.5L, 5.8L, 5.0L, 4.9L - CATALYTIC CONVERTER DIAGNOSTIC TIPS LIGHT TRUCK: 1986-91 BRONCO, ECONOLINE, F-150-350 SERIES 1988-91 F SUPER DUTY, F47 ISSUE: Lack of power or a no start condition may be diagnosed as an exhaust restriction caused by a plugged catalytic converter. A plugged catalytic converter (internal deterioration) is usually caused by abnormal engine operation. ACTION: Diagnose the catalytic converter to confirm internal failure. Refer to the Catalyst and Exhaust System Diagnostic Section, in the Engine/Emissions Diagnostic Shop Manual and the following procedures for service details. 1. Lack of proper HEGO operation may cause, or be the result of a rich or lean fuel condition, which could cause additional heat in the catalyst. Perform self test KOEO and KOER, service any codes. NOTE: IF TWO DIGIT CODES 41, 42, 85 OR THREE DIGIT CODES 171, 172, 173, 179, 181, 182, 183 AND 565 ARE RECEIVED, CHECK FOR PROPER HEGO GROUND. If the HEGO ground is good, the following areas may be at fault: ^ Ignition Coil ^ Distributor Cap ^ Distributor Rotor ^ Fouled Spark Plug ^ Spark Plug Wires ^ Air Filter ^ Stuck Open Injector ^ Fuel Contamination Engine OIL ^ Manifold Leaks Intake/ Exhaust ^ Fuel Pressure ^ Poor Power Ground ^ Engine Not At Normal Operating Temperature ^ HEGO Sensor 2. Spark timing that is retarded from specification may increase exhaust gas temperature and shorten catalyst life. Refer to the following procedure for service details. a. Check spark timing. Check base timing with spout disconnected. Set base timing to the specification on the vehicle emission decal. b. Check computed timing with spout connected. NOTE: COMPUTED TIMING IS EQUAL TO BASE TIMING PLUS 20~ BTDC +/- 3~. 3. Misfiring spark plugs may cause an unburned fuel air mixture to pass through the catalyst, which could cause higher than normal catalyst temperatures. Refer to the following procedure for service details. a. Check secondary ignition, hook the vehicle up to an engine analyzer and check for a secondary ignition misfire. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Element <--> [Air Filter Element] > Component Information > Technical Service Bulletins > Engine - Lack of Power/No Start Diagnosis > Page 935 NOTE: SERVICE ANY ITEM THAT IS NOT PERFORMING AT PROPER SPECIFICATIONS BEFORE CONTINUING. 4. Fuel pressure that is too high may cause rich air fuel mixtures to pass through the catalyst which could cause higher than normal catalyst temperatures. Refer to the following procedure for service details. a. Check fuel pressure, install fuel pressure gauge, start and run the engine at idle. Fuel pressures between 28 and 34 PSI are typical (4.9L typically is 15 PSI higher). b. Disconnect the vacuum line going to the fuel pressure regulator. Fuel pressure typically jumps to 40 PSI +/- 3 PSI (4.9L typically is 15 PSI higher). Visually inspect vacuum line for raw fuel. NOTE: FUEL PRESSURES ABOVE THESE VALUES SHOULD BE CORRECTED. HOWEVER, THIS MAY NOT BE THE CAUSE OF THE CONCERN. SERVICE AS NECESSARY. 5. Throttle plates in the throttle body not returning to the proper closed position may cause excessive catalyst temperatures during downhill grades. Refer to the following procedure for service details. a. Visually inspect the throttle body and linkage for: ^ Binding or sticking throttle linkage. ^ Tight speed control linkage or cable. ^ Vacuum line interference. ^ Electrical harness interference. NOTE: AFTERMARKET GOVERNORS, THROTTLE LINKAGE AND CABLES ASSOCIATED WITH POWER TAKE-OFF UNITS, MAY ALSO INTERFERE WITH PROPER THROTTLE RETURN. SERVICE AS NECESSARY. 6. It is extremely important that all systems related to the engine and emission systems operate properly. a. Visually inspect the engine compartment to make sure all vacuum hoses and spark plug wires are properly routed and securely connected. b. Inspect all wiring harnesses and connectors for insulation damage, burned, overheated, loose or broken conditions. c. Verify proper operation of the thermactor system. Thermactor systems that fail to dump thermactor air to the atmosphere properly or at the correct time can cause high catalyst temperatures. d. Visually inspect thermactor system for damaged or kinked hoses and perform a function test on following components: air control valve, check valve, silencer, filter and the air bypass solenoid. e. Verify proper operation of the engine cooling system thermostat. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under Basic Warranty Coverage, Emissions Warranty Coverage OPERATION DESCRIPTION TIME 911211A Diagnostics - Perform 0.5 Hrs. KOEO And KOER Self Tests 911211B Timing - Check Or Adjust 0.5 Hrs. Spark Timing, Check Computed Timing And Check Secondary Ignition System With Engine Analyzer. 911211C Check - Fuel Pressure And 0.2 Hrs. Inspect Vacuum Line For Raw Fuel. 911211D Inspect - Throttle Body And 0.1 Hrs. Linkage. 911211E Inspect - Vacuum Hoses, 0.1 Hrs. Electrical Harnesses, Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Element <--> [Air Filter Element] > Component Information > Technical Service Bulletins > Engine - Lack of Power/No Start Diagnosis > Page 936 Connectors And Spark Plug Wires For Routing Damage. 911211F Thermactor System - 0.3 Hrs. Inspect For Proper Operation And Damaged Component. Includes Function Check Of Air Control Valve, Thermactor Air Bypass Solenoid, Check Valves, Silencer And Filter. 911211G Thermostat - Check For 0.2 Hrs. Proper Operation. DEALER CODING BASIC PART NO. CONDITION CODE 5E212 25 OASIS CODES: 403000, 603300, 614000 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Service and Repair Fuel Filter: Service and Repair REMOVAL - Remove the air cleaner. - Hold the fuel filter inlet hex nut with a backup wrench and unscrew the fuel line tube nut from the fuel filter inlet. WARNING: Use care to prevent combustion from fuel spillage. - Unscrew the fuel inlet fitting. - Remove the gasket, filter and spring. - Discard the gasket and filter. INSTALLATION - Install the spring, new filter and gasket. - Hand start the fuel inlet fitting into the carburetor then, tighten to 30-35 Nm (22-26 lb-ft). Apply oil, ESE-M2C39-E or equivalent to the fuel tube nut threads and tube flare. - Hand start the fuel line tube nut into the fuel inlet fitting (approximately two threads). - Use a backup wrench on the fuel inlet fitting while tightening the fuel line tube nut to 20-24 Nm (15-18 lb-ft). - Start the engine and check for fuel leak. - Install the air cleaner. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications Firing Order: Specifications Location On Distributor FIRING ORDER: 1-3-7-2-6-5-4-8 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Timing > Ignition Timing Connector > Component Information > Description and Operation Ignition Timing Connector: Description and Operation Fig. 20 Ignition Timing Vacuum Switch Below vacuum setting, this switch, Fig. 20, used on some vehicles, is open and signals the ignition module to retard spark timing. The switch is closed above the vacuum setting and the ignition module is in the non-retard spark timing mode. Calibration resistors inside the switch control the amount of retard. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Timing > Ignition Timing Connector > Component Information > Description and Operation > Page 947 Ignition Timing Connector: Testing and Inspection Ignition Timing Vacuum Switch Ignition Timing Vacuum Switch Test Chart 1. Disconnect switch from ignition module. 2. Connect suitable ohmmeter across switch terminals and compare resistance measured to ``less than'' values in the Ignition Timing vacuum Switch Test chart. 3. Apply vacuum to switch, using an outside vacuum source. Compare resistance now measured across switch terminals to ``greater than'' values in the Ignition Timing vacuum Switch Test chart. 4. Replace switch if resistance is not within specifications. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Timing > Number One Cylinder > Component Information > Locations Number One Cylinder: Locations Cylinder Numbering And Distributor Location Location On Distributor Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Timing > Timing Marks and Indicators > System Information > Diagrams Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Engine - Lack of Power/No Start Diagnosis Ignition Cable: Technical Service Bulletins Engine - Lack of Power/No Start Diagnosis Article No. 91-12-11 06/12/91 LACK OF POWER 7.5L, 5.8L, 5.0L, 4.9L - CATALYTIC CONVERTER DIAGNOSTIC TIPS LIGHT TRUCK: 1986-91 BRONCO, ECONOLINE, F-150-350 SERIES 1988-91 F SUPER DUTY, F47 ISSUE: Lack of power or a no start condition may be diagnosed as an exhaust restriction caused by a plugged catalytic converter. A plugged catalytic converter (internal deterioration) is usually caused by abnormal engine operation. ACTION: Diagnose the catalytic converter to confirm internal failure. Refer to the Catalyst and Exhaust System Diagnostic Section, in the Engine/Emissions Diagnostic Shop Manual and the following procedures for service details. 1. Lack of proper HEGO operation may cause, or be the result of a rich or lean fuel condition, which could cause additional heat in the catalyst. Perform self test KOEO and KOER, service any codes. NOTE: IF TWO DIGIT CODES 41, 42, 85 OR THREE DIGIT CODES 171, 172, 173, 179, 181, 182, 183 AND 565 ARE RECEIVED, CHECK FOR PROPER HEGO GROUND. If the HEGO ground is good, the following areas may be at fault: ^ Ignition Coil ^ Distributor Cap ^ Distributor Rotor ^ Fouled Spark Plug ^ Spark Plug Wires ^ Air Filter ^ Stuck Open Injector ^ Fuel Contamination Engine OIL ^ Manifold Leaks Intake/ Exhaust ^ Fuel Pressure ^ Poor Power Ground ^ Engine Not At Normal Operating Temperature ^ HEGO Sensor 2. Spark timing that is retarded from specification may increase exhaust gas temperature and shorten catalyst life. Refer to the following procedure for service details. a. Check spark timing. Check base timing with spout disconnected. Set base timing to the specification on the vehicle emission decal. b. Check computed timing with spout connected. NOTE: COMPUTED TIMING IS EQUAL TO BASE TIMING PLUS 20~ BTDC +/- 3~. 3. Misfiring spark plugs may cause an unburned fuel air mixture to pass through the catalyst, which could cause higher than normal catalyst temperatures. Refer to the following procedure for service details. a. Check secondary ignition, hook the vehicle up to an engine analyzer and check for a secondary ignition misfire. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Engine - Lack of Power/No Start Diagnosis > Page 958 NOTE: SERVICE ANY ITEM THAT IS NOT PERFORMING AT PROPER SPECIFICATIONS BEFORE CONTINUING. 4. Fuel pressure that is too high may cause rich air fuel mixtures to pass through the catalyst which could cause higher than normal catalyst temperatures. Refer to the following procedure for service details. a. Check fuel pressure, install fuel pressure gauge, start and run the engine at idle. Fuel pressures between 28 and 34 PSI are typical (4.9L typically is 15 PSI higher). b. Disconnect the vacuum line going to the fuel pressure regulator. Fuel pressure typically jumps to 40 PSI +/- 3 PSI (4.9L typically is 15 PSI higher). Visually inspect vacuum line for raw fuel. NOTE: FUEL PRESSURES ABOVE THESE VALUES SHOULD BE CORRECTED. HOWEVER, THIS MAY NOT BE THE CAUSE OF THE CONCERN. SERVICE AS NECESSARY. 5. Throttle plates in the throttle body not returning to the proper closed position may cause excessive catalyst temperatures during downhill grades. Refer to the following procedure for service details. a. Visually inspect the throttle body and linkage for: ^ Binding or sticking throttle linkage. ^ Tight speed control linkage or cable. ^ Vacuum line interference. ^ Electrical harness interference. NOTE: AFTERMARKET GOVERNORS, THROTTLE LINKAGE AND CABLES ASSOCIATED WITH POWER TAKE-OFF UNITS, MAY ALSO INTERFERE WITH PROPER THROTTLE RETURN. SERVICE AS NECESSARY. 6. It is extremely important that all systems related to the engine and emission systems operate properly. a. Visually inspect the engine compartment to make sure all vacuum hoses and spark plug wires are properly routed and securely connected. b. Inspect all wiring harnesses and connectors for insulation damage, burned, overheated, loose or broken conditions. c. Verify proper operation of the thermactor system. Thermactor systems that fail to dump thermactor air to the atmosphere properly or at the correct time can cause high catalyst temperatures. d. Visually inspect thermactor system for damaged or kinked hoses and perform a function test on following components: air control valve, check valve, silencer, filter and the air bypass solenoid. e. Verify proper operation of the engine cooling system thermostat. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under Basic Warranty Coverage, Emissions Warranty Coverage OPERATION DESCRIPTION TIME 911211A Diagnostics - Perform 0.5 Hrs. KOEO And KOER Self Tests 911211B Timing - Check Or Adjust 0.5 Hrs. Spark Timing, Check Computed Timing And Check Secondary Ignition System With Engine Analyzer. 911211C Check - Fuel Pressure And 0.2 Hrs. Inspect Vacuum Line For Raw Fuel. 911211D Inspect - Throttle Body And 0.1 Hrs. Linkage. 911211E Inspect - Vacuum Hoses, 0.1 Hrs. Electrical Harnesses, Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Engine - Lack of Power/No Start Diagnosis > Page 959 Connectors And Spark Plug Wires For Routing Damage. 911211F Thermactor System - 0.3 Hrs. Inspect For Proper Operation And Damaged Component. Includes Function Check Of Air Control Valve, Thermactor Air Bypass Solenoid, Check Valves, Silencer And Filter. 911211G Thermostat - Check For 0.2 Hrs. Proper Operation. DEALER CODING BASIC PART NO. CONDITION CODE 5E212 25 OASIS CODES: 403000, 603300, 614000 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Engine - Lack of Power/No Start Diagnosis > Page 960 Ignition Cable: Technical Service Bulletins Ignition System - Diagnostics Manual Correction Article No. 89-5A-4 EEC IV - TFI IV - IGNITION SYSTEM - REVISED TIMING PROCEDURES AND DIAGNOSTICS SHOP MANUAL CORRECTION FORD: 1984-86 LTD 1984-88 EXP 1984-88 ESCORT THUNDERBIRD, MUSTANG, TEMPO, AND CROWN VICTORIA LINCOLN-MERCURY: 1984-86 CAPRI, MARQUIS 1984-87 LYNX 1984-88 COUGAR, TOPAZ, GRAND MARQUIS, CONTINENTAL, MARK VII, AND LINCOLN TOWN CAR LIGHT TRUCK: 1984-88 RANGER, BRONCO II, ECONOLINE, BRONCO, AND F-SERIES 1986-88 AEROSTAR ISSUE: The Ignition Coil and Secondary Wire Test Steps on pages 13-51 and 13-65 of the 1989 Engine Emissions Diagnosis Shop Manual, Volume H, have been revised. The new service information directs technicians to use a substitute coil instead of a resistance test. ACTION: Refer to this TSB for revised ignition coil and secondary wire test information. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" OASIS CODES: 680000 1989 Ignition Systems, Timing Procedures and Diagnostics 13-51 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Engine - Lack of Power/No Start Diagnosis > Page 961 Ignition Coil and Secondary Wire TFI-IV And TFI With CCD Part 2 Test 7 1989 13-52 Ignition Systems, Timing Procedures and Diagnostics Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Engine - Lack of Power/No Start Diagnosis > Page 962 EEC-IV - TFI-IV TFI-IV And TFI-IV With CCD Part 2 Test 8 1989 Ignition Systems, Timing Procedures and Diagnostics 13-65 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Engine - Lack of Power/No Start Diagnosis > Page 963 Ignition Coil And Secondary Wire TFI-IV Closed Bowl Distributor Part 2 Test 8 1989 13-66 Ignition Systems, Timing Procedures and Diagnostics Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Engine - Lack of Power/No Start Diagnosis > Page 964 EEC-IV - Wiring TFI-IV Closed Bowl Distributor Part 2 Test 9 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Page 965 Ignition Cable: Testing and Inspection Spark Plug Wire Resistance *** UPDATED BY TSB #85-9-33 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Distributor, Ignition > Distributor Advance Unit > Component Information > Specifications DISTRIBUTOR TIMING ADVANCE Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Distributor, Ignition > Distributor Advance Unit > Component Information > Description and Operation > Vacuum Spark Advance Mechanism Distributor Advance Unit: Description and Operation Vacuum Spark Advance Mechanism The vacuum spark control mechanism can provide spark advance if a single diaphragm assembly is used or spark advance and retard if a dual diaphragm assembly is used. The diaphragm assembly used depends on the engine calibration. Single Diaphragm Assembly SINGLE DIAPHRAGM ASSEMBLY The single diaphragm assembly, Fig. 11, also changes the armature to stator relationship to give spark advance. The stator assembly position is changed by means of vacuum being applied to the diaphragm assembly. Vacuum applied to the diaphragm assembly causes the diaphragm and attached diaphragm rod to move, compressing the advance spring, which controls the rate of advance. The movement of the diaphragm rod, which is attached to the stator assembly, makes the the stator assembly move with respect to the armature. This changes the initial armature to stator relationship set during initial timing, causing spark advance. The stator assembly is mounted on the lower plate assembly which with the diaphragm assembly, is attached to the distributor base. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Distributor, Ignition > Distributor Advance Unit > Component Information > Description and Operation > Vacuum Spark Advance Mechanism > Page 972 Dual Diaphragm Assembly DUAL DIAPHRAGM ASSEMBLY The dual diaphragm assembly, Fig. 12, obtains spark advance in the same manner as the single diaphragm assembly. In this case vacuum applied to the vacuum advance port causes the advance diaphragm and attached rod to move, otherwise the action is the same. Spark retard is done by applying vacuum to the vacuum retard port. This causes the retard diaphragm to move, compressing the retard spring, which controls the rate of spark retard. Compressing the retard spring allows the diaphragm rod stop to move due to the force applied by the advance spring pushing against it by means of the diaphragm rod. The result is the diaphragm rod moves causing the attached stator assembly to change position with respect to the armature. In this instance the direction of the stator assembly movement is opposite that occurring during vacuum advance, resulting in spark retard. NOTE: Any vacuum applied to the advance port overrides any spark retard caused by vacuum being applied to the retard port. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Distributor, Ignition > Distributor Advance Unit > Component Information > Description and Operation > Vacuum Spark Advance Mechanism > Page 973 Distributor Advance Unit: Description and Operation Centrifugal Spark Advance Mechanism Distributor - Exploded view The centrifugal advance mechanism varies the relationship of the armature to the stator assembly. The armature is mounted to the sleeve and plate assembly which rotates in relation to the distributor shaft. The rotation is a result of the centrifugal weights moving in response to engine RPM. The movement of the weights change the initial relationship of the armature to the stator assembly by rotating the sleeve and plate assembly ahead of its static position on the distributor shaft Fig. 1. This produces spark advance. The rate of movement of the weights is controlled by calibrated springs. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Distributor, Ignition > Distributor Advance Unit > Component Information > Description and Operation > Page 974 Distributor Advance Unit: Service and Repair 1. Remove distributor cap and rotor. 2. Disconnect vacuum lines, then remove snap ring that secures vacuum advance link to pickup assembly. 3. Remove vacuum advance attaching screws, then tilt unit downward to disconnect link. 4. Carefully remove unit from distributor. 5. Reverse procedure to install. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Distributor, Ignition > Distributor Cap > Component Information > Technical Service Bulletins > Engine - Lack of Power/No Start Diagnosis Distributor Cap: Technical Service Bulletins Engine - Lack of Power/No Start Diagnosis Article No. 91-12-11 06/12/91 LACK OF POWER 7.5L, 5.8L, 5.0L, 4.9L - CATALYTIC CONVERTER DIAGNOSTIC TIPS LIGHT TRUCK: 1986-91 BRONCO, ECONOLINE, F-150-350 SERIES 1988-91 F SUPER DUTY, F47 ISSUE: Lack of power or a no start condition may be diagnosed as an exhaust restriction caused by a plugged catalytic converter. A plugged catalytic converter (internal deterioration) is usually caused by abnormal engine operation. ACTION: Diagnose the catalytic converter to confirm internal failure. Refer to the Catalyst and Exhaust System Diagnostic Section, in the Engine/Emissions Diagnostic Shop Manual and the following procedures for service details. 1. Lack of proper HEGO operation may cause, or be the result of a rich or lean fuel condition, which could cause additional heat in the catalyst. Perform self test KOEO and KOER, service any codes. NOTE: IF TWO DIGIT CODES 41, 42, 85 OR THREE DIGIT CODES 171, 172, 173, 179, 181, 182, 183 AND 565 ARE RECEIVED, CHECK FOR PROPER HEGO GROUND. If the HEGO ground is good, the following areas may be at fault: ^ Ignition Coil ^ Distributor Cap ^ Distributor Rotor ^ Fouled Spark Plug ^ Spark Plug Wires ^ Air Filter ^ Stuck Open Injector ^ Fuel Contamination Engine OIL ^ Manifold Leaks Intake/ Exhaust ^ Fuel Pressure ^ Poor Power Ground ^ Engine Not At Normal Operating Temperature ^ HEGO Sensor 2. Spark timing that is retarded from specification may increase exhaust gas temperature and shorten catalyst life. Refer to the following procedure for service details. a. Check spark timing. Check base timing with spout disconnected. Set base timing to the specification on the vehicle emission decal. b. Check computed timing with spout connected. NOTE: COMPUTED TIMING IS EQUAL TO BASE TIMING PLUS 20~ BTDC +/- 3~. 3. Misfiring spark plugs may cause an unburned fuel air mixture to pass through the catalyst, which could cause higher than normal catalyst temperatures. Refer to the following procedure for service details. a. Check secondary ignition, hook the vehicle up to an engine analyzer and check for a secondary ignition misfire. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Distributor, Ignition > Distributor Cap > Component Information > Technical Service Bulletins > Engine - Lack of Power/No Start Diagnosis > Page 979 NOTE: SERVICE ANY ITEM THAT IS NOT PERFORMING AT PROPER SPECIFICATIONS BEFORE CONTINUING. 4. Fuel pressure that is too high may cause rich air fuel mixtures to pass through the catalyst which could cause higher than normal catalyst temperatures. Refer to the following procedure for service details. a. Check fuel pressure, install fuel pressure gauge, start and run the engine at idle. Fuel pressures between 28 and 34 PSI are typical (4.9L typically is 15 PSI higher). b. Disconnect the vacuum line going to the fuel pressure regulator. Fuel pressure typically jumps to 40 PSI +/- 3 PSI (4.9L typically is 15 PSI higher). Visually inspect vacuum line for raw fuel. NOTE: FUEL PRESSURES ABOVE THESE VALUES SHOULD BE CORRECTED. HOWEVER, THIS MAY NOT BE THE CAUSE OF THE CONCERN. SERVICE AS NECESSARY. 5. Throttle plates in the throttle body not returning to the proper closed position may cause excessive catalyst temperatures during downhill grades. Refer to the following procedure for service details. a. Visually inspect the throttle body and linkage for: ^ Binding or sticking throttle linkage. ^ Tight speed control linkage or cable. ^ Vacuum line interference. ^ Electrical harness interference. NOTE: AFTERMARKET GOVERNORS, THROTTLE LINKAGE AND CABLES ASSOCIATED WITH POWER TAKE-OFF UNITS, MAY ALSO INTERFERE WITH PROPER THROTTLE RETURN. SERVICE AS NECESSARY. 6. It is extremely important that all systems related to the engine and emission systems operate properly. a. Visually inspect the engine compartment to make sure all vacuum hoses and spark plug wires are properly routed and securely connected. b. Inspect all wiring harnesses and connectors for insulation damage, burned, overheated, loose or broken conditions. c. Verify proper operation of the thermactor system. Thermactor systems that fail to dump thermactor air to the atmosphere properly or at the correct time can cause high catalyst temperatures. d. Visually inspect thermactor system for damaged or kinked hoses and perform a function test on following components: air control valve, check valve, silencer, filter and the air bypass solenoid. e. Verify proper operation of the engine cooling system thermostat. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under Basic Warranty Coverage, Emissions Warranty Coverage OPERATION DESCRIPTION TIME 911211A Diagnostics - Perform 0.5 Hrs. KOEO And KOER Self Tests 911211B Timing - Check Or Adjust 0.5 Hrs. Spark Timing, Check Computed Timing And Check Secondary Ignition System With Engine Analyzer. 911211C Check - Fuel Pressure And 0.2 Hrs. Inspect Vacuum Line For Raw Fuel. 911211D Inspect - Throttle Body And 0.1 Hrs. Linkage. 911211E Inspect - Vacuum Hoses, 0.1 Hrs. Electrical Harnesses, Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Distributor, Ignition > Distributor Cap > Component Information > Technical Service Bulletins > Engine - Lack of Power/No Start Diagnosis > Page 980 Connectors And Spark Plug Wires For Routing Damage. 911211F Thermactor System - 0.3 Hrs. Inspect For Proper Operation And Damaged Component. Includes Function Check Of Air Control Valve, Thermactor Air Bypass Solenoid, Check Valves, Silencer And Filter. 911211G Thermostat - Check For 0.2 Hrs. Proper Operation. DEALER CODING BASIC PART NO. CONDITION CODE 5E212 25 OASIS CODES: 403000, 603300, 614000 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Distributor, Ignition > Ignition Rotor > Component Information > Technical Service Bulletins > Customer Interest: > 85218 > Oct > 85 > Distributor Rotor Engine Bucking/Surging Ignition Rotor: Customer Interest Distributor Rotor - Engine Bucking/Surging Article No. 85-21-8 ENGINE MISS - DISTRIBUTOR WITH BLADE ROTOR - SILICONE GREASE ENGINE SURGE - DISTRIBUTOR WITH BLADE ROTOR - SILICONE GREASE RADIO NOISE - DISTRIBUTOR WITH BLADE ROTOR - SILICONE GREASE FORD 1986 ESCORT, EXP, TEMPO, MUSTANG, THUNDERBIRD, TAURUS, LTD, CROWN VICTORIA LINCOLN-MERCURY 1986 LYNX, TOPAZ, CAPRI, COUGAR, SABLE, MARQUIS, CONTINENTAL, MARK VII, LINCOLN LIGHT TRUCK 1986 E/F SERIES, BRONCO, RANGER, BRONCO II, AEROSTAR CALIBRATION: All with EEC IV 1986 vehicles are equipped with a new "blade" design distributor rotor. This design replaces the multi-point rotor used in recent model years. This new rotor requires the use of silicone grease on the blade. Electrical interference can result from a blade rotor that does not have silicone grease. The electrical interference affects the distributor stator assembly and can cause engine "missing", "bucking", or "surging". These drive concerns are usually intermittent and tend to occur during crank and heavy or wide-open throttle. It is important to remember not to remove the silicone grease for radio noise concerns, on 1986 vehicles with EEC IV; removing the grease can cause driveability concerns. A future TSB article will address the radio noise issue. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Distributor, Ignition > Ignition Rotor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Rotor: > 911211 > Jun > 91 > Engine - Lack of Power/No Start Diagnosis Ignition Rotor: All Technical Service Bulletins Engine - Lack of Power/No Start Diagnosis Article No. 91-12-11 06/12/91 LACK OF POWER 7.5L, 5.8L, 5.0L, 4.9L - CATALYTIC CONVERTER DIAGNOSTIC TIPS LIGHT TRUCK: 1986-91 BRONCO, ECONOLINE, F-150-350 SERIES 1988-91 F SUPER DUTY, F47 ISSUE: Lack of power or a no start condition may be diagnosed as an exhaust restriction caused by a plugged catalytic converter. A plugged catalytic converter (internal deterioration) is usually caused by abnormal engine operation. ACTION: Diagnose the catalytic converter to confirm internal failure. Refer to the Catalyst and Exhaust System Diagnostic Section, in the Engine/Emissions Diagnostic Shop Manual and the following procedures for service details. 1. Lack of proper HEGO operation may cause, or be the result of a rich or lean fuel condition, which could cause additional heat in the catalyst. Perform self test KOEO and KOER, service any codes. NOTE: IF TWO DIGIT CODES 41, 42, 85 OR THREE DIGIT CODES 171, 172, 173, 179, 181, 182, 183 AND 565 ARE RECEIVED, CHECK FOR PROPER HEGO GROUND. If the HEGO ground is good, the following areas may be at fault: ^ Ignition Coil ^ Distributor Cap ^ Distributor Rotor ^ Fouled Spark Plug ^ Spark Plug Wires ^ Air Filter ^ Stuck Open Injector ^ Fuel Contamination Engine OIL ^ Manifold Leaks Intake/ Exhaust ^ Fuel Pressure ^ Poor Power Ground ^ Engine Not At Normal Operating Temperature ^ HEGO Sensor 2. Spark timing that is retarded from specification may increase exhaust gas temperature and shorten catalyst life. Refer to the following procedure for service details. a. Check spark timing. Check base timing with spout disconnected. Set base timing to the specification on the vehicle emission decal. b. Check computed timing with spout connected. NOTE: COMPUTED TIMING IS EQUAL TO BASE TIMING PLUS 20~ BTDC +/- 3~. 3. Misfiring spark plugs may cause an unburned fuel air mixture to pass through the catalyst, which could cause higher than normal catalyst temperatures. Refer to the following procedure for service details. a. Check secondary ignition, hook the vehicle up to an engine analyzer and check for a secondary ignition misfire. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Distributor, Ignition > Ignition Rotor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Rotor: > 911211 > Jun > 91 > Engine - Lack of Power/No Start Diagnosis > Page 994 NOTE: SERVICE ANY ITEM THAT IS NOT PERFORMING AT PROPER SPECIFICATIONS BEFORE CONTINUING. 4. Fuel pressure that is too high may cause rich air fuel mixtures to pass through the catalyst which could cause higher than normal catalyst temperatures. Refer to the following procedure for service details. a. Check fuel pressure, install fuel pressure gauge, start and run the engine at idle. Fuel pressures between 28 and 34 PSI are typical (4.9L typically is 15 PSI higher). b. Disconnect the vacuum line going to the fuel pressure regulator. Fuel pressure typically jumps to 40 PSI +/- 3 PSI (4.9L typically is 15 PSI higher). Visually inspect vacuum line for raw fuel. NOTE: FUEL PRESSURES ABOVE THESE VALUES SHOULD BE CORRECTED. HOWEVER, THIS MAY NOT BE THE CAUSE OF THE CONCERN. SERVICE AS NECESSARY. 5. Throttle plates in the throttle body not returning to the proper closed position may cause excessive catalyst temperatures during downhill grades. Refer to the following procedure for service details. a. Visually inspect the throttle body and linkage for: ^ Binding or sticking throttle linkage. ^ Tight speed control linkage or cable. ^ Vacuum line interference. ^ Electrical harness interference. NOTE: AFTERMARKET GOVERNORS, THROTTLE LINKAGE AND CABLES ASSOCIATED WITH POWER TAKE-OFF UNITS, MAY ALSO INTERFERE WITH PROPER THROTTLE RETURN. SERVICE AS NECESSARY. 6. It is extremely important that all systems related to the engine and emission systems operate properly. a. Visually inspect the engine compartment to make sure all vacuum hoses and spark plug wires are properly routed and securely connected. b. Inspect all wiring harnesses and connectors for insulation damage, burned, overheated, loose or broken conditions. c. Verify proper operation of the thermactor system. Thermactor systems that fail to dump thermactor air to the atmosphere properly or at the correct time can cause high catalyst temperatures. d. Visually inspect thermactor system for damaged or kinked hoses and perform a function test on following components: air control valve, check valve, silencer, filter and the air bypass solenoid. e. Verify proper operation of the engine cooling system thermostat. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under Basic Warranty Coverage, Emissions Warranty Coverage OPERATION DESCRIPTION TIME 911211A Diagnostics - Perform 0.5 Hrs. KOEO And KOER Self Tests 911211B Timing - Check Or Adjust 0.5 Hrs. Spark Timing, Check Computed Timing And Check Secondary Ignition System With Engine Analyzer. 911211C Check - Fuel Pressure And 0.2 Hrs. Inspect Vacuum Line For Raw Fuel. 911211D Inspect - Throttle Body And 0.1 Hrs. Linkage. 911211E Inspect - Vacuum Hoses, 0.1 Hrs. Electrical Harnesses, Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Distributor, Ignition > Ignition Rotor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Rotor: > 911211 > Jun > 91 > Engine - Lack of Power/No Start Diagnosis > Page 995 Connectors And Spark Plug Wires For Routing Damage. 911211F Thermactor System - 0.3 Hrs. Inspect For Proper Operation And Damaged Component. Includes Function Check Of Air Control Valve, Thermactor Air Bypass Solenoid, Check Valves, Silencer And Filter. 911211G Thermostat - Check For 0.2 Hrs. Proper Operation. DEALER CODING BASIC PART NO. CONDITION CODE 5E212 25 OASIS CODES: 403000, 603300, 614000 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Distributor, Ignition > Ignition Rotor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Rotor: > 85218 > Oct > 85 > Distributor Rotor - Engine Bucking/Surging Ignition Rotor: All Technical Service Bulletins Distributor Rotor - Engine Bucking/Surging Article No. 85-21-8 ENGINE MISS - DISTRIBUTOR WITH BLADE ROTOR - SILICONE GREASE ENGINE SURGE - DISTRIBUTOR WITH BLADE ROTOR - SILICONE GREASE RADIO NOISE - DISTRIBUTOR WITH BLADE ROTOR - SILICONE GREASE FORD 1986 ESCORT, EXP, TEMPO, MUSTANG, THUNDERBIRD, TAURUS, LTD, CROWN VICTORIA LINCOLN-MERCURY 1986 LYNX, TOPAZ, CAPRI, COUGAR, SABLE, MARQUIS, CONTINENTAL, MARK VII, LINCOLN LIGHT TRUCK 1986 E/F SERIES, BRONCO, RANGER, BRONCO II, AEROSTAR CALIBRATION: All with EEC IV 1986 vehicles are equipped with a new "blade" design distributor rotor. This design replaces the multi-point rotor used in recent model years. This new rotor requires the use of silicone grease on the blade. Electrical interference can result from a blade rotor that does not have silicone grease. The electrical interference affects the distributor stator assembly and can cause engine "missing", "bucking", or "surging". These drive concerns are usually intermittent and tend to occur during crank and heavy or wide-open throttle. It is important to remember not to remove the silicone grease for radio noise concerns, on 1986 vehicles with EEC IV; removing the grease can cause driveability concerns. A future TSB article will address the radio noise issue. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Distributor, Ignition > Ignition Rotor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Rotor: > 911211 > Jun > 91 > Engine - Lack of Power/No Start Diagnosis Ignition Rotor: All Technical Service Bulletins Engine - Lack of Power/No Start Diagnosis Article No. 91-12-11 06/12/91 LACK OF POWER 7.5L, 5.8L, 5.0L, 4.9L - CATALYTIC CONVERTER DIAGNOSTIC TIPS LIGHT TRUCK: 1986-91 BRONCO, ECONOLINE, F-150-350 SERIES 1988-91 F SUPER DUTY, F47 ISSUE: Lack of power or a no start condition may be diagnosed as an exhaust restriction caused by a plugged catalytic converter. A plugged catalytic converter (internal deterioration) is usually caused by abnormal engine operation. ACTION: Diagnose the catalytic converter to confirm internal failure. Refer to the Catalyst and Exhaust System Diagnostic Section, in the Engine/Emissions Diagnostic Shop Manual and the following procedures for service details. 1. Lack of proper HEGO operation may cause, or be the result of a rich or lean fuel condition, which could cause additional heat in the catalyst. Perform self test KOEO and KOER, service any codes. NOTE: IF TWO DIGIT CODES 41, 42, 85 OR THREE DIGIT CODES 171, 172, 173, 179, 181, 182, 183 AND 565 ARE RECEIVED, CHECK FOR PROPER HEGO GROUND. If the HEGO ground is good, the following areas may be at fault: ^ Ignition Coil ^ Distributor Cap ^ Distributor Rotor ^ Fouled Spark Plug ^ Spark Plug Wires ^ Air Filter ^ Stuck Open Injector ^ Fuel Contamination Engine OIL ^ Manifold Leaks Intake/ Exhaust ^ Fuel Pressure ^ Poor Power Ground ^ Engine Not At Normal Operating Temperature ^ HEGO Sensor 2. Spark timing that is retarded from specification may increase exhaust gas temperature and shorten catalyst life. Refer to the following procedure for service details. a. Check spark timing. Check base timing with spout disconnected. Set base timing to the specification on the vehicle emission decal. b. Check computed timing with spout connected. NOTE: COMPUTED TIMING IS EQUAL TO BASE TIMING PLUS 20~ BTDC +/- 3~. 3. Misfiring spark plugs may cause an unburned fuel air mixture to pass through the catalyst, which could cause higher than normal catalyst temperatures. Refer to the following procedure for service details. a. Check secondary ignition, hook the vehicle up to an engine analyzer and check for a secondary ignition misfire. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Distributor, Ignition > Ignition Rotor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Rotor: > 911211 > Jun > 91 > Engine - Lack of Power/No Start Diagnosis > Page 1005 NOTE: SERVICE ANY ITEM THAT IS NOT PERFORMING AT PROPER SPECIFICATIONS BEFORE CONTINUING. 4. Fuel pressure that is too high may cause rich air fuel mixtures to pass through the catalyst which could cause higher than normal catalyst temperatures. Refer to the following procedure for service details. a. Check fuel pressure, install fuel pressure gauge, start and run the engine at idle. Fuel pressures between 28 and 34 PSI are typical (4.9L typically is 15 PSI higher). b. Disconnect the vacuum line going to the fuel pressure regulator. Fuel pressure typically jumps to 40 PSI +/- 3 PSI (4.9L typically is 15 PSI higher). Visually inspect vacuum line for raw fuel. NOTE: FUEL PRESSURES ABOVE THESE VALUES SHOULD BE CORRECTED. HOWEVER, THIS MAY NOT BE THE CAUSE OF THE CONCERN. SERVICE AS NECESSARY. 5. Throttle plates in the throttle body not returning to the proper closed position may cause excessive catalyst temperatures during downhill grades. Refer to the following procedure for service details. a. Visually inspect the throttle body and linkage for: ^ Binding or sticking throttle linkage. ^ Tight speed control linkage or cable. ^ Vacuum line interference. ^ Electrical harness interference. NOTE: AFTERMARKET GOVERNORS, THROTTLE LINKAGE AND CABLES ASSOCIATED WITH POWER TAKE-OFF UNITS, MAY ALSO INTERFERE WITH PROPER THROTTLE RETURN. SERVICE AS NECESSARY. 6. It is extremely important that all systems related to the engine and emission systems operate properly. a. Visually inspect the engine compartment to make sure all vacuum hoses and spark plug wires are properly routed and securely connected. b. Inspect all wiring harnesses and connectors for insulation damage, burned, overheated, loose or broken conditions. c. Verify proper operation of the thermactor system. Thermactor systems that fail to dump thermactor air to the atmosphere properly or at the correct time can cause high catalyst temperatures. d. Visually inspect thermactor system for damaged or kinked hoses and perform a function test on following components: air control valve, check valve, silencer, filter and the air bypass solenoid. e. Verify proper operation of the engine cooling system thermostat. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under Basic Warranty Coverage, Emissions Warranty Coverage OPERATION DESCRIPTION TIME 911211A Diagnostics - Perform 0.5 Hrs. KOEO And KOER Self Tests 911211B Timing - Check Or Adjust 0.5 Hrs. Spark Timing, Check Computed Timing And Check Secondary Ignition System With Engine Analyzer. 911211C Check - Fuel Pressure And 0.2 Hrs. Inspect Vacuum Line For Raw Fuel. 911211D Inspect - Throttle Body And 0.1 Hrs. Linkage. 911211E Inspect - Vacuum Hoses, 0.1 Hrs. Electrical Harnesses, Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Distributor, Ignition > Ignition Rotor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Rotor: > 911211 > Jun > 91 > Engine - Lack of Power/No Start Diagnosis > Page 1006 Connectors And Spark Plug Wires For Routing Damage. 911211F Thermactor System - 0.3 Hrs. Inspect For Proper Operation And Damaged Component. Includes Function Check Of Air Control Valve, Thermactor Air Bypass Solenoid, Check Valves, Silencer And Filter. 911211G Thermostat - Check For 0.2 Hrs. Proper Operation. DEALER CODING BASIC PART NO. CONDITION CODE 5E212 25 OASIS CODES: 403000, 603300, 614000 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Distributor, Ignition > Distributor Plate W/ Pick-up Sensor > Component Information > Service and Repair Distributor Plate W/ Pick-up Sensor: Service and Repair 1. Remove distributor cap and rotor. 2. Remove vacuum advance unit and magnetic pickup assembly. 3. Remove attaching screws and lift base plate from distributor. 4. Reverse procedure to install. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Engine - Lack of Power/No Start Diagnosis Spark Plug: Technical Service Bulletins Engine - Lack of Power/No Start Diagnosis Article No. 91-12-11 06/12/91 LACK OF POWER 7.5L, 5.8L, 5.0L, 4.9L - CATALYTIC CONVERTER DIAGNOSTIC TIPS LIGHT TRUCK: 1986-91 BRONCO, ECONOLINE, F-150-350 SERIES 1988-91 F SUPER DUTY, F47 ISSUE: Lack of power or a no start condition may be diagnosed as an exhaust restriction caused by a plugged catalytic converter. A plugged catalytic converter (internal deterioration) is usually caused by abnormal engine operation. ACTION: Diagnose the catalytic converter to confirm internal failure. Refer to the Catalyst and Exhaust System Diagnostic Section, in the Engine/Emissions Diagnostic Shop Manual and the following procedures for service details. 1. Lack of proper HEGO operation may cause, or be the result of a rich or lean fuel condition, which could cause additional heat in the catalyst. Perform self test KOEO and KOER, service any codes. NOTE: IF TWO DIGIT CODES 41, 42, 85 OR THREE DIGIT CODES 171, 172, 173, 179, 181, 182, 183 AND 565 ARE RECEIVED, CHECK FOR PROPER HEGO GROUND. If the HEGO ground is good, the following areas may be at fault: ^ Ignition Coil ^ Distributor Cap ^ Distributor Rotor ^ Fouled Spark Plug ^ Spark Plug Wires ^ Air Filter ^ Stuck Open Injector ^ Fuel Contamination Engine OIL ^ Manifold Leaks Intake/ Exhaust ^ Fuel Pressure ^ Poor Power Ground ^ Engine Not At Normal Operating Temperature ^ HEGO Sensor 2. Spark timing that is retarded from specification may increase exhaust gas temperature and shorten catalyst life. Refer to the following procedure for service details. a. Check spark timing. Check base timing with spout disconnected. Set base timing to the specification on the vehicle emission decal. b. Check computed timing with spout connected. NOTE: COMPUTED TIMING IS EQUAL TO BASE TIMING PLUS 20~ BTDC +/- 3~. 3. Misfiring spark plugs may cause an unburned fuel air mixture to pass through the catalyst, which could cause higher than normal catalyst temperatures. Refer to the following procedure for service details. a. Check secondary ignition, hook the vehicle up to an engine analyzer and check for a secondary ignition misfire. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Engine - Lack of Power/No Start Diagnosis > Page 1014 NOTE: SERVICE ANY ITEM THAT IS NOT PERFORMING AT PROPER SPECIFICATIONS BEFORE CONTINUING. 4. Fuel pressure that is too high may cause rich air fuel mixtures to pass through the catalyst which could cause higher than normal catalyst temperatures. Refer to the following procedure for service details. a. Check fuel pressure, install fuel pressure gauge, start and run the engine at idle. Fuel pressures between 28 and 34 PSI are typical (4.9L typically is 15 PSI higher). b. Disconnect the vacuum line going to the fuel pressure regulator. Fuel pressure typically jumps to 40 PSI +/- 3 PSI (4.9L typically is 15 PSI higher). Visually inspect vacuum line for raw fuel. NOTE: FUEL PRESSURES ABOVE THESE VALUES SHOULD BE CORRECTED. HOWEVER, THIS MAY NOT BE THE CAUSE OF THE CONCERN. SERVICE AS NECESSARY. 5. Throttle plates in the throttle body not returning to the proper closed position may cause excessive catalyst temperatures during downhill grades. Refer to the following procedure for service details. a. Visually inspect the throttle body and linkage for: ^ Binding or sticking throttle linkage. ^ Tight speed control linkage or cable. ^ Vacuum line interference. ^ Electrical harness interference. NOTE: AFTERMARKET GOVERNORS, THROTTLE LINKAGE AND CABLES ASSOCIATED WITH POWER TAKE-OFF UNITS, MAY ALSO INTERFERE WITH PROPER THROTTLE RETURN. SERVICE AS NECESSARY. 6. It is extremely important that all systems related to the engine and emission systems operate properly. a. Visually inspect the engine compartment to make sure all vacuum hoses and spark plug wires are properly routed and securely connected. b. Inspect all wiring harnesses and connectors for insulation damage, burned, overheated, loose or broken conditions. c. Verify proper operation of the thermactor system. Thermactor systems that fail to dump thermactor air to the atmosphere properly or at the correct time can cause high catalyst temperatures. d. Visually inspect thermactor system for damaged or kinked hoses and perform a function test on following components: air control valve, check valve, silencer, filter and the air bypass solenoid. e. Verify proper operation of the engine cooling system thermostat. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under Basic Warranty Coverage, Emissions Warranty Coverage OPERATION DESCRIPTION TIME 911211A Diagnostics - Perform 0.5 Hrs. KOEO And KOER Self Tests 911211B Timing - Check Or Adjust 0.5 Hrs. Spark Timing, Check Computed Timing And Check Secondary Ignition System With Engine Analyzer. 911211C Check - Fuel Pressure And 0.2 Hrs. Inspect Vacuum Line For Raw Fuel. 911211D Inspect - Throttle Body And 0.1 Hrs. Linkage. 911211E Inspect - Vacuum Hoses, 0.1 Hrs. Electrical Harnesses, Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Engine - Lack of Power/No Start Diagnosis > Page 1015 Connectors And Spark Plug Wires For Routing Damage. 911211F Thermactor System - 0.3 Hrs. Inspect For Proper Operation And Damaged Component. Includes Function Check Of Air Control Valve, Thermactor Air Bypass Solenoid, Check Valves, Silencer And Filter. 911211G Thermostat - Check For 0.2 Hrs. Proper Operation. DEALER CODING BASIC PART NO. CONDITION CODE 5E212 25 OASIS CODES: 403000, 603300, 614000 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Page 1016 Spark Plug: Specifications SPARK PLUGS Gap ...................................................................................................................................................... ............................................................ 0.044 in Torque ...................................................................... ................................................................................................................. 9-20 Nm (7-15 ft-lbs) Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Page 1017 Spark Plug: Service and Repair REMOVAL - Remove the wire from each spark plug by grasping the molded boot with tool T74P-6666-A or equivalent. Twist the boot until it loosens and then pull it off the spark plug. Do not pull on the wire, as the connection may become damaged. - Any wire damaged must be replaced. Each original spark plug wire is numbered for the cylinder to which it is designated. If wires are not numbered, each wire should be numbered as to the plug from which it was removed. - Clean the area around each spark plug port with compressed air. - Using the proper size spark plug socket remove the spark plugs. INSTALLATION Check the gap on each new spark plug and set to specification. See: Specifications - Install each spark plug and tighten to 9-20 Nm (7-15 ft-lbs). Cylinder Numbering And Distributor Location Location On Distributor - Coat the inside of each spark plug boot with silicone dielectric compound. Connect each spark plug wire to the plug from which it was removed. Be sure each wire is fully depressed on each plug and molded boot is firmly in place. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Compression Check > System Information > System Diagnosis Compression Check: Testing and Inspection COMPRESSION TEST 1. Ensure oil in crankcase is of the correct viscosity and at proper level and battery is properly charged. Operate vehicle until engine is at normal operating temperature. Turn OFF ignition switch, then remove all spark plugs. 2. Set throttle plates (and choke plates, if equipped) in wide-open position. 3. Install a compression gauge such as Rotunda Compression Tester 059-00009 or equivalent in No. 1 cylinder. 4. Install an auxiliary starter switch in starting circuit. With ignition switch in the OFF position, and using auxiliary starter switch, crank engine at least five compression strokes and record highest reading. Note the approximate number of compression strokes required to obtain the highest reading. 5. Repeat test on each cylinder cranking the engine approximately the same number of compression strokes. TEST CONCLUSION 1. The indicated compression pressures are considered within specification if the lowest reading cylinder is within 75 percent of the highest. 2. If one or more cylinders read low, squirt approximately one tablespoon of heavy SAE 50 weight or equivalent engine oil on top of the pistons in the low reading cylinders. Repeat compression pressure check on these cylinders. a. If compression improves considerably, piston rings are at fault. b. If compression does not improve, valves are sticking or seating poorly. c. If two adjacent cylinders indicate low compression pressures and squirting oil on pistons does not increase compression, cause may be a cylinder head gasket leak between cylinders. Engine oil and/or coolant in cylinders could result from this problem. Compression Pressure Limit Chart NOTE: Refer to the compression pressure limit chart for pressure specifications. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications Valve Clearance: Specifications ENGINE YEAR CLEARANCE V6-232 82-83 .088-.189 V8-255 81-82 .123-.173 6-300 80-87 .125-.175 V8-302 80-87 .096-.165 V8-351M 80-81 .125 V8-351W 80-87 .123-.173 V8-400 80-82 .175 V8-460 80-87 .100-.150 On engines with hydraulic lifters, clearance specified is at valve stem tip with lifter collapsed. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications > Page 1024 Valve Clearance: Locations FRONT TO REAR 6-300 E-I-E-I-E-I-E-I-E-I-E-I V6-232 Right I-E-I-E-I-E V6-232 Left E-I-E-I-E-I V8-255, 302 Left Bank E-I-E-I-E-I-E-I V8-255, 302 Right Bank I-E-I-E-I-E-I-E V8-351, 400 Right Bank I-E-I-E-I-E-I-E V8-351, 400 Left Bank E-I-E-I-E-I-E-I V8-460 Left Bank E-I-E-I-E-I-E-I V8-460 Right Bank I-E-I-E-I-E-I-E Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications > Page 1025 Valve Clearance: Adjustments Fig. 2 Positioning crankshaft for valve clearance check Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications > Page 1026 Fig. 3 Checking collapsed tappet clearance Valves, Adjust To provide a means to compensate for dimensional changes in the valve train and provide for valve adjustment, .060 inch shorter or longer pushrods are available. If the valve clearance is less than the minimum, the .060 inch shorter pushrod should be used. If the clearance is more than the maximum, the longer pushrod should be used. To check the valve clearance, proceed as follows: 1. Mark crankshaft pulley at three locations, with No. 1 location at TDC timing mark (end of compression stroke), location No. 2 one full turn (360°) clockwise from TDC and No. 3 location one quarter turn clockwise (90°) from position No. 2, Fig. 2. 2. Turn crankshaft to number 1 location, then compress valve lifter using tool T71P-6513-A or equivalent, Fig. 3, and check the clearance on the following valves: a. On V8-302 and 460 engines, check intake valve Nos. 1 , 7 and 8; exhaust valve Nos. 1, 4 and 5. b. On V8-351, check intake valve Nos. 1, 4 and No. 8; exhaust valve Nos. 1, 3 and 7. 3. Turn crankshaft to number 2 location, then compress valve lifter using tool T71P-6513-A or equivalent, Fig. 3, and check the clearance on the following valves: a. On V8-301 and 460 engines check intake valve Nos. 4 and 5; exhaust valve Nos. 2 and 6. b. On V8-351 engines, check intake valve Nos. 3 and 7; exhaust valve Nos. 2 and 6. 4. Turn crankshaft to number 3 location, then compress valve lifter using tool T71P-6513-A or equivalent and check the clearance on the following valves: a. V8-302 and 460 engines check intake valve Nos. 2, 3 and 6; exhaust valve Nos. 3, 7 and 8. b. On V8-351 engines, check intake valve Nos. 2, 5 and 6; exhaust valve Nos. 4, 5 and 8. Valve Arrangement Front to Rear V8-302 Left Bank.................................................................................................................................. ...........................................................E-I-E-I-E-I-E-I V8-302 Right Bank............................................. ..............................................................................................................................................I-E-I-E-IE-I-E V8-351 Right Bank...................................................................................................................... .....................................................................I-E-I-E-I-E-I-E V8-351 Left Bank...................................... .......................................................................................................................................................E-IE-I-E-I-E-I V8-460 Left Bank................................................................................................................. ............................................................................E-I-E-I-E-I-E-I V8-460 Right Bank............................ .............................................................................................................................................................. .I-E-I-E-I-E-I-E Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Customer Interest for Drive Belt: > 87531 > Mar > 87 > Accessory Drive Belt - Squealing Noise Drive Belt: Customer Interest Accessory Drive Belt - Squealing Noise ^ ACCESSORY DRIVE BELT - SQUEALS Article No. 87-5-31 ^ NOISE - ACCESSORY DRIVE "V" BELT SQUEALS LIGHT TRUCK 1985-87 E SERIES, F SERIES ISSUE: Accessory drive "V" belt squeals on F Series and E-250/350 vehicles 8500 lbs. GVW with dual thermactors and a 5.8L 4V engine equipped with power steering may be caused by the design of the current production belt. ACTION: To correct this, two new high profile "V" belts, E6TZ-8620-C and E6TZ- 8620-D, with an increased surface area and improved qualities less likely to stretch during normal service, are now available. Refer to the Truck Shop Manual for "V" belt installation and adjustment specifications. NOTE: When installing a now "V" belt, a belt tension gauge should be used. Refer to the following application chart for the proper "V" belt application. ACCESSORY DRIVE "V" BELT APPLICATION CHART Service Part No. Vehicle Application E6TZ-8620-C * 1985-87 F-250/350 over 8500 lbs. GVW with dual thermactors and 5.8L 4V engine - power steering and water pump drive. E6TZ-8620-D * 1985-87 E-250/350 over 8500 lbs. GVW with dual thermactors and 5.8L 4V engine - power steering and water pump drive. C9PZ-8620-CP 1985-87 F Series and Bronco with 5.8L engine without A/C - power steering and water pump drive. D9PZ-8620-P 1985-87 Econoline with 5.8L engine without A/C - power steering and water pump drive. D9PZ-8620-P 1985-87 F Series and Bronco with 5.8L engine and A/C (except F/B- 250/350 over 8500 lbs. GVW with A/C and dual thermactor) - power steering and water pump drive. D9PZ-8620-U 1985-87 Econoline with 5.8L engine and A/C (except E-250/350 over 8500 lbs. GVW with A/C and dual thermactor) - power steering and water pump drive. * Now high profile "V" belts. PART NUMBER PART NAME CLASS E6TZ-8620-C V-Drive Belt B E6TZ-8620-D V-Drive Belt B C9PZ-8620-CP V-Drive Belt AM D9PZ-8620-P V-Drive Belt AM D9PZ-8620-U V-Drive Belt AQ OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Drive Belt: > 87531 > Mar > 87 > Accessory Drive Belt - Squealing Noise Drive Belt: All Technical Service Bulletins Accessory Drive Belt - Squealing Noise ^ ACCESSORY DRIVE BELT - SQUEALS Article No. 87-5-31 ^ NOISE - ACCESSORY DRIVE "V" BELT SQUEALS LIGHT TRUCK 1985-87 E SERIES, F SERIES ISSUE: Accessory drive "V" belt squeals on F Series and E-250/350 vehicles 8500 lbs. GVW with dual thermactors and a 5.8L 4V engine equipped with power steering may be caused by the design of the current production belt. ACTION: To correct this, two new high profile "V" belts, E6TZ-8620-C and E6TZ- 8620-D, with an increased surface area and improved qualities less likely to stretch during normal service, are now available. Refer to the Truck Shop Manual for "V" belt installation and adjustment specifications. NOTE: When installing a now "V" belt, a belt tension gauge should be used. Refer to the following application chart for the proper "V" belt application. ACCESSORY DRIVE "V" BELT APPLICATION CHART Service Part No. Vehicle Application E6TZ-8620-C * 1985-87 F-250/350 over 8500 lbs. GVW with dual thermactors and 5.8L 4V engine - power steering and water pump drive. E6TZ-8620-D * 1985-87 E-250/350 over 8500 lbs. GVW with dual thermactors and 5.8L 4V engine - power steering and water pump drive. C9PZ-8620-CP 1985-87 F Series and Bronco with 5.8L engine without A/C - power steering and water pump drive. D9PZ-8620-P 1985-87 Econoline with 5.8L engine without A/C - power steering and water pump drive. D9PZ-8620-P 1985-87 F Series and Bronco with 5.8L engine and A/C (except F/B- 250/350 over 8500 lbs. GVW with A/C and dual thermactor) - power steering and water pump drive. D9PZ-8620-U 1985-87 Econoline with 5.8L engine and A/C (except E-250/350 over 8500 lbs. GVW with A/C and dual thermactor) - power steering and water pump drive. * Now high profile "V" belts. PART NUMBER PART NAME CLASS E6TZ-8620-C V-Drive Belt B E6TZ-8620-D V-Drive Belt B C9PZ-8620-CP V-Drive Belt AM D9PZ-8620-P V-Drive Belt AM D9PZ-8620-U V-Drive Belt AQ OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Page 1040 Drive Belt: Specifications A belt in operation 10 minutes is considered a used belt. 1988-89 Automatic tensioner used. Deflection method: Table lists deflection at midpoint of belt segment. Strand Tension method: Use a strand tension gauge. Measurements are in pounds. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Page 1041 Drive Belt: Adjustments A belt in operation 10 minutes is considered a used belt. 1988-89 Automatic tensioner used. Deflection method: Table lists deflection at midpoint of belt segment. Strand Tension method: Use a strand tension gauge. Measurements are in pounds. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Cleaner Element <--> [Air Filter Element] > Component Information > Technical Service Bulletins > Engine - Lack of Power/No Start Diagnosis Air Cleaner Element: Technical Service Bulletins Engine - Lack of Power/No Start Diagnosis Article No. 91-12-11 06/12/91 LACK OF POWER 7.5L, 5.8L, 5.0L, 4.9L - CATALYTIC CONVERTER DIAGNOSTIC TIPS LIGHT TRUCK: 1986-91 BRONCO, ECONOLINE, F-150-350 SERIES 1988-91 F SUPER DUTY, F47 ISSUE: Lack of power or a no start condition may be diagnosed as an exhaust restriction caused by a plugged catalytic converter. A plugged catalytic converter (internal deterioration) is usually caused by abnormal engine operation. ACTION: Diagnose the catalytic converter to confirm internal failure. Refer to the Catalyst and Exhaust System Diagnostic Section, in the Engine/Emissions Diagnostic Shop Manual and the following procedures for service details. 1. Lack of proper HEGO operation may cause, or be the result of a rich or lean fuel condition, which could cause additional heat in the catalyst. Perform self test KOEO and KOER, service any codes. NOTE: IF TWO DIGIT CODES 41, 42, 85 OR THREE DIGIT CODES 171, 172, 173, 179, 181, 182, 183 AND 565 ARE RECEIVED, CHECK FOR PROPER HEGO GROUND. If the HEGO ground is good, the following areas may be at fault: ^ Ignition Coil ^ Distributor Cap ^ Distributor Rotor ^ Fouled Spark Plug ^ Spark Plug Wires ^ Air Filter ^ Stuck Open Injector ^ Fuel Contamination Engine OIL ^ Manifold Leaks Intake/ Exhaust ^ Fuel Pressure ^ Poor Power Ground ^ Engine Not At Normal Operating Temperature ^ HEGO Sensor 2. Spark timing that is retarded from specification may increase exhaust gas temperature and shorten catalyst life. Refer to the following procedure for service details. a. Check spark timing. Check base timing with spout disconnected. Set base timing to the specification on the vehicle emission decal. b. Check computed timing with spout connected. NOTE: COMPUTED TIMING IS EQUAL TO BASE TIMING PLUS 20~ BTDC +/- 3~. 3. Misfiring spark plugs may cause an unburned fuel air mixture to pass through the catalyst, which could cause higher than normal catalyst temperatures. Refer to the following procedure for service details. a. Check secondary ignition, hook the vehicle up to an engine analyzer and check for a secondary ignition misfire. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Cleaner Element <--> [Air Filter Element] > Component Information > Technical Service Bulletins > Engine - Lack of Power/No Start Diagnosis > Page 1048 NOTE: SERVICE ANY ITEM THAT IS NOT PERFORMING AT PROPER SPECIFICATIONS BEFORE CONTINUING. 4. Fuel pressure that is too high may cause rich air fuel mixtures to pass through the catalyst which could cause higher than normal catalyst temperatures. Refer to the following procedure for service details. a. Check fuel pressure, install fuel pressure gauge, start and run the engine at idle. Fuel pressures between 28 and 34 PSI are typical (4.9L typically is 15 PSI higher). b. Disconnect the vacuum line going to the fuel pressure regulator. Fuel pressure typically jumps to 40 PSI +/- 3 PSI (4.9L typically is 15 PSI higher). Visually inspect vacuum line for raw fuel. NOTE: FUEL PRESSURES ABOVE THESE VALUES SHOULD BE CORRECTED. HOWEVER, THIS MAY NOT BE THE CAUSE OF THE CONCERN. SERVICE AS NECESSARY. 5. Throttle plates in the throttle body not returning to the proper closed position may cause excessive catalyst temperatures during downhill grades. Refer to the following procedure for service details. a. Visually inspect the throttle body and linkage for: ^ Binding or sticking throttle linkage. ^ Tight speed control linkage or cable. ^ Vacuum line interference. ^ Electrical harness interference. NOTE: AFTERMARKET GOVERNORS, THROTTLE LINKAGE AND CABLES ASSOCIATED WITH POWER TAKE-OFF UNITS, MAY ALSO INTERFERE WITH PROPER THROTTLE RETURN. SERVICE AS NECESSARY. 6. It is extremely important that all systems related to the engine and emission systems operate properly. a. Visually inspect the engine compartment to make sure all vacuum hoses and spark plug wires are properly routed and securely connected. b. Inspect all wiring harnesses and connectors for insulation damage, burned, overheated, loose or broken conditions. c. Verify proper operation of the thermactor system. Thermactor systems that fail to dump thermactor air to the atmosphere properly or at the correct time can cause high catalyst temperatures. d. Visually inspect thermactor system for damaged or kinked hoses and perform a function test on following components: air control valve, check valve, silencer, filter and the air bypass solenoid. e. Verify proper operation of the engine cooling system thermostat. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under Basic Warranty Coverage, Emissions Warranty Coverage OPERATION DESCRIPTION TIME 911211A Diagnostics - Perform 0.5 Hrs. KOEO And KOER Self Tests 911211B Timing - Check Or Adjust 0.5 Hrs. Spark Timing, Check Computed Timing And Check Secondary Ignition System With Engine Analyzer. 911211C Check - Fuel Pressure And 0.2 Hrs. Inspect Vacuum Line For Raw Fuel. 911211D Inspect - Throttle Body And 0.1 Hrs. Linkage. 911211E Inspect - Vacuum Hoses, 0.1 Hrs. Electrical Harnesses, Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Cleaner Element <--> [Air Filter Element] > Component Information > Technical Service Bulletins > Engine - Lack of Power/No Start Diagnosis > Page 1049 Connectors And Spark Plug Wires For Routing Damage. 911211F Thermactor System - 0.3 Hrs. Inspect For Proper Operation And Damaged Component. Includes Function Check Of Air Control Valve, Thermactor Air Bypass Solenoid, Check Valves, Silencer And Filter. 911211G Thermostat - Check For 0.2 Hrs. Proper Operation. DEALER CODING BASIC PART NO. CONDITION CODE 5E212 25 OASIS CODES: 403000, 603300, 614000 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Filters > EGR Filter > Component Information > Description and Operation EGR Filter: Description and Operation The EGR vacuum control valve filter is used to vent various emission control components to atmosphere. If the filter is blocked, replace it. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Filters > Fuel Filter > Component Information > Service and Repair Fuel Filter: Service and Repair REMOVAL - Remove the air cleaner. - Hold the fuel filter inlet hex nut with a backup wrench and unscrew the fuel line tube nut from the fuel filter inlet. WARNING: Use care to prevent combustion from fuel spillage. - Unscrew the fuel inlet fitting. - Remove the gasket, filter and spring. - Discard the gasket and filter. INSTALLATION - Install the spring, new filter and gasket. - Hand start the fuel inlet fitting into the carburetor then, tighten to 30-35 Nm (22-26 lb-ft). Apply oil, ESE-M2C39-E or equivalent to the fuel tube nut threads and tube flare. - Hand start the fuel line tube nut into the fuel inlet fitting (approximately two threads). - Use a backup wrench on the fuel inlet fitting while tightening the fuel line tube nut to 20-24 Nm (15-18 lb-ft). - Start the engine and check for fuel leak. - Install the air cleaner. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Filters > Refrigerant Filter > Component Information > Technical Service Bulletins > A/C - Filtering Refrigerant After Compressor Replacement Technical Service Bulletin # 98-12-5 Date: 980622 A/C - Filtering Refrigerant After Compressor Replacement Article No. 98-12-5 06/22/98 AIR CONDITIONING - FILTERING REFRIGERANT AFTER A/C COMPRESSOR REPLACEMENT - SERVICE TIPS FORD: 1980-98 CROWN VICTORIA 1981-98 ESCORT 1982-83 FAIRMONT 1982-88 EXP 1982-97 THUNDERBIRD 1982-98 MUSTANG 1983-86 LTD 1984-94 TEMPO 1986-98 TAURUS 1988-93 FESTIVA 1989-97 PROBE 1994-98 ASPIRE 1995-98 CONTOUR LINCOLN-MERCURY: 1980-98 GRAND MARQUIS, TOWN CAR 1982-83 ZEPHYR 1982-86 CAPRI 1982-87 LN7 1982-97 COUGAR 1982-98 CONTINENTAL 1983-86 MARQUIS 1984-92 MARK VII 1984-94 TOPAZ 1986-98 SABLE 1991-94 CAPRI 1991-98 TRACER 1993-98 MARK VIII 1995-98-MYSTIQUE 1999 COUGAR LIGHT TRUCK: 1980-96 BRONCO 1980-97 F SUPER DUTY 1980-98 ECONOLINE, F-150, F-150, F-350 1983-98 RANGER 1984-90 BRONCO II 1986-97 AEROSTAR 1988-97 F-47 1991-98 EXPLORER 1993-98 VILLAGER 1995-98 WINDSTAR 1997-98 EXPEDITION, MOUNTAINEER 1999 SUPER DUTY F SERIES This TSB article is being republished in its entirety to revise the Service Procedure and to update the model years. ISSUE Vehicles that have and inoperative A/C compressor, due to internal causes, MUST have the refrigerant system cleaned to remove any debris or contaminants that may be present to prevent damage to the replacement compressor. ACTION Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Filters > Refrigerant Filter > Component Information > Technical Service Bulletins > A/C - Filtering Refrigerant After Compressor Replacement > Page 1060 Install a Service Filter Kit in the refrigerant system prior to installing the replacement compressor. Refer to the following Service Procedure for details. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 96-15-5 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 1992-99 Models And 1991 Lincolns, Basic Warranty Coverage For All Other Models And Major Component Warranty Coverage For All Other Lincoins OPERATION DESCRIPTION TIME 981205A Kit Installation 1.2 Hrs. 981205B Extra Time For Refrigerant 0.4 Hr. (R-12) Recovery DEALER CODING CONDITION BASIC PART NO. CODE 19703 49 OASIS CODES: 208000, 208999 Service Procedure THIS PROCEDURE IS OPTIONAL IF THE SYSTEM IS FLUSHED USING THE ROTUNDA A/C FLUSHER. CAUTION THIS FILTERING PROCEDURE MAY BE USED FOR EITHER R-12 OR R-134a REFRIGERANT SYSTEMS. BECAUSE THE TWO (2) SYSTEMS USE DIFFERENT REFRIGERANT OILS AND BECAUSE THE COMPRESSOR COULD BE DAMAGED IF THE WRONG OIL IS USED, SYSTEM IDENTIFICATION IS VERY IMPORTANT. BE SURE SYSTEM IS CORRECTLY IDENTIFIED BEFORE STARTING THE FILTERING PROCEDURE. Each Service Filter Kit includes the following items: ^ One (1) Pancake Filter (to be installed in the liquid line between the condenser and the orifice tube) ^ One (1) Instruction Sheet NOTE ON 1993-94 RANGER/EXPLORER VEHICLES, TECHNICIANS MAY EXPERIENCE DIFFICULTY WHEN CONNECTING THE PANCAKE FILTER HOSE FITTINGS TO THE EVAPORATOR INLET WITH THE ORIFICE TUBE INSTALLED. REMOVE THE OFFICE TUBE AND RUN THE SYSTEM FOR 1 HOUR AS DESCRIBED IN THE FILTERING PROCEDURE. REINSTALL THE ORIFICE TUBE AFTER FILTERING IS COMPLETE. CAUTION FOLLOW ALL REFRIGERANT SYSTEM SAFETY AND SERVICE PRECAUTIONS OUTLINED IN THE APPROPRIATE SERVICE OR WORKSHOP MANUAL. 1. Before removing any refrigerant system components, recover the refrigerant from the system following the recycling methods outlined In the appropriate Service/Workshop Manual. 2. Remove the suction accumulator/drier assembly and drain the oil into a calibrated container. 3. Install a new suction accumulator/drier and add new refrigerant oil to replace the old oil. The quantity of the new oil to be added is the amount to match that drained from the old accumulator plus 60 mL (2 oz). Refer to the Dealer Master Parts Catalog for the correct suction accumulator/drier part number. CAUTION REMEMBER TO USE MOTORCRAFT YN-9-A REFRIGERANT COMPRESSOR OIL WITH R-12 SYSTEMS AND MOTORCRAFT YN-12-C REFRIGERANT COMPRESSOR OIL WITH R-134a SYSTEMS. FAILURE TO USE THE CORRECT REFRIGERANT OIL MAY RESULT IN DAMAGE TO SYSTEM COMPONENTS. 4. Install a new orifice tube. Refer to the Dealer Master Parts Catalog for the correct orifice tube part number. If the orifice tube in the vehicle is located in the liquid line between the condenser and the evaporator, replace the liquid line assembly. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Filters > Refrigerant Filter > Component Information > Technical Service Bulletins > A/C - Filtering Refrigerant After Compressor Replacement > Page 1061 5. Install pancake filter in the liquid line between the condenser and the orifice tube, Figure 1. a. Be sure orifice inlet is toward the condenser. b. Connections can be made using Test Adapter Set D93L-19703-B, or equivalent, and flexible refrigerant hose of 2500 psi burst rating. Individual fittings are also available. 6. Remove the old compressor following Service/Workshop Manual procedures. Drain the oil into a calibrated container. 7. Drain the oil from the replacement compressor into a clean calibrated container. NOTE: IT WILL BE NECESSARY TO TRANSFER THE MAGNET CLUTCH FROM THE OLD COMPRESSOR TO THE REPLACEMENT COMPRESSOR. FOLLOW SERVICE/WORKSHOP MANUAL PROCEDURES. 8. A new FX-15 service compressor contains 207 mL (7 oz.) of R-12 refrigerant oil. A new FS-10 service compressor does not contain any oil and can be used with an R-12 or an R-134a system. CAUTION REMEMBER TO USE YN-9-A (MINERAL) OIL WITH R-12 SYSTEMS AND YN-12-C (PAG) OIL WITH R-134a SYSTEMS. FAILURE TO USE THE CORRECT REFRIGERANT OIL MAY RESULT IN DAMAGE TO SYSTEM COMPONENTS. ^ If the amount of oil drained from the removed compressor is between 90 and 148 mL (3-5 oz), pour the same amount of clean refrigerant oil into the new compressor. ^ If the amount of oil drained from the old compressor is greater than 90 mL (3 oz), pour 90 mL (3 oz) of clean refrigerant oil into the new compressor. 9. Install the new compressor following Service/Workshop Manual procedures. Make sure all mounting bolts are tightened properly. Check the tension of the compressor drive belt. Adjust if necessary. 10. Evacuate, charge and leak test the system, following Service/Workshop Manual procedures. 11. Check all refrigerant system hoses, lines and the position of the newly-installed filters to make sure they do not interfere with other engine compartment components. If necessary, use tie straps to make adjustments. 12. Set the A/C control on Max A/C, high blower and temperature control at full cold. a. Start engine and let idle briefly. b. Be sure A/C system is operating properly. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Filters > Refrigerant Filter > Component Information > Technical Service Bulletins > A/C - Filtering Refrigerant After Compressor Replacement > Page 1062 13. Gradually bring the engine up to 1200 rpm by running it at lower rpms for short periods (first at 800 rpm, then at 1000 rpm). Set the engine at 1200 rpm and run it for an hour with the A/C system operating. 14. Stop the engine. NOTE: IT WILL BE NECESSARY TO RECOVER THE SYSTEM REFRIGERANT CHARGE BEFORE PROCEEDING. 15. Allow the engine to cool sufficiently to remove the fittings, flexible hoses and pancake filter from the liquid line. 16. Discard the filter. It can be used one (1) tie only. 17. Reconnect the liquid line back into the system. 18. Evacuate, charge and leak test the system. Make any necessary adjustments. 19. Check the operation of the system in all models. PART NUMBER PART NAME F8VZ-19E773-AA Filter Kit F73Z-19577-AA Refrigerant Oil - Motorcraft YN-9-A (For R-12 Refrigerant Systems Only) F7AZ-19589-DA Refrigerant Oil - Motorcraft YN-12-C (PAG-Type Oil For R-134a Refrigerant Systems Only) NOTE THE TOTAL REPAIR TIME IS FOR INSTALLING SERVICE FILTER KIT PER INSTRUCTIONS THIS INCLUDES INSTALLATION OF AND DISCARD OF FILTER. REFER TO SERVICE LABOR TIME STANDARDS MANUALS IF ADDITIONAL LABOR OPERATIONS ARE REQUIRED. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Hoses > System Information > Service Precautions Hoses: Service Precautions SERVICE PRECAUTIONS To prevent vehicle damage, always observe the following precautions: After servicing a hose, check for leaks before and after test driving the vehicle. - Always use the correct size hose. Do not use standard sized hose in place of metric hose or vice versa. Always use the correct type of hose. Never use vacuum hose in place of fuel hose. Never use heater hose in place of PCV hose. - When replacing hoses which are attached to the engine on one end and the frame or body on the other end, always leave sufficient length to compensate for engine movement (from torque). Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Recycled Engine Coolant - Service Tips Coolant: Technical Service Bulletins Recycled Engine Coolant - Service Tips Article No. 95-18-2 09/11/95 ^ COOLANT - USE OF RECYCLED ENGINE, COOLANT - SERVICE TIP ^ COOLING SYSTEM - USE OF RECYCLED ENGINE, COOLANT - SERVICE TIP FORD: 1980 and after CROWN VICTORIA, MUSTANG, THUNDERBIRD 1981 and after ESCORT 1982-88 EXP 1984-94 TEMPO 1986 and after TAURUS 1988-93 FESTIVA 1989 and after PROBE 1994 and after ASPIRE 1995 and after CONTOUR LINCOLN-MERCURY: 1980 and after CONTINENTAL, COUGAR, GRAND MARQUIS, TOWN CAR 1981-86 CAPRI 1981-87 LYNX 1984-92 MARK VII 1984-94 TOPAZ 1986 and after SABLE 1987-89 TRACER 1991-94 CAPRI 1991 and after TRACER 1993 and after MARK VIII 1995 and after MYSTIQUE MERKUR: 1985-89 XR4TI 1988-89 SCORPIO LIGHT TRUCK: 1980 and after F-150-350 SERIES 1981 and after ECONOLINE 1982 and after BRONCO 1983 and after RANGER 1984-90 BRONCO II 1986 and after AEROSTAR 1988 and after F SUPER DUTY 1991 and after EXPLORER 1993 and after VILLAGER 1995 and after WINDSTAR This TSB is being republished in its entirety to include warranty information when using recycled coolant ISSUE: Ford Motor Company authorizes the use of recycled engine coolant that, when properly processed and reinhibited, meets Ford specification ESE-M97B44-A. At this time, the Rotunda Coolant Recycler (181-00003) process is the only approved coolant recycling method available through Ford that is capable of producing recycled engine coolant that meets Ford specification ESE-M97B44-A. ACTION: Refer to the following Service Procedure for coolant processing and reinhibiting using Rotunda Coolant Recycler (181-00003). NOTE: WHILE TESTING SHOWS THAT RECYCLED ENGINE COOLANT CAN PROVIDE ACCEPTABLE PERFORMANCE, THE COOLANT PRODUCED FROM ROTUNDA EQUIPMENT IS INTENDED FOR USE WITHIN DEALERSHIPS ON WARRANTY AND CUSTOMER PAY REPAIRS ONLY AND NOT INTENDED FOR RETAIL SALE. THERE ARE REGULATORY, PACKAGING AND LABELING CONCERNS Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Recycled Engine Coolant - Service Tips > Page 1071 ASSOCIATED WITH THE RETAIL SALE OF CHEMICAL PRODUCTS. CAUTION: THE REINHIBITOR CHEMICALS PROVIDED WITH THIS EQUIPMENT ARE NOT APPROPRIATE FOR USE ON MEDIUM/HEAVY TRUCK APPLICATIONS. WARNING: ROTUNDA PREMIUM COOLANT REINHIBITORS # 1 AND # 2 HAVE BEEN SPECIFICALLY FORMULATED TO WORK WITH ROTUNDA COOLANT RECYCLER (181-00003). USE OF ANY OTHER CHEMICAL ADDITIVES WITH THIS SYSTEM WILL VOID ALL WARRANTIES FOR THE EQUIPMENT AND FOR THE FINAL COOLANT PRODUCT. SERVICE PROCEDURE DIRECTIONS FOR PROCESSING USED ENGINE COOLANT WITH ROTUNDA COOLANT RECYCLER 1. Close the drain valve on the unit. 2. Open the fill valve. 3. Pour used engine coolant into the funnel on the side of the unit. NOTE: MAXIMUM CAPACITY 15 25 GALLONS (95 L). 4. Insert the outlet hoses of the recycler into clean, properly labeled containers. One (1) container is for the outlet process water and the other container is for distilled ethylene glycol. 5. Push the "ON" switch on the front to start the operation. The unit will process 1 gallon (3.8 L) per hour of operation and will automatically shut off when cycle is complete. 6. Add reinhibitor following the directions in this article. 7. Open the drain valve to drain the residue from the distillation vessel. Dispose of residue in accordance with all local. state and federal regulations. ADDING REINHIBITOR CHEMICALS 1. Process the coolant according to the directions listed in this article 2. Thoroughly mix 4 fl oz (118 ml) of Reinhibitor # 1 to each gallon of distilled ethylene glycol. 3. Thoroughly mix 4 fl oz (118 ml) of Reinhibitor # 2 to each gallon of distilled ethylene glycol. 4. Mix well. 5. Check the pH level of the coolant. The pH level must be between 9 and 11. 6. Add enough water to the concentrated coolant to produce a 50/50 mixture of coolant and water. NOTE: THE CONCENTRATED COOLANT MUST BE MIXED WITH WATER TO MEET THE NECESSARY ENGINE FREEZE PROTECTION. 7. Check the coolant freeze point of the 50% coolant solution. Freeze point should be -34°F (-37°C). Consult the Rotunda Coolant Recycler Manual for more detailed operating instructions. Call 1-800-ROTUNDA, 8 AM to 8 PM EST, for inquiries regarding the Rotunda Coolant Recycler and to order the Reinhibitor (187-R0001). PART NUMBER PART NAME Rotunda # 187-R0001 Rotunda Premium Coolant Reinhibitor WARRANTY CLAIMS: Dealer can claim recycled engine coolant by Ford approved process via a warranty repair on an 1863 claim as follows: Part Number: RECCOOL (not a valid part number, but it is recognized on an 1863 claim). Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Recycled Engine Coolant - Service Tips > Page 1072 Quantity: Indicate the number of QUARTS of recycled coolant used. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 95-16-6 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 402000 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Recycled Engine Coolant - Service Tips > Page 1073 Coolant: Technical Service Bulletins Engine Coolant - Recycled Coolant Not Authorized Article No. 90-4-10 COOLING SYSTEM - USE OF RECYCLED ENGINE COOLANT - SERVICE TIP FORD: 1984-90 CROWN VICTORIA, ESCORT, MUSTANG, TEMPO, THUNDERBIRD 1986-90 TAURUS 1988-90 FESTIVA 1989-90 PROBE LINCOLN-MERCURY: 1984-86 CAPRI 1984-87 LYNX 1984-90 CONTINENTAL, COUGAR, GRAND MARQUIS, MARK VII, TOPAZ, TOWN CAR 1986-90 SABLE 1987-90 TRACER MERKUR: 1985-90 XR4TI 1988-89 SCORPIO LIGHT TRUCK: 1984-90 BRONCO II, BRONCO, ECONOLINE, F-150, F-250, F-350, RANGER 1986-90 AEROSTAR MEDIUM/HEAVY TRUCK: 1984-90 C SERIES, F & B SERIES, L SERIES 1986-90 CARGO SERIES ISSUE: Ford Motor Company does not authorize the use of recycled engine coolant nor do they sanction the use of any machines or devices that recycle engine coolant. Recycled engine coolant is not equivalent to the factory fill OEM coolant, the Ford premium cooling system fluid (E2FZ-19549-AA) or the Ford heavy duty low silicate cooling fluid (E6HZ-19549-A). The quality of engine coolant degenerates with use. Recycling used engine coolant is very difficult to do without exposing the used coolant to additional foreign substances. Merely adding an additive to the coolant will not restore it. ACTION: Use new engine coolant that meets Ford Motor coolant specifications for the engine being serviced. Properly dispose of the used coolant. WARNING: THE DISPOSAL OF ALL USED ENGINE COOLANT MUST ALWAYS BE DONE IN ACCORDANCE WITH ALL APPLICABLE FEDERAL, STATE AND LOCAL LAWS AND REGULATIONS. PART NUMBER PART NAME CLASS E2FZ-19549-AA Coolant System Fluid - Ford V Premium E6HZ-19549-A Coolant System Fluid - Ford V Heavy Duty Low Silicate (For use in diesel powered med/hvy trucks) OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 4300 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Capacity Specifications Coolant: Capacity Specifications Coolant Capacity Manual Transmission Less A/C .............................................................................................................................................. ............................................................... 15 qts A/C ............................................................................ ......................................................................................................................................... 16 qts A/C And Super Cooling .............................................................................................................................. ....................................................... 17 qts Automatic Transmission Less A/C and Super Cooling ............................................................................................................... ............................................................... 16 qts Super Cooling With A/C ............................................ ........................................................................................................................................ 17 qts All Other Models With A/C ................................................................................................................... ................................................................... 15 qts Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Capacity Specifications > Page 1076 Coolant: Fluid Type Specifications COOLING SYSTEM FLUID, PREMIUM Ford Part No. U.S.A (Except Oregon) ............................................................................................................................................................ E2FZ-19549-AA or -B Canada ............................................................................................................ .............................................................................................. CXC-8-B Oregon .................................. ............................................................................................................................................................. F5FZ-19549-CC Ford Specification ................................................................................................................................ ................................................... ESE-M97B44-A COOLING SYSTEM FLUSH Ford Part No. ....................................................................................................................................... ................................................... F1AZ-19A503-A Ford Specification ................................................. ..................................................................................................................................... ESR-M14P7-A Coolant Mixture with Water ................................................................................................................. ...................................................................... 50% Warning: Do not mix coolant types. Check the owners manual or refer to your local dealer for the correct coolant type. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > Customer Interest: > 861117 > Jun > 86 > A/T - Synthetic Fluid Availability Fluid - A/T: Customer Interest A/T - Synthetic Fluid Availability Article No. 86-11-17 TRANSMISSION - AUTOMATIC - NEW SYNTHETIC DEXRON II ALL WEATHER AUTOMATIC TRANSMISSION FLUID FORD 1986 and PRIOR ESCORT, EXP, FORD, LTD, THUNDERBIRD, MUSTANG, TEMPO; 1986 TAURUS LINCOLN-MERCURY 1982-83 LN7; 1986 and PRIOR LYNX, MERCURY, MARQUIS, COUGAR, CAPRI, TOPAZ, LINCOLN, MARK, CONTINENTAL; 1986 SABLE LIGHT TRUCK 1986 and PRIOR E, F SERIES, BRONCO, BRONCO II, RANGER A new synthetic Dexron II automatic transmission fluid specification number ESR-M2C163-A2, part number E6AZ-19582-B is now available. This fluid will maintain a more constant viscosity through a wider range of temperatures. In the event a vehicle will be operated in extremely cold temperatures for an extended period of time, remove all existing fluid from the transmission (using the procedure shown in the applicable 1986 Car or Light Truck Shop Manual) and replace with the new synthetic Dexron II fluid, E6AZ-19582-B. The synthetic fluid is year 'round fluid and will not require replacement for warmer weather. CAUTION: DO NOT use synthetic Dexron II fluid in transmissions designed to use Type "F" fluid. PART NUMBER PART NAME CLASS E6AZ-19582-B Synthetic Dexron Oil V Automatic Transmission Oil OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid - A/T: > 06-14-4 > Jul > 06 > A/T - Mercon V ATF Usage Fluid - A/T: All Technical Service Bulletins A/T - Mercon V ATF Usage TSB 06-14-4 07/24/06 MERCON ATF IS BEING REPLACED BY MERCON V ATF AS A SERVICE FLUID. FORD: 1980-1997 Crown Victoria 1981-1997 Mustang, Thunderbird 1981-2003 Escort 1986-1993 Festiva 1986-1997 Taurus 1989-1997 Probe 1994-1997 Aspire 1995-2000 Contour 1980-1996 Bronco 1981-2003 F-150 1981-2004 E-Series, F-Super Duty 1983-1996 Ranger 1986-1996 Aerostar 1991-1997 Explorer 1993-2004 F-53 Motorhome Chassis 1995-1998 Windstar 1997-2004 Expedition 2000-2005 Excursion 2001-2007 Escape 1987-2000 F-B-Series 2000-2007 F-650, F-750 LINCOLN: 1980-1997 Town Car 1981-1997 Continental 1993-1997 Mark VIII 1998-2004 Navigator 2002-2003 Blackwood MERCURY: 1980-1997 Grand Marquis 1981-1997 Cougar 1986-1997 Sable 1987-1999 Tracer 1995-2000 Mystique 1999-2002 Cougar 1993-2002 Villager 1997 Mountaineer 2005-2007 Mariner MERKUR: 1985-1989 XR4TI This article supersedes TSB 01-15-7 to update the vehicle application chart. ISSUE MERCON(R) Automatic Transmission Fluid is being replaced by MERCON(R) V as a service fluid. ACTION Beginning immediately all automatic transmission / transaxle applications requiring MERCON(R) can now be serviced using MERCON(R) V or MERCON(R) Automatic Transmission Fluid or dual usage fluids labeled MERCON(R) / MERCON(R) V. After July 1, 2007, MERCON(R) Automatic Transmission Fluid will no longer be manufactured, therefore, availability of this fluid will only continue for however long it takes to deplete what remains in inventory. SERVICE PROCEDURE Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid - A/T: > 06-14-4 > Jul > 06 > A/T - Mercon V ATF Usage > Page 1090 Service automatic transmissions requiring MERCON(R) with MERCON(R) V or MERCON(R) Automatic Transmission Fluid or dual usage fluids labeled MERCON(R) / MERCON(R) V For proper fluid application on current and past model vehicles equipped with automatic transmissions I transaxles refer to the fluid usage chart. (Figure 1) CAUTION AUTOMATIC TRANSMISSIONS / TRANSAXLES THAT REQUIRE MERCON® V SHOULD STILL ONLY USE MERCON(R) V OR DUAL USAGE FLUID LABELED MERCON(R) / MERCON(R) V. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid - A/T: > 06-14-4 > Jul > 06 > A/T - Mercon V ATF Usage > Page 1091 CAUTION MERCON(R) SP, MOTORCRAFT PREMIUM AUTOMATIC TRANSMISSION FLUID AND MOTORCRAFT M5 ATFS ARE UNIQUE FLUIDS AND MUST BE USED IN APPLICATIONS RECOMMENDING THAT PARTICULAR FLUID. USE OF ANY OTHER FLUID MAY CAUSE REDUCED FUNCTIONALITY OR TRANSMISSION DAMAGE. CAUTION THE FUNCTIONAL CHARACTERISTICS OF FLUIDS FOR CVT TRANSMISSIONS ARE VERY DIFFERENT THAN THOSE OF OTHER AUTOMATIC TRANSMISSION FLUIDS (ATFS). USE OF A FLUID OTHER THAN MOTORCRAFT CONTINUOUSLY VARIABLE CHAIN TYPE TRANSMISSION FLUID OR ONE LABELED AS MEETING MERCON(R) C WILL CAUSE FUNCTIONALITY CONCERNS AND INTERNAL TRANSMISSION DAMAGE. CAUTION DO NOT USE AUTOMATIC TRANSMISSION FLUID SUPPLEMENTS, ADDITIVES, TREATMENTS OR CLEANING AGENTS. Parts Block WARRANTY STATUS: Information Only Disclaimer Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid - A/T: > 871814 > Sep > 87 > A/T, M/T - New `Mercon' Transmission Fluid Fluid - A/T: All Technical Service Bulletins A/T, M/T - New `Mercon' Transmission Fluid TRANSMISSION - AUTOMATIC/MANUAL - Article No. NEW FLUID AND USAGE CHART 87-18-14 FORD: 1986 And Prior LTD 1988 And Prior ESCORT, TEMPO, MUSTANG, TAURUS, THUNDERBIRD, FORD LINCOLN-MERCURY: 1986 And Prior CAPRI, MARQUIS 1987 And Prior LYNX 1988 And Prior TOPAZ, SABLE, COUGAR, MERCURY, MARK VII, CONTINENTAL, LINCOLN TOWN CAR MERKUR: 1985-88 XR4Ti 1988 SCORPIO LIGHT TRUCK: 1988 And Prior E SERIES, F SERIES, BRONCO, RANGER, BRONCO II, AEROSTAR ISSUE: A new Transmission Fluid, MERCON (Ford Specification "MERCON") (XT-2- QDX, Quart), (XT-2-DDX, 55 Gallon Drum) is available for service. Use of the Motorcraft "MERCON" transmission fluid, where specified, will improve cold weather shift effort and synchronized operation. ACTION: The chart on page 44 of this TSB gives transmission fluid applications for automatic transmissions and certain manual transmissions for Ford, Lincoln-Mercury, and Merkur vehicles. NOTE: The use of MERCON is NOT RECOMMENDED for power steering systems. The manual transmission lubricant for the 1985 Merkur XR4Ti is a semi-synthetic oil. When adding oil to the transmission, use only E5RY-19C547-A (Ford Specification ESD-M2C175-A) or equivalent. PART NUMBER PART NAME CLASS XT-2-QDX MERCON - Quart V Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid - A/T: > 871814 > Sep > 87 > A/T, M/T - New `Mercon' Transmission Fluid > Page 1096 XT-2-DDX MERCON - 55 Gallon V Drum E5RY-19C547-A Semi-Synthetic Oil B OTHER APPLICABLE ARTICLES: 82-9-9 Supersedes 85-1-15, 85-6-7 WARRANTY STATUS: "INFORMATION ONLY" Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid - A/T: > 861117 > Jun > 86 > A/T - Synthetic Fluid Availability Fluid - A/T: All Technical Service Bulletins A/T - Synthetic Fluid Availability Article No. 86-11-17 TRANSMISSION - AUTOMATIC - NEW SYNTHETIC DEXRON II ALL WEATHER AUTOMATIC TRANSMISSION FLUID FORD 1986 and PRIOR ESCORT, EXP, FORD, LTD, THUNDERBIRD, MUSTANG, TEMPO; 1986 TAURUS LINCOLN-MERCURY 1982-83 LN7; 1986 and PRIOR LYNX, MERCURY, MARQUIS, COUGAR, CAPRI, TOPAZ, LINCOLN, MARK, CONTINENTAL; 1986 SABLE LIGHT TRUCK 1986 and PRIOR E, F SERIES, BRONCO, BRONCO II, RANGER A new synthetic Dexron II automatic transmission fluid specification number ESR-M2C163-A2, part number E6AZ-19582-B is now available. This fluid will maintain a more constant viscosity through a wider range of temperatures. In the event a vehicle will be operated in extremely cold temperatures for an extended period of time, remove all existing fluid from the transmission (using the procedure shown in the applicable 1986 Car or Light Truck Shop Manual) and replace with the new synthetic Dexron II fluid, E6AZ-19582-B. The synthetic fluid is year 'round fluid and will not require replacement for warmer weather. CAUTION: DO NOT use synthetic Dexron II fluid in transmissions designed to use Type "F" fluid. PART NUMBER PART NAME CLASS E6AZ-19582-B Synthetic Dexron Oil V Automatic Transmission Oil OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid - A/T: > 06-14-4 > Jul > 06 > A/T - Mercon V ATF Usage Fluid - A/T: All Technical Service Bulletins A/T - Mercon V ATF Usage TSB 06-14-4 07/24/06 MERCON ATF IS BEING REPLACED BY MERCON V ATF AS A SERVICE FLUID. FORD: 1980-1997 Crown Victoria 1981-1997 Mustang, Thunderbird 1981-2003 Escort 1986-1993 Festiva 1986-1997 Taurus 1989-1997 Probe 1994-1997 Aspire 1995-2000 Contour 1980-1996 Bronco 1981-2003 F-150 1981-2004 E-Series, F-Super Duty 1983-1996 Ranger 1986-1996 Aerostar 1991-1997 Explorer 1993-2004 F-53 Motorhome Chassis 1995-1998 Windstar 1997-2004 Expedition 2000-2005 Excursion 2001-2007 Escape 1987-2000 F-B-Series 2000-2007 F-650, F-750 LINCOLN: 1980-1997 Town Car 1981-1997 Continental 1993-1997 Mark VIII 1998-2004 Navigator 2002-2003 Blackwood MERCURY: 1980-1997 Grand Marquis 1981-1997 Cougar 1986-1997 Sable 1987-1999 Tracer 1995-2000 Mystique 1999-2002 Cougar 1993-2002 Villager 1997 Mountaineer 2005-2007 Mariner MERKUR: 1985-1989 XR4TI This article supersedes TSB 01-15-7 to update the vehicle application chart. ISSUE MERCON(R) Automatic Transmission Fluid is being replaced by MERCON(R) V as a service fluid. ACTION Beginning immediately all automatic transmission / transaxle applications requiring MERCON(R) can now be serviced using MERCON(R) V or MERCON(R) Automatic Transmission Fluid or dual usage fluids labeled MERCON(R) / MERCON(R) V. After July 1, 2007, MERCON(R) Automatic Transmission Fluid will no longer be manufactured, therefore, availability of this fluid will only continue for however long it takes to deplete what remains in inventory. SERVICE PROCEDURE Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid - A/T: > 06-14-4 > Jul > 06 > A/T - Mercon V ATF Usage > Page 1106 Service automatic transmissions requiring MERCON(R) with MERCON(R) V or MERCON(R) Automatic Transmission Fluid or dual usage fluids labeled MERCON(R) / MERCON(R) V For proper fluid application on current and past model vehicles equipped with automatic transmissions I transaxles refer to the fluid usage chart. (Figure 1) CAUTION AUTOMATIC TRANSMISSIONS / TRANSAXLES THAT REQUIRE MERCON® V SHOULD STILL ONLY USE MERCON(R) V OR DUAL USAGE FLUID LABELED MERCON(R) / MERCON(R) V. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid - A/T: > 06-14-4 > Jul > 06 > A/T - Mercon V ATF Usage > Page 1107 CAUTION MERCON(R) SP, MOTORCRAFT PREMIUM AUTOMATIC TRANSMISSION FLUID AND MOTORCRAFT M5 ATFS ARE UNIQUE FLUIDS AND MUST BE USED IN APPLICATIONS RECOMMENDING THAT PARTICULAR FLUID. USE OF ANY OTHER FLUID MAY CAUSE REDUCED FUNCTIONALITY OR TRANSMISSION DAMAGE. CAUTION THE FUNCTIONAL CHARACTERISTICS OF FLUIDS FOR CVT TRANSMISSIONS ARE VERY DIFFERENT THAN THOSE OF OTHER AUTOMATIC TRANSMISSION FLUIDS (ATFS). USE OF A FLUID OTHER THAN MOTORCRAFT CONTINUOUSLY VARIABLE CHAIN TYPE TRANSMISSION FLUID OR ONE LABELED AS MEETING MERCON(R) C WILL CAUSE FUNCTIONALITY CONCERNS AND INTERNAL TRANSMISSION DAMAGE. CAUTION DO NOT USE AUTOMATIC TRANSMISSION FLUID SUPPLEMENTS, ADDITIVES, TREATMENTS OR CLEANING AGENTS. Parts Block WARRANTY STATUS: Information Only Disclaimer Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid - A/T: > 871814 > Sep > 87 > A/T, M/T - New `Mercon' Transmission Fluid Fluid - A/T: All Technical Service Bulletins A/T, M/T - New `Mercon' Transmission Fluid TRANSMISSION - AUTOMATIC/MANUAL - Article No. NEW FLUID AND USAGE CHART 87-18-14 FORD: 1986 And Prior LTD 1988 And Prior ESCORT, TEMPO, MUSTANG, TAURUS, THUNDERBIRD, FORD LINCOLN-MERCURY: 1986 And Prior CAPRI, MARQUIS 1987 And Prior LYNX 1988 And Prior TOPAZ, SABLE, COUGAR, MERCURY, MARK VII, CONTINENTAL, LINCOLN TOWN CAR MERKUR: 1985-88 XR4Ti 1988 SCORPIO LIGHT TRUCK: 1988 And Prior E SERIES, F SERIES, BRONCO, RANGER, BRONCO II, AEROSTAR ISSUE: A new Transmission Fluid, MERCON (Ford Specification "MERCON") (XT-2- QDX, Quart), (XT-2-DDX, 55 Gallon Drum) is available for service. Use of the Motorcraft "MERCON" transmission fluid, where specified, will improve cold weather shift effort and synchronized operation. ACTION: The chart on page 44 of this TSB gives transmission fluid applications for automatic transmissions and certain manual transmissions for Ford, Lincoln-Mercury, and Merkur vehicles. NOTE: The use of MERCON is NOT RECOMMENDED for power steering systems. The manual transmission lubricant for the 1985 Merkur XR4Ti is a semi-synthetic oil. When adding oil to the transmission, use only E5RY-19C547-A (Ford Specification ESD-M2C175-A) or equivalent. PART NUMBER PART NAME CLASS XT-2-QDX MERCON - Quart V Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid - A/T: > 871814 > Sep > 87 > A/T, M/T - New `Mercon' Transmission Fluid > Page 1112 XT-2-DDX MERCON - 55 Gallon V Drum E5RY-19C547-A Semi-Synthetic Oil B OTHER APPLICABLE ARTICLES: 82-9-9 Supersedes 85-1-15, 85-6-7 WARRANTY STATUS: "INFORMATION ONLY" Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Refill Capacity Fluid - A/T: Specifications TYPE MA CAPACITY, Initial Refill*: C-6 5.0 qt (US) With the engine at operating temperature, shift transmission through all gears. Check fluid level in PARK and add fluid as needed Others 3.0 qt (US) Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Refill Capacity > Page 1115 Fluid - A/T: Specifications Fluid Capacity 11.8 qt (US) Note: 4 x 4 models, 13.4 qts. Approximate. Make final check with dipstick. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Technical Service Bulletins > Drivetrain - Lubricant Usage Fluid - M/T: Technical Service Bulletins Drivetrain - Lubricant Usage Article No. 89-8-16 ^ DRIVETRAIN - LUBRICATION USAGE ^ TRANSMISSION - MANUAL - LUBRICATION USAGE LIGHT TRUCK: 1980-89 BRONCO, ECONOLINE, F-150, F-250, F-350 1983-89 RANGER 1984-89 BRONCO II 1986-89 AEROSTAR ISSUE: A quick reference manual transmission fluid usage chart and a quick reference drivetrain lubrication usage chart for light trucks has been put together to assist technicians in the event service is required. FIGURE 1 FIGURE 2 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Technical Service Bulletins > Drivetrain - Lubricant Usage > Page 1120 ACTION: Refer to the transmission fluid application chart in Figure 1 for the correct fluid usage. Refer to the drivetrain lubrication application chart in Figure 2 for the correct lubricant usage. PART NUMBER PART NAME CLASS D8DZ-19C547-A Standard Transmission BG Lubricant - 5 gallons C1AZ-19590-BA Long Life Lubricant B (molybdenum disulfide) - 14.5 ounces DOAZ-19584-AA Multi-Purpose Grease - 4 ounce B tube D7AZ-19584-AA Multi-Purpose Grease - 15 B ounce aerosol can XT-2-QDX Transmission Fluid (Mercon) - V quart can (pkg. of 12) C6AZ-19580-E Gear Oil (Dana axle) - 1 gallon AG C8AZ-19B546-A Additive Friction Modifier - 4 AM ounce bottle D7AZ-19590-A Disc Brake Caliper Slide AM Grease - 4 ounce tube E8TZ-19590-A Grease - 14.5 ounces B E1TZ-19590-A Automatic Hublock Grease - 5 B ounce tube E5RY-19C547-A Merkur Synthetic Manual B Transmission Fluid OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 5970 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Technical Service Bulletins > Drivetrain - Lubricant Usage > Page 1121 Fluid - M/T: Technical Service Bulletins A/T, M/T - New `Mercon' Transmission Fluid TRANSMISSION - AUTOMATIC/MANUAL - Article No. NEW FLUID AND USAGE CHART 87-18-14 FORD: 1986 And Prior LTD 1988 And Prior ESCORT, TEMPO, MUSTANG, TAURUS, THUNDERBIRD, FORD LINCOLN-MERCURY: 1986 And Prior CAPRI, MARQUIS 1987 And Prior LYNX 1988 And Prior TOPAZ, SABLE, COUGAR, MERCURY, MARK VII, CONTINENTAL, LINCOLN TOWN CAR MERKUR: 1985-88 XR4Ti 1988 SCORPIO LIGHT TRUCK: 1988 And Prior E SERIES, F SERIES, BRONCO, RANGER, BRONCO II, AEROSTAR ISSUE: A new Transmission Fluid, MERCON (Ford Specification "MERCON") (XT-2- QDX, Quart), (XT-2-DDX, 55 Gallon Drum) is available for service. Use of the Motorcraft "MERCON" transmission fluid, where specified, will improve cold weather shift effort and synchronized operation. ACTION: The chart on page 44 of this TSB gives transmission fluid applications for automatic transmissions and certain manual transmissions for Ford, Lincoln-Mercury, and Merkur vehicles. NOTE: The use of MERCON is NOT RECOMMENDED for power steering systems. The manual transmission lubricant for the 1985 Merkur XR4Ti is a semi-synthetic oil. When adding oil to the transmission, use only E5RY-19C547-A (Ford Specification ESD-M2C175-A) or equivalent. PART NUMBER PART NAME CLASS XT-2-QDX MERCON - Quart V Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Technical Service Bulletins > Drivetrain - Lubricant Usage > Page 1122 XT-2-DDX MERCON - 55 Gallon V Drum E5RY-19C547-A Semi-Synthetic Oil B OTHER APPLICABLE ARTICLES: 82-9-9 Supersedes 85-1-15, 85-6-7 WARRANTY STATUS: "INFORMATION ONLY" Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Technical Service Bulletins > Page 1123 Fluid - M/T: Specifications See TSB 06-14-4 1987 5-speed Mercon(R) V Automatic Transmission Fluid All others 80W EP CAPACITY, Refill: 3-speed 3.5 pt (US) 4-speed ex. OD 7.0 pt (US) W/OD 4.5 pt (US) 5-speed 7.4 pt (US) Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Technical Service Bulletins > Customer Interest: > 86198 > Sep > 86 > Rear Locking Differential - Noise On Turns Fluid - Differential: Customer Interest Rear Locking Differential - Noise On Turns Article No. 86-19-8 AXLE - REAR - TRACTION-LOK 7.5" AND 8.8" - NOISE ON TURNS NOISE ON TURNS - REAR AXLE - TRACTION-LOK 7.5" AND 8.8" FORD 1986 MUSTANG, THUNDERBIRD, LTD, FORD LINCOLN-MERCURY 1986 CAPRI, COUGAR, MARQUIS, MERCURY, LINCOLN TOWN CAR, MARK VII, CONTINENTAL LIGHT TRUCK 1986 AEROSTAR, RANGER, BRONCO II, BRONCO, E SERIES, F SERIES Traction-Lok limited slip differentials may exhibit a slip stick noise on turns after extended highway driving. The noise may be caused by the lubricant (friction modifier) breaking down. This condition will not damage the internal parts of the axle. However, to correct, drain and refill the axle with E0AZ-19580-A or equivalent rear axle lubricant. Refer to the appropriate 1986 Shop Manual for fill capacities. After filling, add four ounces of friction modifier, C8AZ-19B546-A or equivalent. PART NUMBER PART NAME CLASS E0AZ-19580-A Rear Axle Lubricant A C8AZ-19B546-A Friction Modifier A OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION: 4036A - Passenger Car TIME: 0.4 Hr. OPERATION: 4036A - Light Truck TIME: 0.5 Hr. DLR. CODING: Basic Part No. 4209 - Code: 53 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 89816 > Apr > 89 > Drivetrain - Lubricant Usage Fluid - Differential: All Technical Service Bulletins Drivetrain - Lubricant Usage Article No. 89-8-16 ^ DRIVETRAIN - LUBRICATION USAGE ^ TRANSMISSION - MANUAL - LUBRICATION USAGE LIGHT TRUCK: 1980-89 BRONCO, ECONOLINE, F-150, F-250, F-350 1983-89 RANGER 1984-89 BRONCO II 1986-89 AEROSTAR ISSUE: A quick reference manual transmission fluid usage chart and a quick reference drivetrain lubrication usage chart for light trucks has been put together to assist technicians in the event service is required. FIGURE 1 FIGURE 2 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 89816 > Apr > 89 > Drivetrain - Lubricant Usage > Page 1137 ACTION: Refer to the transmission fluid application chart in Figure 1 for the correct fluid usage. Refer to the drivetrain lubrication application chart in Figure 2 for the correct lubricant usage. PART NUMBER PART NAME CLASS D8DZ-19C547-A Standard Transmission BG Lubricant - 5 gallons C1AZ-19590-BA Long Life Lubricant B (molybdenum disulfide) - 14.5 ounces DOAZ-19584-AA Multi-Purpose Grease - 4 ounce B tube D7AZ-19584-AA Multi-Purpose Grease - 15 B ounce aerosol can XT-2-QDX Transmission Fluid (Mercon) - V quart can (pkg. of 12) C6AZ-19580-E Gear Oil (Dana axle) - 1 gallon AG C8AZ-19B546-A Additive Friction Modifier - 4 AM ounce bottle D7AZ-19590-A Disc Brake Caliper Slide AM Grease - 4 ounce tube E8TZ-19590-A Grease - 14.5 ounces B E1TZ-19590-A Automatic Hublock Grease - 5 B ounce tube E5RY-19C547-A Merkur Synthetic Manual B Transmission Fluid OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 5970 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 86198 > Sep > 86 > Rear Locking Differential - Noise On Turns Fluid - Differential: All Technical Service Bulletins Rear Locking Differential - Noise On Turns Article No. 86-19-8 AXLE - REAR - TRACTION-LOK 7.5" AND 8.8" - NOISE ON TURNS NOISE ON TURNS - REAR AXLE - TRACTION-LOK 7.5" AND 8.8" FORD 1986 MUSTANG, THUNDERBIRD, LTD, FORD LINCOLN-MERCURY 1986 CAPRI, COUGAR, MARQUIS, MERCURY, LINCOLN TOWN CAR, MARK VII, CONTINENTAL LIGHT TRUCK 1986 AEROSTAR, RANGER, BRONCO II, BRONCO, E SERIES, F SERIES Traction-Lok limited slip differentials may exhibit a slip stick noise on turns after extended highway driving. The noise may be caused by the lubricant (friction modifier) breaking down. This condition will not damage the internal parts of the axle. However, to correct, drain and refill the axle with E0AZ-19580-A or equivalent rear axle lubricant. Refer to the appropriate 1986 Shop Manual for fill capacities. After filling, add four ounces of friction modifier, C8AZ-19B546-A or equivalent. PART NUMBER PART NAME CLASS E0AZ-19580-A Rear Axle Lubricant A C8AZ-19B546-A Friction Modifier A OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION: 4036A - Passenger Car TIME: 0.4 Hr. OPERATION: 4036A - Light Truck TIME: 0.5 Hr. DLR. CODING: Basic Part No. 4209 - Code: 53 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid - Differential: > 911211 > Jun > 91 > Engine - Lack of Power/No Start Diagnosis Ignition Rotor: All Technical Service Bulletins Engine - Lack of Power/No Start Diagnosis Article No. 91-12-11 06/12/91 LACK OF POWER 7.5L, 5.8L, 5.0L, 4.9L - CATALYTIC CONVERTER DIAGNOSTIC TIPS LIGHT TRUCK: 1986-91 BRONCO, ECONOLINE, F-150-350 SERIES 1988-91 F SUPER DUTY, F47 ISSUE: Lack of power or a no start condition may be diagnosed as an exhaust restriction caused by a plugged catalytic converter. A plugged catalytic converter (internal deterioration) is usually caused by abnormal engine operation. ACTION: Diagnose the catalytic converter to confirm internal failure. Refer to the Catalyst and Exhaust System Diagnostic Section, in the Engine/Emissions Diagnostic Shop Manual and the following procedures for service details. 1. Lack of proper HEGO operation may cause, or be the result of a rich or lean fuel condition, which could cause additional heat in the catalyst. Perform self test KOEO and KOER, service any codes. NOTE: IF TWO DIGIT CODES 41, 42, 85 OR THREE DIGIT CODES 171, 172, 173, 179, 181, 182, 183 AND 565 ARE RECEIVED, CHECK FOR PROPER HEGO GROUND. If the HEGO ground is good, the following areas may be at fault: ^ Ignition Coil ^ Distributor Cap ^ Distributor Rotor ^ Fouled Spark Plug ^ Spark Plug Wires ^ Air Filter ^ Stuck Open Injector ^ Fuel Contamination Engine OIL ^ Manifold Leaks Intake/ Exhaust ^ Fuel Pressure ^ Poor Power Ground ^ Engine Not At Normal Operating Temperature ^ HEGO Sensor 2. Spark timing that is retarded from specification may increase exhaust gas temperature and shorten catalyst life. Refer to the following procedure for service details. a. Check spark timing. Check base timing with spout disconnected. Set base timing to the specification on the vehicle emission decal. b. Check computed timing with spout connected. NOTE: COMPUTED TIMING IS EQUAL TO BASE TIMING PLUS 20~ BTDC +/- 3~. 3. Misfiring spark plugs may cause an unburned fuel air mixture to pass through the catalyst, which could cause higher than normal catalyst temperatures. Refer to the following procedure for service details. a. Check secondary ignition, hook the vehicle up to an engine analyzer and check for a secondary ignition misfire. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid - Differential: > 911211 > Jun > 91 > Engine - Lack of Power/No Start Diagnosis > Page 1147 NOTE: SERVICE ANY ITEM THAT IS NOT PERFORMING AT PROPER SPECIFICATIONS BEFORE CONTINUING. 4. Fuel pressure that is too high may cause rich air fuel mixtures to pass through the catalyst which could cause higher than normal catalyst temperatures. Refer to the following procedure for service details. a. Check fuel pressure, install fuel pressure gauge, start and run the engine at idle. Fuel pressures between 28 and 34 PSI are typical (4.9L typically is 15 PSI higher). b. Disconnect the vacuum line going to the fuel pressure regulator. Fuel pressure typically jumps to 40 PSI +/- 3 PSI (4.9L typically is 15 PSI higher). Visually inspect vacuum line for raw fuel. NOTE: FUEL PRESSURES ABOVE THESE VALUES SHOULD BE CORRECTED. HOWEVER, THIS MAY NOT BE THE CAUSE OF THE CONCERN. SERVICE AS NECESSARY. 5. Throttle plates in the throttle body not returning to the proper closed position may cause excessive catalyst temperatures during downhill grades. Refer to the following procedure for service details. a. Visually inspect the throttle body and linkage for: ^ Binding or sticking throttle linkage. ^ Tight speed control linkage or cable. ^ Vacuum line interference. ^ Electrical harness interference. NOTE: AFTERMARKET GOVERNORS, THROTTLE LINKAGE AND CABLES ASSOCIATED WITH POWER TAKE-OFF UNITS, MAY ALSO INTERFERE WITH PROPER THROTTLE RETURN. SERVICE AS NECESSARY. 6. It is extremely important that all systems related to the engine and emission systems operate properly. a. Visually inspect the engine compartment to make sure all vacuum hoses and spark plug wires are properly routed and securely connected. b. Inspect all wiring harnesses and connectors for insulation damage, burned, overheated, loose or broken conditions. c. Verify proper operation of the thermactor system. Thermactor systems that fail to dump thermactor air to the atmosphere properly or at the correct time can cause high catalyst temperatures. d. Visually inspect thermactor system for damaged or kinked hoses and perform a function test on following components: air control valve, check valve, silencer, filter and the air bypass solenoid. e. Verify proper operation of the engine cooling system thermostat. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under Basic Warranty Coverage, Emissions Warranty Coverage OPERATION DESCRIPTION TIME 911211A Diagnostics - Perform 0.5 Hrs. KOEO And KOER Self Tests 911211B Timing - Check Or Adjust 0.5 Hrs. Spark Timing, Check Computed Timing And Check Secondary Ignition System With Engine Analyzer. 911211C Check - Fuel Pressure And 0.2 Hrs. Inspect Vacuum Line For Raw Fuel. 911211D Inspect - Throttle Body And 0.1 Hrs. Linkage. 911211E Inspect - Vacuum Hoses, 0.1 Hrs. Electrical Harnesses, Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid - Differential: > 911211 > Jun > 91 > Engine - Lack of Power/No Start Diagnosis > Page 1148 Connectors And Spark Plug Wires For Routing Damage. 911211F Thermactor System - 0.3 Hrs. Inspect For Proper Operation And Damaged Component. Includes Function Check Of Air Control Valve, Thermactor Air Bypass Solenoid, Check Valves, Silencer And Filter. 911211G Thermostat - Check For 0.2 Hrs. Proper Operation. DEALER CODING BASIC PART NO. CONDITION CODE 5E212 25 OASIS CODES: 403000, 603300, 614000 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid - Differential: > 85218 > Oct > 85 > Distributor Rotor - Engine Bucking/Surging Ignition Rotor: All Technical Service Bulletins Distributor Rotor - Engine Bucking/Surging Article No. 85-21-8 ENGINE MISS - DISTRIBUTOR WITH BLADE ROTOR - SILICONE GREASE ENGINE SURGE - DISTRIBUTOR WITH BLADE ROTOR - SILICONE GREASE RADIO NOISE - DISTRIBUTOR WITH BLADE ROTOR - SILICONE GREASE FORD 1986 ESCORT, EXP, TEMPO, MUSTANG, THUNDERBIRD, TAURUS, LTD, CROWN VICTORIA LINCOLN-MERCURY 1986 LYNX, TOPAZ, CAPRI, COUGAR, SABLE, MARQUIS, CONTINENTAL, MARK VII, LINCOLN LIGHT TRUCK 1986 E/F SERIES, BRONCO, RANGER, BRONCO II, AEROSTAR CALIBRATION: All with EEC IV 1986 vehicles are equipped with a new "blade" design distributor rotor. This design replaces the multi-point rotor used in recent model years. This new rotor requires the use of silicone grease on the blade. Electrical interference can result from a blade rotor that does not have silicone grease. The electrical interference affects the distributor stator assembly and can cause engine "missing", "bucking", or "surging". These drive concerns are usually intermittent and tend to occur during crank and heavy or wide-open throttle. It is important to remember not to remove the silicone grease for radio noise concerns, on 1986 vehicles with EEC IV; removing the grease can cause driveability concerns. A future TSB article will address the radio noise issue. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid - Differential: > 911211 > Jun > 91 > Engine - Lack of Power/No Start Diagnosis > Page 1158 NOTE: SERVICE ANY ITEM THAT IS NOT PERFORMING AT PROPER SPECIFICATIONS BEFORE CONTINUING. 4. Fuel pressure that is too high may cause rich air fuel mixtures to pass through the catalyst which could cause higher than normal catalyst temperatures. Refer to the following procedure for service details. a. Check fuel pressure, install fuel pressure gauge, start and run the engine at idle. Fuel pressures between 28 and 34 PSI are typical (4.9L typically is 15 PSI higher). b. Disconnect the vacuum line going to the fuel pressure regulator. Fuel pressure typically jumps to 40 PSI +/- 3 PSI (4.9L typically is 15 PSI higher). Visually inspect vacuum line for raw fuel. NOTE: FUEL PRESSURES ABOVE THESE VALUES SHOULD BE CORRECTED. HOWEVER, THIS MAY NOT BE THE CAUSE OF THE CONCERN. SERVICE AS NECESSARY. 5. Throttle plates in the throttle body not returning to the proper closed position may cause excessive catalyst temperatures during downhill grades. Refer to the following procedure for service details. a. Visually inspect the throttle body and linkage for: ^ Binding or sticking throttle linkage. ^ Tight speed control linkage or cable. ^ Vacuum line interference. ^ Electrical harness interference. NOTE: AFTERMARKET GOVERNORS, THROTTLE LINKAGE AND CABLES ASSOCIATED WITH POWER TAKE-OFF UNITS, MAY ALSO INTERFERE WITH PROPER THROTTLE RETURN. SERVICE AS NECESSARY. 6. It is extremely important that all systems related to the engine and emission systems operate properly. a. Visually inspect the engine compartment to make sure all vacuum hoses and spark plug wires are properly routed and securely connected. b. Inspect all wiring harnesses and connectors for insulation damage, burned, overheated, loose or broken conditions. c. Verify proper operation of the thermactor system. Thermactor systems that fail to dump thermactor air to the atmosphere properly or at the correct time can cause high catalyst temperatures. d. Visually inspect thermactor system for damaged or kinked hoses and perform a function test on following components: air control valve, check valve, silencer, filter and the air bypass solenoid. e. Verify proper operation of the engine cooling system thermostat. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under Basic Warranty Coverage, Emissions Warranty Coverage OPERATION DESCRIPTION TIME 911211A Diagnostics - Perform 0.5 Hrs. KOEO And KOER Self Tests 911211B Timing - Check Or Adjust 0.5 Hrs. Spark Timing, Check Computed Timing And Check Secondary Ignition System With Engine Analyzer. 911211C Check - Fuel Pressure And 0.2 Hrs. Inspect Vacuum Line For Raw Fuel. 911211D Inspect - Throttle Body And 0.1 Hrs. Linkage. 911211E Inspect - Vacuum Hoses, 0.1 Hrs. Electrical Harnesses, Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid - Differential: > 911211 > Jun > 91 > Engine - Lack of Power/No Start Diagnosis > Page 1159 Connectors And Spark Plug Wires For Routing Damage. 911211F Thermactor System - 0.3 Hrs. Inspect For Proper Operation And Damaged Component. Includes Function Check Of Air Control Valve, Thermactor Air Bypass Solenoid, Check Valves, Silencer And Filter. 911211G Thermostat - Check For 0.2 Hrs. Proper Operation. DEALER CODING BASIC PART NO. CONDITION CODE 5E212 25 OASIS CODES: 403000, 603300, 614000 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Specifications > Capacity Specifications Fluid - Differential: Capacity Specifications TYPE: Standard 90 HP Limited-Slip 90 HP* 8.8" & 10 1/4" has removable cover, 9.0" does not CAPACITY, Refill: Front: Dana 44 3.8 pt (US) LIMITED-SLIP OR TRACTION-LOK IDENTIFICATION: Label on door lock pillar shows letter and number Dana 50 4.0 pt (US) Dana 60 5.8 pt (US) Rear: Ford w/8.8" ring gear* 5.5 pt (US) 10 1/4 ring gear* 6.5 pt (US) Dana 60 & 61 6.0 pt (US) Dana 70 HD 7.4 pt (US) Dana 70 6.5 pt (US) Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Specifications > Capacity Specifications > Page 1166 Fluid - Differential: Fluid Type Specifications BL Self-adjusting Brake Lubricant EC Ethylene Glycol Coolant Mix 50/50 with water to at least -20°F (-29°C) protection EP Extreme Pressure Gear Lubricant Ford Part No. D8DZ-19C547-A FA Automatic Transmission Fluid, Type F GL-5 Gear Oil, API Service GL-5 HBH Hydraulic Brake Fluid, Extra Heavy-Duty HP Hypoid Gear Oil Ford Part No. E0AZ-19580-A HP* Hypoid Gear Oil for Limited-Slip or Traction-Lok Differential LM Lithium Grease, with Polyethylene LS Steering Gear Lubricant MA MERCONAutomatic Transmission Fluid MERCON(R) automatic Transmission Fluid is being replaced by MERCON(R) V as a service fluid, as per TSB 06-14-4. MH Manifold Heat Valve Solvent SG Motor Oil, API Service SG Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Technical Service Bulletins > Drivetrain - Lubricant Usage Fluid - Transfer Case: Technical Service Bulletins Drivetrain - Lubricant Usage Article No. 89-8-16 ^ DRIVETRAIN - LUBRICATION USAGE ^ TRANSMISSION - MANUAL - LUBRICATION USAGE LIGHT TRUCK: 1980-89 BRONCO, ECONOLINE, F-150, F-250, F-350 1983-89 RANGER 1984-89 BRONCO II 1986-89 AEROSTAR ISSUE: A quick reference manual transmission fluid usage chart and a quick reference drivetrain lubrication usage chart for light trucks has been put together to assist technicians in the event service is required. FIGURE 1 FIGURE 2 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Technical Service Bulletins > Drivetrain - Lubricant Usage > Page 1171 ACTION: Refer to the transmission fluid application chart in Figure 1 for the correct fluid usage. Refer to the drivetrain lubrication application chart in Figure 2 for the correct lubricant usage. PART NUMBER PART NAME CLASS D8DZ-19C547-A Standard Transmission BG Lubricant - 5 gallons C1AZ-19590-BA Long Life Lubricant B (molybdenum disulfide) - 14.5 ounces DOAZ-19584-AA Multi-Purpose Grease - 4 ounce B tube D7AZ-19584-AA Multi-Purpose Grease - 15 B ounce aerosol can XT-2-QDX Transmission Fluid (Mercon) - V quart can (pkg. of 12) C6AZ-19580-E Gear Oil (Dana axle) - 1 gallon AG C8AZ-19B546-A Additive Friction Modifier - 4 AM ounce bottle D7AZ-19590-A Disc Brake Caliper Slide AM Grease - 4 ounce tube E8TZ-19590-A Grease - 14.5 ounces B E1TZ-19590-A Automatic Hublock Grease - 5 B ounce tube E5RY-19C547-A Merkur Synthetic Manual B Transmission Fluid OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 5970 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins > Engine - Oil Level Checking Procedure Engine Oil: Technical Service Bulletins Engine - Oil Level Checking Procedure Article No. 85-25-20 OIL DIPSTICK - ENGINE OIL LEVEL CHECKING PROCEDURE - GASOLINE ENGINES LIGHT TRUCK 1986 AND PRIOR MEDIUM/HEAVY TRUCK 1986 AND PRIOR Figure 17 - Dipstick To correctly check the engine oil level, the vehicle must be parked on a level surface. Allow a few minutes after shutting the engine off for oil to drain down before checking. For consistent oil level readings, insert the dipstick with the loop of the handle as shown in Figure 17. Figure 18 - Dipstick - Calibration Figure 19 - Dipstick - Calibration Dipsticks in Ford vehicles do not incorporate a Full mark. Instead, the dipstick will have marks indicating a Safe range and an Add range as shown in Figure 18 or 19. When the correct amount of oil is in the engine, the oil level indication will be in the Safe range or above the Minimum mark, but not necessarily at the top of the Safe range or at the Maximum mark. When the indicated oil level is in the Add range put one quart of oil in the engine. Recheck the oil level to determine if the oil level is now in the Safe range or above the Minimum mark. Add and recheck oil level one quart at a time until the oil level indicator moves into the Safe range or above the Minimum mark. Do not add additional oil to bring the level to the top of the Safe range or to the Maximum mark since this may result in overfill and increased oil consumption. If the accuracy of the engine oil dipstick is in doubt, it may be verified in the following manner: ^ Drain the oil and install a new filter. ^ Put in the specified amount of oil for an oil and filter change. (See owner guide) ^ Start the engine and operate a few minutes. ^ Shut off the engine and allow a few minutes for the oil to drain down. ^ Check the oil level with the dipstick. ^ If the oil level does not indicate in the Safe range or above the Minimum mark, rework or replace the dipstick. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Capacity Specifications Engine Oil: Capacity Specifications Engine oil capacity ............................................................................................................................... ........................................................... 5.0 Qts.(4.7L) Note: Add 1 Qt. with filter change. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Capacity Specifications > Page 1178 Engine Oil: Fluid Type Specifications BL Self-adjusting Brake Lubricant EC Ethylene Glycol Coolant Mix 50/50 with water to at least -20°F (-29°C) protection EP Extreme Pressure Gear Lubricant Ford Part No. D8DZ-19C547-A FA Automatic Transmission Fluid, Type F GL-5 Gear Oil, API Service GL-5 HBH Hydraulic Brake Fluid, Extra Heavy-Duty HP Hypoid Gear Oil Ford Part No. E0AZ-19580-A HP* Hypoid Gear Oil for Limited-Slip or Traction-Lok Differential LM Lithium Grease, with Polyethylene LS Steering Gear Lubricant MA MERCONAutomatic Transmission Fluid MH Manifold Heat Valve Solvent SG Motor Oil, API Service SG Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > A/C - Identification of Non Approved Refrigerants Technical Service Bulletin # 99-19-6 Date: 990920 A/C - Identification of Non Approved Refrigerants Article No. 99-19-6 09/20/99 ^ AIR CONDITIONING - IDENTIFICATION OF NON-FORD APPROVED REFRIGERANTS ^ AIR CONDITIONING - PURGING AIR FROM SYSTEM FORD: 1985-1986 LTD 1985-1988 EXP 1985-1994 TEMPO 1985-1997 THUNDERBIRD 1985-2000 CROWN VICTORIA, ESCORT, MUSTANG 1986-2000 TAURUS 1988-1993 FESTIVA 1989-1997 PROBE 1994-1997 ASPIRE 1995-2000 CONTOUR 2000 FOCUS 1985-1990 BRONCO II 1985-1996 BRONCO 1985-1997 F-250 HD, F-350 1985-2000 ECONOLINE, F-150, F-250 LD, RANGER 1986-1997 AEROSTAR 1988-1997 F SUPER DUTY 1991-2000 EXPLORER 1995-2000 WINDSTAR 1997-2000 EXPEDITION 1999-2000 SUPER DUTY F SERIES 1985-1991 CL-CLT-9000 SERIES 1985-1999 L SERIES 1985-2000 F & B SERIES 1986-1998 CARGO SERIES 1997-1998 AEROMAX, LOUISVILLE LINCOLN: 1985-1992 MARK VII 1985-2000 CONTINENTAL, TOWN CAR 1993-1998 MARK VIII 2000 LS 1998-2000 NAVIGATOR MERCURY: 1985-1986 MARQUIS 1985-1987 LYNX 1985-1994 TOPAZ 1985-1997 COUGAR 1985-2000 GRAND MARQUIS 1986-2000 SABLE 1987-1989 TRACER 1991-1994 CAPRI 1991-2000 TRACER 1995-2000 MYSTIQUE 1999-2000 COUGAR 1993-2000 VILLAGER 1997-2000 MOUNTAINEER MERKUR: 1985-1989 XR4TI 1988-1989 SCORPIO Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > A/C - Identification of Non Approved Refrigerants > Page 1183 This TSB article is being republished in its entirety to add model year vehicles ISSUE A number of non-approved/alternate refrigerants have entered the marketplace and are being advertised as "drop-in replacements" for R-12 and R-134a. The use of non-approved refrigerants such as R-22, hydrocarbons, and other refrigerant blends could cause safety, durability, and performance concerns if they are installed in Ford A/C systems. Identification of the type of refrigerant contained in vehicle A/C systems, before servicing, is necessary to prevent dealer service equipment and refrigerant supplies from being contaminated with non-approved refrigerants. ACTION Refrigerant identification must be performed prior to recovering the refrigerant into a recovery machine to prevent cross-contamination of the recovery machine and other A/C systems being serviced with that recovery machine. Refer to the following text. OTHER APPLICABLE ARTICLES: 94-14-3, 95-18-4 SUPERSEDES: 98-12-8 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 1993-2000 Model Year Vehicles, Basic Warranty Coverage For All Other Model Year Vehicles OPERATION DESCRIPTION TIME 991906A Test A/C System For 0.3 Hr. Contaminated Refrigerant DEALER CODING CONDITION BASIC PART NO. CODE R-12 49 OASIS CODES: 208000, 208999 A/C Refrigerant Analyzer Function Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > A/C - Identification of Non Approved Refrigerants > Page 1184 Ford Motor Company has approved the Rotunda Deluxe A/C Refrigerant Analyzer (198-00003) for use on Ford and Lincoln-Mercury vehicles (Figure 1). The analyzer provides the technician with a quick and easy way to identify the type and percentage of refrigerant (R-134a, R-12, R-22, or flammable hydrocarbon). The analyzer can also provide the percentage of air in the A/C system and automatically purge air from the system. The A/C Refrigerant Analyzer is designed to identify vapor gas samples taken directly from automotive air conditioning systems or refrigerant storage cylinders. Refrigerant vapor passes through the multiple sensor Non-Dispersive Infra-Red (NDIR) sensing unit. The microprocessor calculates each refrigerant type and purity percentage which is displayed on the analyzer's Liquid Crystal Display (LCD). The analyzer identifies the purity percentage of R-134a, R-12, R-22, hydrocarbon; and air in the sample. If the purity percentage of the R-134a or R-12 is 98% or greater by weight, a green "PASS" Light Emitting Diode (LED) will light. If refrigerants R-134a or R-12 do not meet 98% purity levels, the red "FAIL" LED will light. Levels of R-22 and flammable hydrocarbons above 2% will light the red "FAIL" light. If a hydrocarbon is detected above 5%, both the "FAIL" light and "HYDROCARBON" light will illuminate and a horn will sound alerting the user of potential hazards. The percent of air contained in the sample will be displayed if the R-134a or R-12 content is 98% or above. The analyzer eliminates the effect of air Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > A/C - Identification of Non Approved Refrigerants > Page 1185 when determining the refrigerant sample content because air is not considered a contaminant although air can affect A/C system performance. Air will automatically be purged until a pure refrigerant with a less than 2% by weight air measurement is reached. Recovery of Contaminated Refrigerant If contaminated refrigerant is detected, DO NOT recover the refrigerant into your R-134a or R-12 recovery/recycling equipment. Take the following actions: 1. Repeat the test to verify contaminated refrigerant is present. 2. Advise the customer of the contaminated A/C system and any additional cost to repair the system. The customer may wish to return to the service facility which performed the last A/C service. 3. Recover the contaminated refrigerant using suitable recovery-only equipment designed for capturing and storing contaminated refrigerant. This equipment must only be used to recover contaminated refrigerant to prevent the spread to other vehicles. As an alternative, contact an A/C service facility in your area which has the proper equipment for refrigerant recovery. Repairing A Contaminated A/C System Once the contaminated refrigerant is removed from the system it will be necessary to repair the system. Ford recommends that you do the following to be sure a quality repair is made: 1. Determine the cause of the failure. 2. Determine which parts will need to be replaced. 3. Flush the heat exchangers to remove any oil that may be degraded due to the contaminated refrigerant. 4. Install a new suction/accumulator. 5. Properly oil match the system to verify that the correct amount of clean refrigerant oil is present in the system. 6. Evacuate the system for 45 minutes. 7. Recharge the system, verify proper operation, and leak test. Disposal of Contaminated Refrigerant Disposal of contaminated refrigerant is a new process to the automotive industry Listed below are companies that will assist with disposal of contaminated refrigerant. Ford Motor Company has not evaluated the processes of the listed refrigerant disposal companies and is not endorsing or promoting their companies Business transactions are between the dealership and disposal companies. Disposal costs will vary between $3.00 and $5.00 per pound, plus the cost of round trip cylinder shipping. ^ Omega Refrigerant Reclamation ^ 5263 North Fourth St. ^ Irwindale, CA 91706 ^ (310) 698-0991 FAX: (310) 696-7908 ^ Full Cycle Global ^ 2966 Wireton ^ Blue Island, IL 60406 ^ (708) 388-8551 FAX: (708) 399-6550 ^ U.S. Refrigerant Reclaim, Inc. ^ 12420 North Green River Road ^ Evansville, IN 47711 ^ (800) 207-5931 FAX: (812) 867-1463 ^ Full Cycle Global ^ 343 South Airline Highway Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > A/C - Identification of Non Approved Refrigerants > Page 1186 ^ Gonzales, LA 70737 ^ (504) 644-5333 FAX: (504) 644-1609 ^ CFC Reclamation ^ 1321 Swift North ^ Kansas City, MO 64116 ^ (816) 471-2511 ^ Full Cycle Global ^ 550 James St. ^ Lakewood, NJ 08701 ^ (908) 370-3400 FAX: (908) 370-3088 ^ National Refrigerants, Inc. ^ 11401 Roosevelt Blvd. ^ Philadelphia, PA 19154 ^ (215) 698-6620 FAX: (215) 602-8205 ^ Gartech Refrigerant Reclamation ^ 2002 Platinum ^ Garland, TX 75042 ^ (214) 272-4070 FAX: (214) 272-6548 ^ Refrigerant Reclaim Services ^ 121 S. Norwood Dr. ^ Hurst, TX 76053-7807 ^ (817) 282-0022 FAX: (800) 831-6182 ^ Full Cycle Global ^ 2055 Silber, Suite 109 ^ Houston, TX 77055 ^ (713) 681-7370 FAX: (713) 681-9947 ^ Refrigerant Reclaim, Inc. ^ 122 Old Stage Coach Road ^ Dumfries, VA 22026 ^ (800) 238-5902 FAX: (703) 441-0393 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > 99-19-6 > Sep > 99 > A/C - Identification of Non Approved Refrigerants Technical Service Bulletin # 99-19-6 Date: 990920 A/C - Identification of Non Approved Refrigerants Article No. 99-19-6 09/20/99 ^ AIR CONDITIONING - IDENTIFICATION OF NON-FORD APPROVED REFRIGERANTS ^ AIR CONDITIONING - PURGING AIR FROM SYSTEM FORD: 1985-1986 LTD 1985-1988 EXP 1985-1994 TEMPO 1985-1997 THUNDERBIRD 1985-2000 CROWN VICTORIA, ESCORT, MUSTANG 1986-2000 TAURUS 1988-1993 FESTIVA 1989-1997 PROBE 1994-1997 ASPIRE 1995-2000 CONTOUR 2000 FOCUS 1985-1990 BRONCO II 1985-1996 BRONCO 1985-1997 F-250 HD, F-350 1985-2000 ECONOLINE, F-150, F-250 LD, RANGER 1986-1997 AEROSTAR 1988-1997 F SUPER DUTY 1991-2000 EXPLORER 1995-2000 WINDSTAR 1997-2000 EXPEDITION 1999-2000 SUPER DUTY F SERIES 1985-1991 CL-CLT-9000 SERIES 1985-1999 L SERIES 1985-2000 F & B SERIES 1986-1998 CARGO SERIES 1997-1998 AEROMAX, LOUISVILLE LINCOLN: 1985-1992 MARK VII 1985-2000 CONTINENTAL, TOWN CAR 1993-1998 MARK VIII 2000 LS 1998-2000 NAVIGATOR MERCURY: 1985-1986 MARQUIS 1985-1987 LYNX 1985-1994 TOPAZ 1985-1997 COUGAR 1985-2000 GRAND MARQUIS 1986-2000 SABLE 1987-1989 TRACER 1991-1994 CAPRI 1991-2000 TRACER 1995-2000 MYSTIQUE 1999-2000 COUGAR 1993-2000 VILLAGER 1997-2000 MOUNTAINEER MERKUR: 1985-1989 XR4TI 1988-1989 SCORPIO Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > 99-19-6 > Sep > 99 > A/C - Identification of Non Approved Refrigerants > Page 1192 This TSB article is being republished in its entirety to add model year vehicles ISSUE A number of non-approved/alternate refrigerants have entered the marketplace and are being advertised as "drop-in replacements" for R-12 and R-134a. The use of non-approved refrigerants such as R-22, hydrocarbons, and other refrigerant blends could cause safety, durability, and performance concerns if they are installed in Ford A/C systems. Identification of the type of refrigerant contained in vehicle A/C systems, before servicing, is necessary to prevent dealer service equipment and refrigerant supplies from being contaminated with non-approved refrigerants. ACTION Refrigerant identification must be performed prior to recovering the refrigerant into a recovery machine to prevent cross-contamination of the recovery machine and other A/C systems being serviced with that recovery machine. Refer to the following text. OTHER APPLICABLE ARTICLES: 94-14-3, 95-18-4 SUPERSEDES: 98-12-8 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 1993-2000 Model Year Vehicles, Basic Warranty Coverage For All Other Model Year Vehicles OPERATION DESCRIPTION TIME 991906A Test A/C System For 0.3 Hr. Contaminated Refrigerant DEALER CODING CONDITION BASIC PART NO. CODE R-12 49 OASIS CODES: 208000, 208999 A/C Refrigerant Analyzer Function Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > 99-19-6 > Sep > 99 > A/C - Identification of Non Approved Refrigerants > Page 1193 Ford Motor Company has approved the Rotunda Deluxe A/C Refrigerant Analyzer (198-00003) for use on Ford and Lincoln-Mercury vehicles (Figure 1). The analyzer provides the technician with a quick and easy way to identify the type and percentage of refrigerant (R-134a, R-12, R-22, or flammable hydrocarbon). The analyzer can also provide the percentage of air in the A/C system and automatically purge air from the system. The A/C Refrigerant Analyzer is designed to identify vapor gas samples taken directly from automotive air conditioning systems or refrigerant storage cylinders. Refrigerant vapor passes through the multiple sensor Non-Dispersive Infra-Red (NDIR) sensing unit. The microprocessor calculates each refrigerant type and purity percentage which is displayed on the analyzer's Liquid Crystal Display (LCD). The analyzer identifies the purity percentage of R-134a, R-12, R-22, hydrocarbon; and air in the sample. If the purity percentage of the R-134a or R-12 is 98% or greater by weight, a green "PASS" Light Emitting Diode (LED) will light. If refrigerants R-134a or R-12 do not meet 98% purity levels, the red "FAIL" LED will light. Levels of R-22 and flammable hydrocarbons above 2% will light the red "FAIL" light. If a hydrocarbon is detected above 5%, both the "FAIL" light and "HYDROCARBON" light will illuminate and a horn will sound alerting the user of potential hazards. The percent of air contained in the sample will be displayed if the R-134a or R-12 content is 98% or above. The analyzer eliminates the effect of air Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > 99-19-6 > Sep > 99 > A/C - Identification of Non Approved Refrigerants > Page 1194 when determining the refrigerant sample content because air is not considered a contaminant although air can affect A/C system performance. Air will automatically be purged until a pure refrigerant with a less than 2% by weight air measurement is reached. Recovery of Contaminated Refrigerant If contaminated refrigerant is detected, DO NOT recover the refrigerant into your R-134a or R-12 recovery/recycling equipment. Take the following actions: 1. Repeat the test to verify contaminated refrigerant is present. 2. Advise the customer of the contaminated A/C system and any additional cost to repair the system. The customer may wish to return to the service facility which performed the last A/C service. 3. Recover the contaminated refrigerant using suitable recovery-only equipment designed for capturing and storing contaminated refrigerant. This equipment must only be used to recover contaminated refrigerant to prevent the spread to other vehicles. As an alternative, contact an A/C service facility in your area which has the proper equipment for refrigerant recovery. Repairing A Contaminated A/C System Once the contaminated refrigerant is removed from the system it will be necessary to repair the system. Ford recommends that you do the following to be sure a quality repair is made: 1. Determine the cause of the failure. 2. Determine which parts will need to be replaced. 3. Flush the heat exchangers to remove any oil that may be degraded due to the contaminated refrigerant. 4. Install a new suction/accumulator. 5. Properly oil match the system to verify that the correct amount of clean refrigerant oil is present in the system. 6. Evacuate the system for 45 minutes. 7. Recharge the system, verify proper operation, and leak test. Disposal of Contaminated Refrigerant Disposal of contaminated refrigerant is a new process to the automotive industry Listed below are companies that will assist with disposal of contaminated refrigerant. Ford Motor Company has not evaluated the processes of the listed refrigerant disposal companies and is not endorsing or promoting their companies Business transactions are between the dealership and disposal companies. Disposal costs will vary between $3.00 and $5.00 per pound, plus the cost of round trip cylinder shipping. ^ Omega Refrigerant Reclamation ^ 5263 North Fourth St. ^ Irwindale, CA 91706 ^ (310) 698-0991 FAX: (310) 696-7908 ^ Full Cycle Global ^ 2966 Wireton ^ Blue Island, IL 60406 ^ (708) 388-8551 FAX: (708) 399-6550 ^ U.S. Refrigerant Reclaim, Inc. ^ 12420 North Green River Road ^ Evansville, IN 47711 ^ (800) 207-5931 FAX: (812) 867-1463 ^ Full Cycle Global ^ 343 South Airline Highway Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > 99-19-6 > Sep > 99 > A/C - Identification of Non Approved Refrigerants > Page 1195 ^ Gonzales, LA 70737 ^ (504) 644-5333 FAX: (504) 644-1609 ^ CFC Reclamation ^ 1321 Swift North ^ Kansas City, MO 64116 ^ (816) 471-2511 ^ Full Cycle Global ^ 550 James St. ^ Lakewood, NJ 08701 ^ (908) 370-3400 FAX: (908) 370-3088 ^ National Refrigerants, Inc. ^ 11401 Roosevelt Blvd. ^ Philadelphia, PA 19154 ^ (215) 698-6620 FAX: (215) 602-8205 ^ Gartech Refrigerant Reclamation ^ 2002 Platinum ^ Garland, TX 75042 ^ (214) 272-4070 FAX: (214) 272-6548 ^ Refrigerant Reclaim Services ^ 121 S. Norwood Dr. ^ Hurst, TX 76053-7807 ^ (817) 282-0022 FAX: (800) 831-6182 ^ Full Cycle Global ^ 2055 Silber, Suite 109 ^ Houston, TX 77055 ^ (713) 681-7370 FAX: (713) 681-9947 ^ Refrigerant Reclaim, Inc. ^ 122 Old Stage Coach Road ^ Dumfries, VA 22026 ^ (800) 238-5902 FAX: (703) 441-0393 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > 98-12-5 > Jun > 98 > A/C - Filtering Refrigerant After Compressor Replacement Technical Service Bulletin # 98-12-5 Date: 980622 A/C - Filtering Refrigerant After Compressor Replacement Article No. 98-12-5 06/22/98 AIR CONDITIONING - FILTERING REFRIGERANT AFTER A/C COMPRESSOR REPLACEMENT - SERVICE TIPS FORD: 1980-98 CROWN VICTORIA 1981-98 ESCORT 1982-83 FAIRMONT 1982-88 EXP 1982-97 THUNDERBIRD 1982-98 MUSTANG 1983-86 LTD 1984-94 TEMPO 1986-98 TAURUS 1988-93 FESTIVA 1989-97 PROBE 1994-98 ASPIRE 1995-98 CONTOUR LINCOLN-MERCURY: 1980-98 GRAND MARQUIS, TOWN CAR 1982-83 ZEPHYR 1982-86 CAPRI 1982-87 LN7 1982-97 COUGAR 1982-98 CONTINENTAL 1983-86 MARQUIS 1984-92 MARK VII 1984-94 TOPAZ 1986-98 SABLE 1991-94 CAPRI 1991-98 TRACER 1993-98 MARK VIII 1995-98-MYSTIQUE 1999 COUGAR LIGHT TRUCK: 1980-96 BRONCO 1980-97 F SUPER DUTY 1980-98 ECONOLINE, F-150, F-150, F-350 1983-98 RANGER 1984-90 BRONCO II 1986-97 AEROSTAR 1988-97 F-47 1991-98 EXPLORER 1993-98 VILLAGER 1995-98 WINDSTAR 1997-98 EXPEDITION, MOUNTAINEER 1999 SUPER DUTY F SERIES This TSB article is being republished in its entirety to revise the Service Procedure and to update the model years. ISSUE Vehicles that have and inoperative A/C compressor, due to internal causes, MUST have the refrigerant system cleaned to remove any debris or contaminants that may be present to prevent damage to the replacement compressor. ACTION Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > 98-12-5 > Jun > 98 > A/C - Filtering Refrigerant After Compressor Replacement > Page 1200 Install a Service Filter Kit in the refrigerant system prior to installing the replacement compressor. Refer to the following Service Procedure for details. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 96-15-5 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 1992-99 Models And 1991 Lincolns, Basic Warranty Coverage For All Other Models And Major Component Warranty Coverage For All Other Lincoins OPERATION DESCRIPTION TIME 981205A Kit Installation 1.2 Hrs. 981205B Extra Time For Refrigerant 0.4 Hr. (R-12) Recovery DEALER CODING CONDITION BASIC PART NO. CODE 19703 49 OASIS CODES: 208000, 208999 Service Procedure THIS PROCEDURE IS OPTIONAL IF THE SYSTEM IS FLUSHED USING THE ROTUNDA A/C FLUSHER. CAUTION THIS FILTERING PROCEDURE MAY BE USED FOR EITHER R-12 OR R-134a REFRIGERANT SYSTEMS. BECAUSE THE TWO (2) SYSTEMS USE DIFFERENT REFRIGERANT OILS AND BECAUSE THE COMPRESSOR COULD BE DAMAGED IF THE WRONG OIL IS USED, SYSTEM IDENTIFICATION IS VERY IMPORTANT. BE SURE SYSTEM IS CORRECTLY IDENTIFIED BEFORE STARTING THE FILTERING PROCEDURE. Each Service Filter Kit includes the following items: ^ One (1) Pancake Filter (to be installed in the liquid line between the condenser and the orifice tube) ^ One (1) Instruction Sheet NOTE ON 1993-94 RANGER/EXPLORER VEHICLES, TECHNICIANS MAY EXPERIENCE DIFFICULTY WHEN CONNECTING THE PANCAKE FILTER HOSE FITTINGS TO THE EVAPORATOR INLET WITH THE ORIFICE TUBE INSTALLED. REMOVE THE OFFICE TUBE AND RUN THE SYSTEM FOR 1 HOUR AS DESCRIBED IN THE FILTERING PROCEDURE. REINSTALL THE ORIFICE TUBE AFTER FILTERING IS COMPLETE. CAUTION FOLLOW ALL REFRIGERANT SYSTEM SAFETY AND SERVICE PRECAUTIONS OUTLINED IN THE APPROPRIATE SERVICE OR WORKSHOP MANUAL. 1. Before removing any refrigerant system components, recover the refrigerant from the system following the recycling methods outlined In the appropriate Service/Workshop Manual. 2. Remove the suction accumulator/drier assembly and drain the oil into a calibrated container. 3. Install a new suction accumulator/drier and add new refrigerant oil to replace the old oil. The quantity of the new oil to be added is the amount to match that drained from the old accumulator plus 60 mL (2 oz). Refer to the Dealer Master Parts Catalog for the correct suction accumulator/drier part number. CAUTION REMEMBER TO USE MOTORCRAFT YN-9-A REFRIGERANT COMPRESSOR OIL WITH R-12 SYSTEMS AND MOTORCRAFT YN-12-C REFRIGERANT COMPRESSOR OIL WITH R-134a SYSTEMS. FAILURE TO USE THE CORRECT REFRIGERANT OIL MAY RESULT IN DAMAGE TO SYSTEM COMPONENTS. 4. Install a new orifice tube. Refer to the Dealer Master Parts Catalog for the correct orifice tube part number. If the orifice tube in the vehicle is located in the liquid line between the condenser and the evaporator, replace the liquid line assembly. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > 98-12-5 > Jun > 98 > A/C - Filtering Refrigerant After Compressor Replacement > Page 1201 5. Install pancake filter in the liquid line between the condenser and the orifice tube, Figure 1. a. Be sure orifice inlet is toward the condenser. b. Connections can be made using Test Adapter Set D93L-19703-B, or equivalent, and flexible refrigerant hose of 2500 psi burst rating. Individual fittings are also available. 6. Remove the old compressor following Service/Workshop Manual procedures. Drain the oil into a calibrated container. 7. Drain the oil from the replacement compressor into a clean calibrated container. NOTE: IT WILL BE NECESSARY TO TRANSFER THE MAGNET CLUTCH FROM THE OLD COMPRESSOR TO THE REPLACEMENT COMPRESSOR. FOLLOW SERVICE/WORKSHOP MANUAL PROCEDURES. 8. A new FX-15 service compressor contains 207 mL (7 oz.) of R-12 refrigerant oil. A new FS-10 service compressor does not contain any oil and can be used with an R-12 or an R-134a system. CAUTION REMEMBER TO USE YN-9-A (MINERAL) OIL WITH R-12 SYSTEMS AND YN-12-C (PAG) OIL WITH R-134a SYSTEMS. FAILURE TO USE THE CORRECT REFRIGERANT OIL MAY RESULT IN DAMAGE TO SYSTEM COMPONENTS. ^ If the amount of oil drained from the removed compressor is between 90 and 148 mL (3-5 oz), pour the same amount of clean refrigerant oil into the new compressor. ^ If the amount of oil drained from the old compressor is greater than 90 mL (3 oz), pour 90 mL (3 oz) of clean refrigerant oil into the new compressor. 9. Install the new compressor following Service/Workshop Manual procedures. Make sure all mounting bolts are tightened properly. Check the tension of the compressor drive belt. Adjust if necessary. 10. Evacuate, charge and leak test the system, following Service/Workshop Manual procedures. 11. Check all refrigerant system hoses, lines and the position of the newly-installed filters to make sure they do not interfere with other engine compartment components. If necessary, use tie straps to make adjustments. 12. Set the A/C control on Max A/C, high blower and temperature control at full cold. a. Start engine and let idle briefly. b. Be sure A/C system is operating properly. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > 98-12-5 > Jun > 98 > A/C - Filtering Refrigerant After Compressor Replacement > Page 1202 13. Gradually bring the engine up to 1200 rpm by running it at lower rpms for short periods (first at 800 rpm, then at 1000 rpm). Set the engine at 1200 rpm and run it for an hour with the A/C system operating. 14. Stop the engine. NOTE: IT WILL BE NECESSARY TO RECOVER THE SYSTEM REFRIGERANT CHARGE BEFORE PROCEEDING. 15. Allow the engine to cool sufficiently to remove the fittings, flexible hoses and pancake filter from the liquid line. 16. Discard the filter. It can be used one (1) tie only. 17. Reconnect the liquid line back into the system. 18. Evacuate, charge and leak test the system. Make any necessary adjustments. 19. Check the operation of the system in all models. PART NUMBER PART NAME F8VZ-19E773-AA Filter Kit F73Z-19577-AA Refrigerant Oil - Motorcraft YN-9-A (For R-12 Refrigerant Systems Only) F7AZ-19589-DA Refrigerant Oil - Motorcraft YN-12-C (PAG-Type Oil For R-134a Refrigerant Systems Only) NOTE THE TOTAL REPAIR TIME IS FOR INSTALLING SERVICE FILTER KIT PER INSTRUCTIONS THIS INCLUDES INSTALLATION OF AND DISCARD OF FILTER. REFER TO SERVICE LABOR TIME STANDARDS MANUALS IF ADDITIONAL LABOR OPERATIONS ARE REQUIRED. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > 961710 > Aug > 96 > A/C - R12 Refrigerant Substitutes Service Tip Refrigerant: Technical Service Bulletins A/C - R12 Refrigerant Substitutes Service Tip Article No. 96-17-10 08/12/96 AIR CONDITIONING - USE OF R-12 REFRIGERANT SUBSTITUTES - SERVICE TIP FORD: 1980-93 CROWN VICTORIA 1981-93 ESCORT 1982-83 FAIRMONT 1982-88 EXP 1982-93 MUSTANG, THUNDERBIRD 1983-86 LTD 1984-94 TEMPO 1986-93 TAURUS 1988-93 FESTIVA 1989-93 PROBE LINCOLN-MERCURY: 1980-93 GRAND MARQUIS, TOWN CAR 1981-87 LYNX 1982-83 LN7, ZEPHYR 1982-86 CAPRI 1982-93 COUGAR 1982-94 CONTINENTAL 1983-86 MARQUIS 1984-92 MARK VII 1984-94 TOPAZ 1986-93 SABLE 1991-93 CAPRI, TRACER MERKUR: 1985-89 XR4TI 1988-90 SCORPIO LIGHT TRUCK: 1980-93 BRONCO, ECONOLINE, F SUPER DUTY, F-150-350 SERIES 1983-93 RANGER 1984-90 BRONCO II 1986-93 AEROSTAR 1988-93 F-47 1991-93 EXPLORER 1993 VILLAGER MEDIUM/HEAVY TRUCK: 1985-94 CARGO SERIES, F & B SERIES, L SERIES This TSB article is being republished in its entirety to list Environmental Protection Agency (EPA) reviewed NC substitutes for R-12 refrigerant. ISSUE: A number of manufacturers are producing refrigerant products which are described as being direct replacements for refrigerant R-12. ACTION: If service is required, use only new or of known quality recycled refrigerant R-12. Ford Motor Company has approved R-134a as the only refrigerant substitute for R-12. CAUTION: USING ANY UNAUTHORIZED SUBSTITUTE REFRIGERANT FOR R-12 MAY RESULT IN SEVERE DAMAGE TO THE A/C SYSTEM COMPONENTS. INFORMATION FROM THE EPA Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > 961710 > Aug > 96 > A/C - R12 Refrigerant Substitutes Service Tip > Page 1207 This information has been taken from EPA documents to address Ford specific applications and recommendations. Further EPA information on ozone-depleting substances and regulations regarding its handling can be found on the Internet at World Wide Web site: http://www.epa.gov/ozone/ In 1994, EPA established the Significant New Alternatives Policy (SNAP) program to review alternatives to ozone-depleting substances like R-12. EPA examines new substitutes for their ozone depleting, global warming, flammability, and toxicity characteristics. The SNAP process does not test these substitutes for A/C system compatibility, reliability, durability, or performance. Under the SNAP rule, each new refrigerant must be used in accordance with the following conditions: 1. Unique Fittings - Each new refrigerant must be used with a unique set of fittings to prevent the accidental mixing of different refrigerants. 2. Unique Equipment - Each refrigerant must have dedicated recovery/recycling equipment for that refrigerant. 3. Labels - Whether a vehicle is originally designed to use a new refrigerant or is retrofitted, the technician must apply a detailed label giving specific information about the alternative. This label covers up information about the old refrigerant and provides valuable details on the alternative and how it was used. The technician is required to fill in their name, company performing the retrofit, address and the date retrofitted. 4. Remove Original Refrigerant - The original R-12 must be removed from the system prior to charging with the new refrigerant. This will guarantee that the largest amount of clean R-12 is available for use in vehicles that still need it. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > 961710 > Aug > 96 > A/C - R12 Refrigerant Substitutes Service Tip > Page 1208 A summary of the refrigerants reviewed under EPA's SNAP program for use in motor vehicle air conditioning systems is in the table. OTHER APPLICABLE ARTICLES: 91-9-7, 96-15-7 SUPERSEDES: 93-23-11 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 208000, 208999, 290000 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > 94-14-3 > Jul > 94 > R-12 Refrigerant - Substitutes Refrigerant: Technical Service Bulletins R-12 Refrigerant - Substitutes Article No. 94-14-3 07/13/94 Air Conditioning - Use Of R-12 Refrigerant Substitutes - Service Tip FORD: 1980-93 CROWN VICTORIA 1981-93 ESCORT 1982-83 FAIRMONT 1982-88 EXP 1982-93 MUSTANG, THUNDERBIRD 1983-86 LTD 1984-93 TEMPO 1986-93 TAURUS 1988-93 FESTIVA 1989-93 PROBE LINCOLN-MERCURY: 1980-93 GRAND MARQUIS, TOWN CAR 1981-87 LYNX 1982-83 LN7, ZEPHYR 1982-86 CAPRI 1982-93 CONTINENTAL, COUGAR 1983-86 MARQUIS 1984-92 MARK VII 1984-93 TOPAZ 1986-93 SABLE 1991-93 CAPRI, TRACER MERKUR: 1986-89 SCORPIO, XR4TI LIGHT TRUCK: 1980-93 BRONCO, ECONOLINE, F-150-350 SERIES 1983-93 RANGER 1984-90 BRONCO II 1986-93 AEROSTAR 1988-93 F-47 1991-93 EXPLORER 1992-94 F-53 1993 VILLAGER MEDIUM/HEAVY TRUCK: 1954-90 C SERIES 1970-94 L SERIES 1979-90 CL-9000, CL-CLT-9000 SERIES 1980-94 F SERIES 1986-94 CARGO SERIES This TSB is being republished in its entirety to include Heavy Truck models. ISSUE: A number of manufacturers are producing refrigerant products which are described as being direct replacements for refrigerant R-12. The use of any unauthorized substitute refrigerant may severely damage the A/C system components. ACTION: If service is required, use only NEW or RECYCLED refrigerant R-12. Ford Motor Company has not tested or approved any R-12 refrigerant substitute at this time. R-134a is approved only for systems which specify R-134a, Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > 94-14-3 > Jul > 94 > R-12 Refrigerant - Substitutes > Page 1213 and is not compatible with R-12 systems. R-22 likewise, is not compatible with R-12 systems. CAUTION: USING ANY UNAUTHORIZED SUBSTITUTE REFRIGERANT FOR R-12 MAY RESULT IN SEVERE DAMAGE TO THE A/C SYSTEM COMPONENTS. OTHER APPLICABLE ARTICLES: 91-9-7 SUPERSEDES: 93-23-11 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 208000, 208999, 290000 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > 93206 > Sep > 93 > Air Conditioning - Use of Correct Fluorescent Tracer Dye Refrigerant: Technical Service Bulletins Air Conditioning - Use of Correct Fluorescent Tracer Dye Article No. 93-20-6 09/29/93 AIR CONDITIONING - USE OF CORRECT FLUORESCENT TRACER DYE - SERVICE TIP FORD: 1980-93 CROWN VICTORIA 1981-93 ESCORT 1982-83 FAIRMONT 1982-88 EXP 1982-93 MUSTANG, THUNDERBIRD 1983-86 LTD 1984-93 TEMPO 1986-93 TAURUS 1988-93 FESTIVA 1989-93 PROBE LINCOLN-MERCURY: 1980-93 GRAND MARQUIS, TOWN CAR 1981-87 LYNX 1982-83 LN7, ZEPHYR 1982-86 CAPRI 1982-93 CONTINENTAL, COUGAR 1983-86 MARQUIS 1984-92 MARK VII 1984-93 TOPAZ 1986-93 SABLE 1991-93 CAPRI, TRACER LIGHT TRUCK: 1980-93 BRONCO, ECONOLINE, F-150-350 SERIES 1983-93 RANGER 1984-90 BRONCO II 1986-93 AEROSTAR 1988-93 F-47 1991-93 EXPLORER 1993 VILLAGER ISSUE: Use of untested, unapproved fluorescent tracer dyes for A/C system leak checking may damage the air conditioning system. Some of these materials may not be compatible with Ford A/C systems. ACTION: When leak-checking an R-12 A/C system with a "black light", use only Rotunda-supplied Part No. 112-R0027, Fluoro-Lite brand dye. No other dyes have been approved by Ford Motor Company. NOTE: 112-R0027 DYE IS NOT COMPATIBLE WITH R-134a REFRIGERANT. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 208999 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > 9197 > May > 91 > A/C - R12 Refrigerant Service Tips Refrigerant: Technical Service Bulletins A/C - R12 Refrigerant Service Tips Article No. 91-9-7 05/01/91 AIR CONDITIONING - REFRIGERANT R-12 - SERVICE TIPS FORD: 1985-86 LTD 1985-88 EXP 1985-91 CROWN VICTORIA, ESCORT, MUSTANG, TEMPO, THUNDERBIRD 1986-91 TAURUS 1988-91 FESTIVA 1989-91 PROBE LINCOLN-MERCURY: 1985-87 LYNX 1985-91 CONTINENTAL, COUGAR, GRAND MARQUIS, MARK VII, TOPAZ, TOWN CAR 1986-91 SABLE 1987-91 TRACER 1991 CAPRI MERKUR: 1985-89 XR4TI 1988-89 SCORPIO LIGHT TRUCK: 1985-90 BRONCO II 1985-91 BRONCO, ECONOLINE, F-150-350 SERIES, RANGER 1986-91 AEROSTAR 1988-91 F SUPER DUTY 1991 EXPLORER MEDIUM/HEAVY TRUCK: 1985-90 C SERIES 1985-91 CL-CLT-9000 SERIES, F & B SERIES, L SERIES 1986-91 CARGO SERIES ISSUE: A number of manufacturers are producing refrigerant products which are described as being direct replacements for Refrigerant R-12. The use of any unauthorized substitute refrigerant may severely damage the A/C components. ACTION: If service is required, use only NEW or RECYCLED Refrigerant R-12. CAUTION: USING ANY UNAUTHORIZED SUBSTITUTE REFRIGERANT FOR R-12 MAY RESULT IN SEVERE DAMAGE TO THE A/C SYSTEM COMPONENTS. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 208000, 208200 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > Page 1222 Technical Service Bulletin # 98-12-5 Date: 980622 A/C - Filtering Refrigerant After Compressor Replacement Article No. 98-12-5 06/22/98 AIR CONDITIONING - FILTERING REFRIGERANT AFTER A/C COMPRESSOR REPLACEMENT - SERVICE TIPS FORD: 1980-98 CROWN VICTORIA 1981-98 ESCORT 1982-83 FAIRMONT 1982-88 EXP 1982-97 THUNDERBIRD 1982-98 MUSTANG 1983-86 LTD 1984-94 TEMPO 1986-98 TAURUS 1988-93 FESTIVA 1989-97 PROBE 1994-98 ASPIRE 1995-98 CONTOUR LINCOLN-MERCURY: 1980-98 GRAND MARQUIS, TOWN CAR 1982-83 ZEPHYR 1982-86 CAPRI 1982-87 LN7 1982-97 COUGAR 1982-98 CONTINENTAL 1983-86 MARQUIS 1984-92 MARK VII 1984-94 TOPAZ 1986-98 SABLE 1991-94 CAPRI 1991-98 TRACER 1993-98 MARK VIII 1995-98-MYSTIQUE 1999 COUGAR LIGHT TRUCK: 1980-96 BRONCO 1980-97 F SUPER DUTY 1980-98 ECONOLINE, F-150, F-150, F-350 1983-98 RANGER 1984-90 BRONCO II 1986-97 AEROSTAR 1988-97 F-47 1991-98 EXPLORER 1993-98 VILLAGER 1995-98 WINDSTAR 1997-98 EXPEDITION, MOUNTAINEER 1999 SUPER DUTY F SERIES This TSB article is being republished in its entirety to revise the Service Procedure and to update the model years. ISSUE Vehicles that have and inoperative A/C compressor, due to internal causes, MUST have the refrigerant system cleaned to remove any debris or contaminants that may be present to prevent damage to the replacement compressor. ACTION Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > Page 1223 Install a Service Filter Kit in the refrigerant system prior to installing the replacement compressor. Refer to the following Service Procedure for details. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 96-15-5 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 1992-99 Models And 1991 Lincolns, Basic Warranty Coverage For All Other Models And Major Component Warranty Coverage For All Other Lincoins OPERATION DESCRIPTION TIME 981205A Kit Installation 1.2 Hrs. 981205B Extra Time For Refrigerant 0.4 Hr. (R-12) Recovery DEALER CODING CONDITION BASIC PART NO. CODE 19703 49 OASIS CODES: 208000, 208999 Service Procedure THIS PROCEDURE IS OPTIONAL IF THE SYSTEM IS FLUSHED USING THE ROTUNDA A/C FLUSHER. CAUTION THIS FILTERING PROCEDURE MAY BE USED FOR EITHER R-12 OR R-134a REFRIGERANT SYSTEMS. BECAUSE THE TWO (2) SYSTEMS USE DIFFERENT REFRIGERANT OILS AND BECAUSE THE COMPRESSOR COULD BE DAMAGED IF THE WRONG OIL IS USED, SYSTEM IDENTIFICATION IS VERY IMPORTANT. BE SURE SYSTEM IS CORRECTLY IDENTIFIED BEFORE STARTING THE FILTERING PROCEDURE. Each Service Filter Kit includes the following items: ^ One (1) Pancake Filter (to be installed in the liquid line between the condenser and the orifice tube) ^ One (1) Instruction Sheet NOTE ON 1993-94 RANGER/EXPLORER VEHICLES, TECHNICIANS MAY EXPERIENCE DIFFICULTY WHEN CONNECTING THE PANCAKE FILTER HOSE FITTINGS TO THE EVAPORATOR INLET WITH THE ORIFICE TUBE INSTALLED. REMOVE THE OFFICE TUBE AND RUN THE SYSTEM FOR 1 HOUR AS DESCRIBED IN THE FILTERING PROCEDURE. REINSTALL THE ORIFICE TUBE AFTER FILTERING IS COMPLETE. CAUTION FOLLOW ALL REFRIGERANT SYSTEM SAFETY AND SERVICE PRECAUTIONS OUTLINED IN THE APPROPRIATE SERVICE OR WORKSHOP MANUAL. 1. Before removing any refrigerant system components, recover the refrigerant from the system following the recycling methods outlined In the appropriate Service/Workshop Manual. 2. Remove the suction accumulator/drier assembly and drain the oil into a calibrated container. 3. Install a new suction accumulator/drier and add new refrigerant oil to replace the old oil. The quantity of the new oil to be added is the amount to match that drained from the old accumulator plus 60 mL (2 oz). Refer to the Dealer Master Parts Catalog for the correct suction accumulator/drier part number. CAUTION REMEMBER TO USE MOTORCRAFT YN-9-A REFRIGERANT COMPRESSOR OIL WITH R-12 SYSTEMS AND MOTORCRAFT YN-12-C REFRIGERANT COMPRESSOR OIL WITH R-134a SYSTEMS. FAILURE TO USE THE CORRECT REFRIGERANT OIL MAY RESULT IN DAMAGE TO SYSTEM COMPONENTS. 4. Install a new orifice tube. Refer to the Dealer Master Parts Catalog for the correct orifice tube part number. If the orifice tube in the vehicle is located in the liquid line between the condenser and the evaporator, replace the liquid line assembly. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > Page 1224 5. Install pancake filter in the liquid line between the condenser and the orifice tube, Figure 1. a. Be sure orifice inlet is toward the condenser. b. Connections can be made using Test Adapter Set D93L-19703-B, or equivalent, and flexible refrigerant hose of 2500 psi burst rating. Individual fittings are also available. 6. Remove the old compressor following Service/Workshop Manual procedures. Drain the oil into a calibrated container. 7. Drain the oil from the replacement compressor into a clean calibrated container. NOTE: IT WILL BE NECESSARY TO TRANSFER THE MAGNET CLUTCH FROM THE OLD COMPRESSOR TO THE REPLACEMENT COMPRESSOR. FOLLOW SERVICE/WORKSHOP MANUAL PROCEDURES. 8. A new FX-15 service compressor contains 207 mL (7 oz.) of R-12 refrigerant oil. A new FS-10 service compressor does not contain any oil and can be used with an R-12 or an R-134a system. CAUTION REMEMBER TO USE YN-9-A (MINERAL) OIL WITH R-12 SYSTEMS AND YN-12-C (PAG) OIL WITH R-134a SYSTEMS. FAILURE TO USE THE CORRECT REFRIGERANT OIL MAY RESULT IN DAMAGE TO SYSTEM COMPONENTS. ^ If the amount of oil drained from the removed compressor is between 90 and 148 mL (3-5 oz), pour the same amount of clean refrigerant oil into the new compressor. ^ If the amount of oil drained from the old compressor is greater than 90 mL (3 oz), pour 90 mL (3 oz) of clean refrigerant oil into the new compressor. 9. Install the new compressor following Service/Workshop Manual procedures. Make sure all mounting bolts are tightened properly. Check the tension of the compressor drive belt. Adjust if necessary. 10. Evacuate, charge and leak test the system, following Service/Workshop Manual procedures. 11. Check all refrigerant system hoses, lines and the position of the newly-installed filters to make sure they do not interfere with other engine compartment components. If necessary, use tie straps to make adjustments. 12. Set the A/C control on Max A/C, high blower and temperature control at full cold. a. Start engine and let idle briefly. b. Be sure A/C system is operating properly. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > Page 1225 13. Gradually bring the engine up to 1200 rpm by running it at lower rpms for short periods (first at 800 rpm, then at 1000 rpm). Set the engine at 1200 rpm and run it for an hour with the A/C system operating. 14. Stop the engine. NOTE: IT WILL BE NECESSARY TO RECOVER THE SYSTEM REFRIGERANT CHARGE BEFORE PROCEEDING. 15. Allow the engine to cool sufficiently to remove the fittings, flexible hoses and pancake filter from the liquid line. 16. Discard the filter. It can be used one (1) tie only. 17. Reconnect the liquid line back into the system. 18. Evacuate, charge and leak test the system. Make any necessary adjustments. 19. Check the operation of the system in all models. PART NUMBER PART NAME F8VZ-19E773-AA Filter Kit F73Z-19577-AA Refrigerant Oil - Motorcraft YN-9-A (For R-12 Refrigerant Systems Only) F7AZ-19589-DA Refrigerant Oil - Motorcraft YN-12-C (PAG-Type Oil For R-134a Refrigerant Systems Only) NOTE THE TOTAL REPAIR TIME IS FOR INSTALLING SERVICE FILTER KIT PER INSTRUCTIONS THIS INCLUDES INSTALLATION OF AND DISCARD OF FILTER. REFER TO SERVICE LABOR TIME STANDARDS MANUALS IF ADDITIONAL LABOR OPERATIONS ARE REQUIRED. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > Page 1226 Refrigerant: Technical Service Bulletins Air Conditioning - Use of Correct Fluorescent Tracer Dye Article No. 93-20-6 09/29/93 AIR CONDITIONING - USE OF CORRECT FLUORESCENT TRACER DYE - SERVICE TIP FORD: 1980-93 CROWN VICTORIA 1981-93 ESCORT 1982-83 FAIRMONT 1982-88 EXP 1982-93 MUSTANG, THUNDERBIRD 1983-86 LTD 1984-93 TEMPO 1986-93 TAURUS 1988-93 FESTIVA 1989-93 PROBE LINCOLN-MERCURY: 1980-93 GRAND MARQUIS, TOWN CAR 1981-87 LYNX 1982-83 LN7, ZEPHYR 1982-86 CAPRI 1982-93 CONTINENTAL, COUGAR 1983-86 MARQUIS 1984-92 MARK VII 1984-93 TOPAZ 1986-93 SABLE 1991-93 CAPRI, TRACER LIGHT TRUCK: 1980-93 BRONCO, ECONOLINE, F-150-350 SERIES 1983-93 RANGER 1984-90 BRONCO II 1986-93 AEROSTAR 1988-93 F-47 1991-93 EXPLORER 1993 VILLAGER ISSUE: Use of untested, unapproved fluorescent tracer dyes for A/C system leak checking may damage the air conditioning system. Some of these materials may not be compatible with Ford A/C systems. ACTION: When leak-checking an R-12 A/C system with a "black light", use only Rotunda-supplied Part No. 112-R0027, Fluoro-Lite brand dye. No other dyes have been approved by Ford Motor Company. NOTE: 112-R0027 DYE IS NOT COMPATIBLE WITH R-134a REFRIGERANT. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 208999 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > Page 1227 Refrigerant: Technical Service Bulletins R-12 Refrigerant - Substitutes Article No. 94-14-3 07/13/94 Air Conditioning - Use Of R-12 Refrigerant Substitutes - Service Tip FORD: 1980-93 CROWN VICTORIA 1981-93 ESCORT 1982-83 FAIRMONT 1982-88 EXP 1982-93 MUSTANG, THUNDERBIRD 1983-86 LTD 1984-93 TEMPO 1986-93 TAURUS 1988-93 FESTIVA 1989-93 PROBE LINCOLN-MERCURY: 1980-93 GRAND MARQUIS, TOWN CAR 1981-87 LYNX 1982-83 LN7, ZEPHYR 1982-86 CAPRI 1982-93 CONTINENTAL, COUGAR 1983-86 MARQUIS 1984-92 MARK VII 1984-93 TOPAZ 1986-93 SABLE 1991-93 CAPRI, TRACER MERKUR: 1986-89 SCORPIO, XR4TI LIGHT TRUCK: 1980-93 BRONCO, ECONOLINE, F-150-350 SERIES 1983-93 RANGER 1984-90 BRONCO II 1986-93 AEROSTAR 1988-93 F-47 1991-93 EXPLORER 1992-94 F-53 1993 VILLAGER MEDIUM/HEAVY TRUCK: 1954-90 C SERIES 1970-94 L SERIES 1979-90 CL-9000, CL-CLT-9000 SERIES 1980-94 F SERIES 1986-94 CARGO SERIES This TSB is being republished in its entirety to include Heavy Truck models. ISSUE: A number of manufacturers are producing refrigerant products which are described as being direct replacements for refrigerant R-12. The use of any unauthorized substitute refrigerant may severely damage the A/C system components. ACTION: If service is required, use only NEW or RECYCLED refrigerant R-12. Ford Motor Company has not tested or approved any R-12 refrigerant substitute at this time. R-134a is approved only for systems which specify R-134a, Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > Page 1228 and is not compatible with R-12 systems. R-22 likewise, is not compatible with R-12 systems. CAUTION: USING ANY UNAUTHORIZED SUBSTITUTE REFRIGERANT FOR R-12 MAY RESULT IN SEVERE DAMAGE TO THE A/C SYSTEM COMPONENTS. OTHER APPLICABLE ARTICLES: 91-9-7 SUPERSEDES: 93-23-11 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 208000, 208999, 290000 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Capacity Specifications Refrigerant: Capacity Specifications MAKE, YEAR & MODEL Kg. Oz. FORD TRUCKS 1992 Bronco, F-Series pickup 1.3 44 1992-89 Aerostar 1.5 56 1992-83 Bronco II, Explorer, Ranger 0.9 32 E-Series van: Main unit 1.6 54 Auxiliary unit 2.0 70 1991-84 Bronco, F-Series pickup 1.4 48 1988-86 Aerostar 1.4 54 1983 Bronco, F-Series pickup 1.6 54 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Capacity Specifications > Page 1231 Refrigerant: Fluid Type Specifications Type ..................................................................................................................................................... ............................................... Refrigerant 12 (R-12) Ford Part Number ............................................. ........................................................................................................................................ D4AZ-19B519-A Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Capacity Specifications Refrigerant Oil: Capacity Specifications Air Conditioning Specifications Compressor Ford does not specify a given amount of oil for the compressor. When a compressor is replaced, drain the old compressor oil into a measuring cup. Then record the amound removed from the compressor. This is the amount to be added to the new compressor. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Capacity Specifications > Page 1236 Refrigerant Oil: Fluid Type Specifications Compressor ................................................................................................................... 500 viscosity (C9AZ-19557-B or Motorcraft VN-2 or equivalent) Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Manual Bleeding Brake Bleeding: Service and Repair Manual Bleeding NOTE: Bleed primary and secondary hydraulic brake systems separately, bleeding longest line first on each system. Do not allow reservoir to run dry during bleeding operation. Never reuse fluid that has been drained from hydraulic system. 1. Loosen master cylinder to hydraulic line nuts and wrap shop cloths around tubing below fitting to absorb escaping brake fluid. 2. Depress brake pedal slowly by hand to floor of cab, forcing air trapped in master cylinder out at fitting. 3. Hold pedal down and tighten fittings, then release brake pedal. NOTE: Releasing brake pedal before fittings are tightened will allow air to enter the master cylinder. 4. Repeat steps 1 through 3 until air ceases to escape at fittings and brake pedal is firm. 5. Bleed rear brakes as follows: RR, LR, RF, LF WARNING: Do not bleed the brakes with the drums removed. The wheel-cylinders will over-extend and eject the pistons. a. Pump pedal several times, then hold pedal down firmly. WARNING: Do not Full Stroke the brake pedal, this may damage the master cylinder. Place a 2 inch block of wood under the brake pedal to prevent Full Stroking. b. With pedal firmly depressed, open bleeder screw on one rear brake until pedal fades to floor, then close bleeder valve. NOTE: Do not release the brake pedal until the bleeder valve is fully shut. c. Repeat procedure until a continuous flow of brake fluid is released from bleeder valve. d. Repeat steps 5a through 5c on other rear brake. 6. Bleed front brakes using same procedure as for rear brakes. 7. Fill master cylinder reservoirs to 1/4 inch from top of reservoirs. 9. Check brake operation and ensure pedal is firm, road test vehicle. For additional information see Bleeding Notes. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Manual Bleeding > Page 1241 Brake Bleeding: Service and Repair Master Cylinder Bleeding 1. Support the master cylinder body in a vise, and fill both fluid reservoirs with heavy duty DOT 3 brake fluid. 2. Install plugs in the front and rear brake outlet ports. Bleed the rear brake outlet system first. 3. Loosen the plug in the rear brake outlet port. Depress the primary piston slowly to force the air out of the master cylinder. Tighten plug while piston is depressed or air will enter the master cylinder. 4. Repeat this procedure until air ceases to exit at the outlet port. 5. Repeat steps 3 and 4 for the front brake outlet port with the rear brake outlet plugged. 6. Tighten the plugs and try to depress the piston. Depressing the piston should be harder after all air is expelled. 7. Install the cover and diaphragm assembly making sure the cover retainer is tightened securely. Remove the plugs. For additional information see Bench Bleeding. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Manual Bleeding > Page 1242 Brake Bleeding: Service and Repair Pressure Bleeding Be sure the bleeder tank contains enough of the specified brake fluid to complete the bleeding operation. Charge the tank with approximately 69-206 kPa (10-30 psi). Never exceed 345 kPa (50 psi). Never use brake fluid that has been drained from the hydraulic system. Bleed the longest lines first 1. Clean all dirt from the master cylinder reservoir cap. 2. Remove the master cylinder reservoir cap and fill the master cylinder reservoir with the specified brake fluid. Install the pressure bleeder adapter tool on the master cylinder, and attach the bleeder tank hose to the fitting on the adapter. NOTE: Master cylinder pressure bleeder adapter tools are available from the manufacturers of pressure bleeding equipment. Follow the manufacturer's instructions when installing the adapter. 3. Place a 3/8 inch box wrench on the bleeder fitting on the right rear brake wheel cylinder. Attach a bleeder tube snugly to the bleeder fitting. 4. Open the valve on the bleeder tank and admit pressurized brake fluid to the master cylinder reservoir. 5. Submerge the free end of the tube in a container partially filled with clean brake fluid, and loosen the bleeder fitting. 6. When air bubbles no longer appear in the fluid at the submerged end of the bleeder tube, close the bleeder fitting and remove the tube. 7. Repeat Steps 3 through 6 at the opposite wheel cylinder. On front brakes, bleed the right front caliper first. 8. When the bleeding operation is completed, close the bleeder tank valve and remove the tank hose from the adapter fitting. 9. Remove the pressure bleeder adapter tool. Fill the master cylinder reservoirs with the specified brake fluid to within 3 mm (1/8 in) from the top of the filler neck. Install the master cylinder cover. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Circuit Breaker > Component Information > Locations Circuit Breaker: Locations Circuit Location Amps Power Door Locks.....................Fuse Panel................30 Power Windows........................Fuse Panel................20 Power Tailgate Window................Fuse Panel................25 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Circuit Breaker > Component Information > Locations > Page 1247 Circuit Breaker: Testing and Inspection BRONCO & F-100---350 SERIES The circuit breaker is located in the wiper control switch on all rotary switches. For slide wiper control switches, the circuit breaker is located in the fuse panel. All pin terminal switches have a circuit breaker rating of 8 {1/4} amps. All blade terminal switches have a rating of 7 amps. Two separate tests are necessary to check for correct circuit breaker operation when circuit breaker is part of wiper switch. Fig. 3 Testing circuit breaker. Bronco & F-100---350 Series Test 1 1. Short tester leads together and adjust current draw until it equals circuit breaker rating. 2. Connect switch to tester, Fig. 3. 3. Leave switch connected to tester for 10 minutes, holding current reading on multimeter at rated current. If circuit breaker opens, replace wiper switch assembly. Test 2 1. Short tester leads together and adjust current draw until it equals circuit breaker rating. 2. Connect switch to tester, Fig. 3. 3. Hold current reading on multimeter at twice the rated current of circuit breaker. If it takes more than 30 seconds for tester reading to drop to zero, replace wiper switch assembly. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations Fuse Block: Locations Under LH side of instrument panel, near parking brake. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions Fuse Block: Diagram Information and Instructions Symbol Identification Wire Color Code Identification Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1253 NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1254 Fig. 1 Fuse Panel Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fusible Link > Component Information > Locations > Fuse Link C Fusible Link: Locations Fuse Link C LH Side Of Dash Panel To Junction Block Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fusible Link > Component Information > Locations > Fuse Link C > Page 1259 Fusible Link: Locations Fuse Link D RH Fender Apron At Starter Relay Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fusible Link > Component Information > Locations > Fuse Link C > Page 1260 Fusible Link: Locations Fuse Link E RH Fender Apron At Starter Relay Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fusible Link > Component Information > Locations > Fuse Link C > Page 1261 Fusible Link: Locations Fuse Link F RH Fender Apron At Starter Relay Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fusible Link > Component Information > Locations > Fuse Link C > Page 1262 Fusible Link: Locations Fuse Link C LH Side Of Dash Panel To Junction Block Fuse Link D RH Fender Apron Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fusible Link > Component Information > Locations > Fuse Link C > Page 1263 At Starter Relay Fuse Link E RH Fender Apron At Starter Relay Fuse Link F RH Fender Apron At Starter Relay Fuse Link G Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fusible Link > Component Information > Locations > Fuse Link C > Page 1264 RH Fender Apron At Starter Relay Fuse Link H RH Fender Apron At Starter Relay Fuse Link I Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fusible Link > Component Information > Locations > Fuse Link C > Page 1265 RH Fender Apron At Starter Relay Fuse Link L RH Fender Apron & Dash Panel. Near Dash Panel Applicable to: Diesel Engine Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fusible Link > Component Information > Locations > Fuse Link C > Page 1266 Fuse Link M RH Fender Apron & Dash Panel. Near Dash Panel Applicable to: Diesel Engine Fuse Link R Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fusible Link > Component Information > Locations > Fuse Link C > Page 1267 RH Fender Apron & Dash Panel. Near Voltage Regulator Applicable to: Diesel Engine Fuse Link V Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fusible Link > Component Information > Locations > Fuse Link C > Page 1268 RH Fender Apron & Dash Panel. Near Voltage Regulator Applicable to: Diesel Engine Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Service Reminder Indicators > Coolant Level Indicator Lamp > Component Information > Description and Operation Coolant Level Indicator Lamp: Description and Operation This lamp will be illuminated when engine coolant level in the radiator drops below a pre-determined level. To turn lamp off, check cooling system, then add coolant to bring system to proper level. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Service Reminder Indicators > EGR Maintenance Light > Component Information > Locations EGR Maintenance Light: Locations Back View Of I/P On I/P, To Left Of Steering Column Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Service Reminder Indicators > Emissions Maintenance Light > Component Information > Technical Service Bulletins > Emission Maintenance Warning Module - Service Emissions Maintenance Light: Technical Service Bulletins Emission Maintenance Warning Module - Service Article No. 89-22-8 ^ EMISSION MAINTENANCE WARNING MODULE SERVICE INFORMATION ^ LAMP - "EMISSIONS/CHECK ENGINE" - EMISSION MAINTENANCE WARNING MODULE SERVICE INFORMATION LIGHT TRUCK: 1985-89 BRONCO 1985-87 BRONCO II 1985-89 ECONOLINE, F-150, F-250, F-350 1985-88 RANGER 1986-87 AEROSTAR MEDIUM/HEAVY TRUCK: 1988-90 F & B SERIES ISSUE: The Emission Maintenance Warning "EMW" module operates a light that is located on the instrument panel. For 1985-87 model year vehicles, the light will display the word "EMISSIONS". For 1988-89 model year vehicles, the light will display the words "CHECK ENGINE". When the light is lit, it is indicating that the 60,000 mile emission maintenance should be performed. After the maintenance is performed the EMW module must be reset to zero time. Another type of module is the "IMS" module. This module is not part of the light circuit and does not require maintenance. At a predetermined time, the IMS module directs the EEC IV processor to make a strategy change. A third type of module is the "COMBO" module. This module combines the functions of the IMS and the EMW modules. ACTION: Refer to the following module application charts for the specific vehicle application and location of the different types of modules. NOTE: FOR APPLICATIONS NOT LOSTED IN THE FOLLOWING MODULE APPLICATION CHARTS, THE "CHECK ENGINE" LIGHT IS CONTROLLED BY THE EEC IV PROCESSOR. THESE VEHICLES DO NOT USE THE "EMW" MODULE. 1985 & 1986 MODULE APPLICATION CHART 1987 MODULE APPLICATION CHART Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Service Reminder Indicators > Emissions Maintenance Light > Component Information > Technical Service Bulletins > Emission Maintenance Warning Module - Service > Page 1280 1988 MODULE APPLICATION CHART 1989 MODULE APPLICATION CHART 1990 MODULE APPLICATION CHART PART NUMBER PART NAME CLASS E5TZ-12B514-C EMW Module - 1000 Hr BM E5TZ-12B514-A EMW Module - 2000 Hr AM E7TZ-12B514-A COMBO Module BM OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 2300, 2500 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Service Reminder Indicators > Maintenance Required Lamp/Indicator > Component Information > Description and Operation Maintenance Required Lamp/Indicator: Description and Operation NOTE: This lamp is used only on models with Federal emissions systems. The lamp will be illuminated after approximately 60,000 miles of operation. The amber lens is located on the instrument panel and has the word Emissions, Emiss or EGR printed on it. On 1988 Ranger models with 2.0L/4-122 engine, the lamp lens will indicate Check Engine. After performing the required emission control maintenance, the module must be replaced or reset, depending on type of module used. On module equipped with reset feature, reset the module as follows: 1. Place ignition switch in the Off position. 2. On Aerostar models, the module is located under the instrument panel near the bulkhead connector. On Bronco and F-Series, the module is attached to the instrument cluster to the left of the steering column. On Bronco II and Ranger models, the module is located on the righthand side of the instrument panel below the glove compartment. On E Series models, the module is located under the lefthand side of the instrument panel. 3. On all models, insert a suitable phillips head screwdriver through .2 inch diameter hole located on module near the reset sticker and lightly press down and hold. 4. While still lightly pressing down on screwdriver, turn ignition switch to Run position. The emissions maintenance lamp should remain illuminated for as long as the screwdriver is pressing down. Hold screwdriver in position for approximately five seconds. 5. Remove screwdriver, lamp should go out after approximately two to five seconds, indicating the module has been reset. If lamp fails to go out, repeat reset procedure. Place ignition switch in the Off position. 6. Turn ignition switch to Run position and check to ensure emission maintenance lamp is illuminated for two to five seconds. After approximately two to five seconds the lamp should turn off. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Service Reminder Indicators > Oil Level Warning Indicator > Component Information > Technical Service Bulletins > Customer Interest for Oil Level Warning Indicator: > 932410 > Nov > 93 > Instrument Cluster Warning Lights - Dimly Lit Oil Level Warning Indicator: Customer Interest Instrument Cluster Warning Lights - Dimly Lit Article No. 93-24-10 11/24/93 ^ LAMP - MALFUNCTION OF FOUR PIN LOW OIL LEVEL RELAY - VEHICLES BUILT AFTER 8/1/92 OR 1983-1993 VEHICLES THAT HAVE HAD SERVICE REPLACEMENT IGNITION SWITCHES AFTER 8/1/92 ^ LAMPS - INSTRUMENT CLUSTER WARNING LIGHTS DIMLY LIT - VEHICLES BUILT AFTER 8/1/92 OR 1983-1993 VEHICLES THAT HAVE HAD SERVICE REPLACEMENT IGNITION SWITCHES AFTER 8/1/92 FORD: 1983 FAIRMONT 1983-89 CROWN VICTORIA, ESCORT 1983-93 MUSTANG, THUNDERBIRD 1983-94 PROBE 1984-86 LTD 1984-94 TEMPO LINCOLN-MERCURY: 1983 LN7, ZEPHYR 1983-87 CONTINENTAL, LYNX 1983-89 GRAND MARQUIS, TOWN CAR 1983-93 COUGAR 1984-86 CAPRI, MARQUIS 1984-94 TOPAZ LIGHT TRUCK: 1983-91 BRONCO 1983-93 ECONOLINE, F-150-350 SERIES, RANGER 1986-91 AEROSTAR 1991-93 EXPLORER ISSUE: The instrument cluster warning light(s) may be dimly lit or there may be a malfunction of the four pin low oil relay on vehicles so equipped. This could be due to the ignition switch. ACTION: If the vehicle displays the subject symptoms and meets the following conditions, replace the ignition switch. Refer to the appropriate Car or Light Truck Service Manual (Section 13-04 for 1983-1990 Cars, Section 11-04 for 1991-1993 Cars and Section 13-05 for 1983-1990 Light Trucks, Section 11-05 for 1991-1993 Light Trucks) for removal and installation procedures. Refer to the Parts Block in this article for correct parts usage. CONDITIONS ^ The vehicle has 14401 wiring attached to the P2 terminal of the ignition switch. Refer to the wiring schematic and/or Electrical And Vacuum Troubleshooting Manual (EVTM) for the concern vehicle. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Service Reminder Indicators > Oil Level Warning Indicator > Component Information > Technical Service Bulletins > Customer Interest for Oil Level Warning Indicator: > 932410 > Nov > 93 > Instrument Cluster Warning Lights - Dimly Lit > Page 1292 ^ The vehicle is equipped with one of the ignition switches identified in the Ignition Switch Part Number Chart. NOTE: THE SERVICE PART NUMBERS FOR THE REPLACEMENT IGNITION SWITCHES WILL HAVE THE SAME PART NUMBERS AS THOSE REPLACED. THE NEW SWITCH HAS BEEN IMPROVED TO CORRECT THE SUBJECT ISSUE. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of The Bumper To Bumper For 1992/93 Models, Basic Warranty Coverage For All Other Models Except Lincolns. Major Component Warranty Coverage For Lincolns OPERATION DESCRIPTION TIME 932410A Replace Ignition Switch - 0.5 Hr. All Light and Compact Trucks DEALER CODING BASIC PART NO. CONDITION CODE 11572 X1 OASIS CODES: 201000, 201100, 206000 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Service Reminder Indicators > Oil Level Warning Indicator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oil Level Warning Indicator: > 932410 > Nov > 93 > Instrument Cluster Warning Lights - Dimly Lit Oil Level Warning Indicator: All Technical Service Bulletins Instrument Cluster Warning Lights Dimly Lit Article No. 93-24-10 11/24/93 ^ LAMP - MALFUNCTION OF FOUR PIN LOW OIL LEVEL RELAY - VEHICLES BUILT AFTER 8/1/92 OR 1983-1993 VEHICLES THAT HAVE HAD SERVICE REPLACEMENT IGNITION SWITCHES AFTER 8/1/92 ^ LAMPS - INSTRUMENT CLUSTER WARNING LIGHTS DIMLY LIT - VEHICLES BUILT AFTER 8/1/92 OR 1983-1993 VEHICLES THAT HAVE HAD SERVICE REPLACEMENT IGNITION SWITCHES AFTER 8/1/92 FORD: 1983 FAIRMONT 1983-89 CROWN VICTORIA, ESCORT 1983-93 MUSTANG, THUNDERBIRD 1983-94 PROBE 1984-86 LTD 1984-94 TEMPO LINCOLN-MERCURY: 1983 LN7, ZEPHYR 1983-87 CONTINENTAL, LYNX 1983-89 GRAND MARQUIS, TOWN CAR 1983-93 COUGAR 1984-86 CAPRI, MARQUIS 1984-94 TOPAZ LIGHT TRUCK: 1983-91 BRONCO 1983-93 ECONOLINE, F-150-350 SERIES, RANGER 1986-91 AEROSTAR 1991-93 EXPLORER ISSUE: The instrument cluster warning light(s) may be dimly lit or there may be a malfunction of the four pin low oil relay on vehicles so equipped. This could be due to the ignition switch. ACTION: If the vehicle displays the subject symptoms and meets the following conditions, replace the ignition switch. Refer to the appropriate Car or Light Truck Service Manual (Section 13-04 for 1983-1990 Cars, Section 11-04 for 1991-1993 Cars and Section 13-05 for 1983-1990 Light Trucks, Section 11-05 for 1991-1993 Light Trucks) for removal and installation procedures. Refer to the Parts Block in this article for correct parts usage. CONDITIONS ^ The vehicle has 14401 wiring attached to the P2 terminal of the ignition switch. Refer to the wiring schematic and/or Electrical And Vacuum Troubleshooting Manual (EVTM) for the concern vehicle. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Service Reminder Indicators > Oil Level Warning Indicator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oil Level Warning Indicator: > 932410 > Nov > 93 > Instrument Cluster Warning Lights - Dimly Lit > Page 1298 ^ The vehicle is equipped with one of the ignition switches identified in the Ignition Switch Part Number Chart. NOTE: THE SERVICE PART NUMBERS FOR THE REPLACEMENT IGNITION SWITCHES WILL HAVE THE SAME PART NUMBERS AS THOSE REPLACED. THE NEW SWITCH HAS BEEN IMPROVED TO CORRECT THE SUBJECT ISSUE. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of The Bumper To Bumper For 1992/93 Models, Basic Warranty Coverage For All Other Models Except Lincolns. Major Component Warranty Coverage For Lincolns OPERATION DESCRIPTION TIME 932410A Replace Ignition Switch - 0.5 Hr. All Light and Compact Trucks DEALER CODING BASIC PART NO. CONDITION CODE 11572 X1 OASIS CODES: 201000, 201100, 206000 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Service Reminder Indicators > Oil Level Warning Indicator > Component Information > Technical Service Bulletins > Page 1299 Oil Level Warning Indicator: Description and Operation This system is used to indicate a low engine oil level condition. The lamp will be illuminated during engine starting. If oil level is sufficient, the lamp will go off when engine is operating. If oil level is low the lamp will remain on until engine oil is added and the ignition switch is placed in the Off position. The module may take a few minutes to reset. If the engine is started during this period, the last recorded reading will be displayed. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Tire Wear - Toe Set Prior Vehicle Service Tires: Technical Service Bulletins Tire Wear - Toe Set Prior Vehicle Service Article No. 86-24-28 TIRE WEAR - TOE SET PRIOR TO VEHICLE PLACEMENT INTO SERVICE VEHICLES WITH SNOWPLOW SCHOOL BUSES, AMBULANCES LIGHT TRUCK 1985-86 RANGER, F-SERIES, BRONCO, ECONOLINE Certain model vehicles have a significant weight change on the front axle between manufacture by Ford and placement into service. This occurs when incomplete vehicles are completed by a body company or when equipment is added to a complete vehicle (i.e., winches, plows, tool boxes, etc.). This weight change can affect toe setting so these vehicles require that toe be reset. Figure 25 The tag shown in Figure 25 is attached to the steering column of vehicles originally built with the intent to add additional equipment. These vehicles require toe reset. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Tire Wear - Toe Set Prior Vehicle Service > Page 1305 Tires: Technical Service Bulletins Front Tires - Irregular Wear Pattern Article No. 86-24-27 TIRE WEAR - FRONT - IRREGULAR PATTERN LIGHT TRUCK 1985-87 ALL LIGHT TRUCKS Vehicles may experience front tire wear with all season/all terrain tires described as irregular, heel and toe, or diagonal. The condition may be related to alignment settings, vehicle usage, and tire tread/ carcass/compound design. Tires with minimal wear conditions should be crossrotated to the rear and alignment checked and set to Shop Manual preferred settings for toe. In cases of severe wear, obtain the complete alignment readings and tire information. Contact both your Ford Representative and Tire Manufacturer's Representative for their assistance and participation in resolving the customer's concern. Contacting the "local" tire store may not obtain the assistance which may be available from the tire manufacturer. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Tire Wear - Toe Set Prior Vehicle Service > Page 1306 Tires: Technical Service Bulletins Tires - Best Pressure For Load Application ^33GTIRE - LOAD CAPACITY VERSUS INFLATION PRESSURE ^ TIRE - P - METRIC PASSENGER TIRES USED ON LIGHT TRUCKS ^ TIRE WEAR - EFFECTS OF INFLATION AND LOAD Article No. 89-9-16 LIGHT TRUCK: 1984-89 ALL LIGHT TRUCK LINES ISSUE: Tire wear can be affected by inflation and load. Good tread life is dependent on maintaining proper air pressure in the tires. Other factors that affect tire wear are: ^ alignment ^ speed ^ road surfaces ACTION: Keep tires inflated to the recommended pressures to obtain maximum tread life. Use the following charts and procedures to arrive at the best tire pressure for each load application. FIGURE 1 The chart in Figure 1 shows the affect of inflation and load on tire tread life. Use the chart by finding the specified inflation pressure for the vehicle as shown on the certification label and locating that pressure on the specified inflation pressure on the chart. The affects of actual air pressure and load can now be read directly off the chart. Tire load carrying capacity is a function of tire design and inflation pressures. Each tire has molded into the sidewall a maximum pressure for a specific usage. Use the following guidelines to determine load carrying capacity. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Tire Wear - Toe Set Prior Vehicle Service > Page 1307 FIGURE 2 ^ For P-metric passenger tires on passenger cars, the values are as shown on the tire. ^ For P-metric passenger tires on light trucks, the load ratings are reduced to 91% to reflect the "harsher" truck environment, Figure 2. ^ For light truck style tires used on light trucks, the values are as shown for tires used in single wheel applications. ^ For light truck style tires used in dual wheel applications, the tire capacities are derated. Often, inflation pressures for specific vehicles are less than maximum capacity because the load to be carried is less than the maximum tire capacity. Inflation pressures for originally installed size tires on a vehicle are shown on the vehicle certification label along with the tire size and rated capacity for the axle system. Check the size and inflation information on the label to properly inflate the tires. Be sure that the same size tire is actually on the vehicle and then inflate it to the label's specified pressure. If other than original size tires are on the vehicle, the label's pressures are probably not correct To find proper pressures for other than original tires, use the following procedure. 1. Obtain both front and rear axle capacity ratings (GAWRR and GAWRF). 2. Divide each number by 2 to obtain the capacity at the tire. FIGURE 3 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Tire Wear - Toe Set Prior Vehicle Service > Page 1308 3. For single wheel usage, look up the pressure in the proper chart which will meet the needed capacity, Figure 3. 4. Check the tire side wall label to see if it permits inflation to that pressure. If lower load range tires were installed (i.e., C vs. D or E), the tires may not have the needed capability. 5. Divide the value found in Step 2 by 2 again to obtain individual tire requirements for dual rear wheels. 6. Using a dual wheel inflation pressure chart, Figure 3, determine correct pressure to achieve adequate load capacities. 7. Consult the local tire outlet or the tire manufacturer's home office about tires not shown in the tables. OTHER APPLICABLE ARTICLES: 87-10-11 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 3300 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 911116 > May > 91 > Wheel - Mounting Surface Distorted Lug/Pilot Holes Wheels: Customer Interest Wheel - Mounting Surface Distorted Lug/Pilot Holes Article No. 91-11-16 05/30/91 ^ WHEEL - DISTORTED PILOT HOLES OR LUG HOLES - WITH 16 X 6 SINGLE STEEL WHEELS ^ VIBRATION - WHEEL MOUNTING SURFACE DISTORTED - WITH 16 X 6 SINGLE STEEL WHEELS LIGHT TRUCK: 1985-91 E-250-350, F-250-350 ISSUE: Wheel vibration may be caused by distorted pilot holes or lug holes on the wheel. This does not allow sufficient clamp load between the lug nut, the wheel and the rotor/hub. It may also be difficult to remove the distorted wheel from the vehicle or to place the wheel on the vehicle in a different location. ACTION: To determine if a wheel has been damaged and should not be reused, refer to the following service procedure for details. NOTE: THIS PROCEDURE ONLY APPLIES TO PART # E7UA-1015-JA (16 X 6 SINGLE STEEL WHEEL) INSPECT FOR WHEEL DAMAGE 1. Remove the wheel from the hub. If the wheel is difficult to remove, DO NOT reuse the wheel. 2. Visually inspect the wheel for distortion (turned-up) scallops in the pilot hole. If the pilot hole is distorted, DO NOT reuse the wheel. 3. Inspect the distorted lug holes by placing a lug nut in the lug hole cone seat of the wheel and inspect from the reverse side. If the lug protrudes through the lug hole, DO NOT reuse the wheel. 4. Inspect the wheel mounting surface for distortion. a. Lay a straight edge across the mounting surface of the wheel (the surface of the wheel which makes contact with the rear brake drum or front rotor). b. The straight edge should contact the outer edge of the mounting surface, lying between the bolt holes and across the center of the pilot hole. c. The clearance between the straight edge and the pilot hole can not exceed 0.0300 inch, the straight edge should not contact the pilot holes. If the clearance is more than 0.0300 or the straight edge makes contact with the pilot holes, DO NOT reuse the wheel. INSTALL WHEEL 1. Inspect for lubricants on the studs and lug nuts. 2. If lubricants are present, clean throughly using naphtha or equivalent. 3. Torque lug nuts to (140 ft.lbs./190 N-m) using a torque wrench according to the Shop Manual, Section 04-04. CAUTION: EXCESSIVE TORQUE MAY CAUSE DISTORTION OF THE WHEEL. INADEQUATE TORQUE MAY NOT PROVIDE ADEQUATE CLAMPING FORCE TO ASSURE WHEEL RETENTION. PART NUMBER PART NAME CLASS E5TZ-1015-B Wheel AM OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION DESCRIPTION TIME 911116A Wheel-Inspect 0.7 hrs 911116B Replace One Wheel And 0.4 Hr. Dynamic Balance 911116C Replace Two Wheels And 0.8 Hr. Dynamic Balance Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 911116 > May > 91 > Wheel - Mounting Surface Distorted Lug/Pilot Holes > Page 1317 911116D Replace Three Wheels And 1.2 Hr. Dynamic Balance 911116E Replace Four Wheels And 1.6 Hr. Dynamic Balance DEALER CODING BASIC PART NO. CONDITION CODE 1015 67 OASIS CODES: 306000, 703000 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 911116 > May > 91 > Wheel - Mounting Surface Distorted Lug/Pilot Holes Wheels: All Technical Service Bulletins Wheel - Mounting Surface Distorted Lug/Pilot Holes Article No. 91-11-16 05/30/91 ^ WHEEL - DISTORTED PILOT HOLES OR LUG HOLES - WITH 16 X 6 SINGLE STEEL WHEELS ^ VIBRATION - WHEEL MOUNTING SURFACE DISTORTED - WITH 16 X 6 SINGLE STEEL WHEELS LIGHT TRUCK: 1985-91 E-250-350, F-250-350 ISSUE: Wheel vibration may be caused by distorted pilot holes or lug holes on the wheel. This does not allow sufficient clamp load between the lug nut, the wheel and the rotor/hub. It may also be difficult to remove the distorted wheel from the vehicle or to place the wheel on the vehicle in a different location. ACTION: To determine if a wheel has been damaged and should not be reused, refer to the following service procedure for details. NOTE: THIS PROCEDURE ONLY APPLIES TO PART # E7UA-1015-JA (16 X 6 SINGLE STEEL WHEEL) INSPECT FOR WHEEL DAMAGE 1. Remove the wheel from the hub. If the wheel is difficult to remove, DO NOT reuse the wheel. 2. Visually inspect the wheel for distortion (turned-up) scallops in the pilot hole. If the pilot hole is distorted, DO NOT reuse the wheel. 3. Inspect the distorted lug holes by placing a lug nut in the lug hole cone seat of the wheel and inspect from the reverse side. If the lug protrudes through the lug hole, DO NOT reuse the wheel. 4. Inspect the wheel mounting surface for distortion. a. Lay a straight edge across the mounting surface of the wheel (the surface of the wheel which makes contact with the rear brake drum or front rotor). b. The straight edge should contact the outer edge of the mounting surface, lying between the bolt holes and across the center of the pilot hole. c. The clearance between the straight edge and the pilot hole can not exceed 0.0300 inch, the straight edge should not contact the pilot holes. If the clearance is more than 0.0300 or the straight edge makes contact with the pilot holes, DO NOT reuse the wheel. INSTALL WHEEL 1. Inspect for lubricants on the studs and lug nuts. 2. If lubricants are present, clean throughly using naphtha or equivalent. 3. Torque lug nuts to (140 ft.lbs./190 N-m) using a torque wrench according to the Shop Manual, Section 04-04. CAUTION: EXCESSIVE TORQUE MAY CAUSE DISTORTION OF THE WHEEL. INADEQUATE TORQUE MAY NOT PROVIDE ADEQUATE CLAMPING FORCE TO ASSURE WHEEL RETENTION. PART NUMBER PART NAME CLASS E5TZ-1015-B Wheel AM OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION DESCRIPTION TIME 911116A Wheel-Inspect 0.7 hrs 911116B Replace One Wheel And 0.4 Hr. Dynamic Balance 911116C Replace Two Wheels And 0.8 Hr. Dynamic Balance Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 911116 > May > 91 > Wheel - Mounting Surface Distorted Lug/Pilot Holes > Page 1323 911116D Replace Three Wheels And 1.2 Hr. Dynamic Balance 911116E Replace Four Wheels And 1.6 Hr. Dynamic Balance DEALER CODING BASIC PART NO. CONDITION CODE 1015 67 OASIS CODES: 306000, 703000 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 90199 > Sep > 90 > Lug Nuts - Proper Torqueing Procedure Wheels: All Technical Service Bulletins Lug Nuts - Proper Torqueing Procedure ^ BRAKE SHUDDER - ROTOR DISTORTED - OVERTIGHTENED LUG NUTS ^ WHEEL - NUT INSTALLATION - SERVICE TIP Article No. 90-19-9 FORD: 1986-91 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS, TEMPO, THUNDERBIRD 1988-91 FESTIVA 1989-91 PROBE LINCOLN-MERCURY: 1986 CAPRI 1986-87 LYNX 1986-91 CONTINENTAL, COUGAR, GRAND MARQUIS, MARK VII, SABLE, TOPAZ, TOPAZ, TOWN CAR 1987-89 TRACER 1991 CAPRI, TRACER MERKUR: 1985-88 XR4TI 1988-89 SCORPIO LIGHT TRUCK: 1986-90 BRONCO II 1986-91 AEROSTAR, BRONCO, ECONOLINE, F-150-350 SERIES, RANGER 1988-91 F SUPER DUTY 1991 EXPLORER ISSUE: The use of a power impact wrench to install wheel nuts provides minimal torque control. Undertightening may allow the lug nuts to loosen, and can result in the wheel separating from the vehicle. Overtightening of wheel nuts may cause brake rotor distortion that could result in a brake shudder. Overtightening may cause distortion of the wheel. This can result in a change in the diameter of the center (axle) hole and make it difficult to remove from the axle it is mounted on or difficult or impossible to install on another axle with a smaller center hole diameter. ACTION: Use a manual torque wrench to tighten wheel nuts. Refer to the approriate Shop Manual for specific torque values. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 306000, 301000 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 90199 > Sep > 90 > Lug Nuts - Proper Torqueing Procedure Wheels: All Technical Service Bulletins Lug Nuts - Proper Torqueing Procedure ^ BRAKE SHUDDER - ROTOR DISTORTED - OVERTIGHTENED LUG NUTS ^ WHEEL - NUT INSTALLATION - SERVICE TIP Article No. 90-19-9 FORD: 1986-91 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS, TEMPO, THUNDERBIRD 1988-91 FESTIVA 1989-91 PROBE LINCOLN-MERCURY: 1986 CAPRI 1986-87 LYNX 1986-91 CONTINENTAL, COUGAR, GRAND MARQUIS, MARK VII, SABLE, TOPAZ, TOPAZ, TOWN CAR 1987-89 TRACER 1991 CAPRI, TRACER MERKUR: 1985-88 XR4TI 1988-89 SCORPIO LIGHT TRUCK: 1986-90 BRONCO II 1986-91 AEROSTAR, BRONCO, ECONOLINE, F-150-350 SERIES, RANGER 1988-91 F SUPER DUTY 1991 EXPLORER ISSUE: The use of a power impact wrench to install wheel nuts provides minimal torque control. Undertightening may allow the lug nuts to loosen, and can result in the wheel separating from the vehicle. Overtightening of wheel nuts may cause brake rotor distortion that could result in a brake shudder. Overtightening may cause distortion of the wheel. This can result in a change in the diameter of the center (axle) hole and make it difficult to remove from the axle it is mounted on or difficult or impossible to install on another axle with a smaller center hole diameter. ACTION: Use a manual torque wrench to tighten wheel nuts. Refer to the approriate Shop Manual for specific torque values. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 306000, 301000 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Page 1333 Wheels: Specifications 5 LUG WHEEL 1/2-20 .................................................................................................................................................. ........................................... 135 Nm (100 lb ft) 8 LUG WHEEL 9/16-18 ................................................................................................................................................ ........................................... 190 Nm (140 lb ft) NOTE: Torque specifications are for clean, dirt and paint free dry bolt and nut threads. Never use oil or grease on studs and nuts. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Specifications Wheel Bearing: Specifications Wheel Adjusting Nut [1] ....................................................................................................................... ........................................... 30-33 Nm (22-25 ft lbs) Bearing End Play .............................................................................................................................................................. 0.025-0.254mm (0.001-0.010 in) [1] Back off the adjusting nut 1/8 turn and install the retainer and new cotter pin without additional movement of the adjusting nut. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Specifications > Page 1337 Wheel Bearing: Adjustments 1. Raise the vehicle until the tire clears the floor and install safety stands. 2. Remove the wheel cover. 3. Remove the grease cap from the hub. Wipe the excess grease from the end of the spindle. Remove the cotter pin and locknut. 4. Loosen the adjusting nut three turns. Attempt to obtain running clearance between the rotor brake surface and the disc pads by rocking the wheel, hub and rotor assembly in and out several times to push the pads away from the rotor. If running clearance cannot be maintained throughout bearing adjustment in Steps 5 and 6, the caliper must be removed. NOTE: Do not pry on the phenolic caliper piston. 5. Tighten the wheel adjusting nut to 30-33 Nm (22-25 ft lbs) while rotating the disc brake rotor in the opposite direction. 6. Back off the adjusting nut 1/8 turn and install the retainer and new cotter pin without additional movement of the adjusting nut. Bearing end play should be 0.025-0.254mm (0.001-0.010 in). Bend the ends of the cotter pin around the castellated flange of the locknut. 7. Check front wheel rotation. If the wheel rotates properly, reinstall the grease cap and wheel cover. If rotation is noisy or rough, remove and inspect the bearings. Service as required. WARNING: Before driving the vehicle, pump the brake pedal several times to restore normal brake pedal travel. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Specifications > Page 1338 Wheel Bearing: Service and Repair Wheel bearing lubricant is a lithium-base grease. Sodium-base grease is not compatible with lithium-base grease and should not be intermixed. Therefore, do not lubricate front and/or rear wheel bearings without first identifying the type of original wheel bearing lubricant. Usage of incompatible bearing lubricants may result in premature lubricant breakdown. REMOVAL Front Hub And Rotor Assembly 1. Raise the vehicle until the tire clears the floor and remove the wheel and tire assembly. 2. Remove the brake caliper and secure to the underbody to prevent damage to the brake hose. It is not necessary to disconnect the hose from the caliper. Do not let the caliper hang with its weight on the brake hose or the hose may become stretched, twisted or ruptured. See: Brakes and Traction Control/Disc Brake System/Brake Caliper/Service and Repair 3. Remove the grease cap, cotter pin, retainer adjusting nut and washer. 4. Remove the outer bearing cone and roller. 5. Pull the hub and rotor off the spindle and remove and discard the grease seal. 6. Remove the inner bearing cone and roller from the hub. Remove all traces of old lubricant from bearings, hub and axle spindle. 7. Inspect the cups for scratches, pits or cracks. If the cups are worn or damaged, remove them with a drift. Clean the inner and outer bearing cones and rollers with solvent and dry thoroughly. CAUTION: Do not spin the bearings dry with compressed air. 8. Inspect the cones and rollers for cracks, nicks, brinelling, or seized rollers. Inspect the grease retainer and replace it if it is cracked, nicked, dented or worn. 9. Cover the spindle with a clean cloth. A water dampened cloth or water based solution should be used to remove and dust or loose dirt from the brake assembly. Remove the cloth from the spindle carefully to prevent dirt from falling on the spindle. NOTE: Do not use compressed air. INSTALLATION Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Specifications > Page 1339 Installing Bearing Cups (Typical) 1. If inner or outer bearing cups were removed, install replacement inner and outer bearing cups in the hub with the appropriate bearing cup replacer tool. Be sure to seat the cups properly in the hub. The cups will be properly seated when they are fully bottomed. Replace grease retainers. Polish grease retainer journal on spindle with 400 grit sandpaper. Clean with clean cloth. 2. Pack the inside of the hub with lithium-base grease or equivalent. Fill the hub until the grease is flush with the inside diameters of both bearing cups. Pack the bearing cones and rollers with wheel bearing grease. Use a bearing packer for this operation. If a packer is not available, work as much lubricant as possible between the rollers and cages. Lubricate the cone surfaces with grease. Installing Grease Seal (Typical) 3. Place the inner bearing cone and roller in the inner cup and install the new grease seal. Be sure that the seal is fully seated. 4. Install the hub and rotor on the wheel spindle. Keep the hub centered on the spindle to prevent damage to the grease retainer or the spindle threads. 5. Install the outer bearing cone and roller and the flat washer on the spindle, then install the adjusting nut, and adjust the wheel bearing. 6. Install the retainer, new cotter pin, and grease cap. 7. Install the caliper. 8. Install the wheel and tire assembly. 9. Lower vehicle and torque the lug nuts to specification. Re-install the wheel cover or hub cap. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Specifications > Page 1340 WARNING: Before driving the vehicle, pump the brake pedal several times to restore normal brake pedal travel. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Cover > Component Information > Technical Service Bulletins > Customer Interest for Wheel Cover: > 90118 > May > 90 > Wheel Cover - Centers Damaged By Stones Wheel Cover: Customer Interest Wheel Cover - Centers Damaged By Stones Article No. 90-11-8 WHEEL COVERS-16 INCH TURBINE WHEEL-CENTERS DAMAGED BY STONES LIGHT TRUCK: 1986-90 E-250, E-350, F-250, F-350 ISSUE: The wheel cover centers may be damaged by stones and debris hitting the cover. This condition is most noticeable during cold weather because the wheel cover material becomes very brittle. ACTION: Install new wheel covers made of a more durable plastic. The color of the new plastic material is gray which will help hide any stone chips. Refer to the following Wheel Cover Application Chart for correct parts usage. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION DESCRIPTION TIME 901108A Install Wheel Covers 0.2 Hr. DEALER CODING BASIC PART NO. CONDITION CODE 1130 01 OASIS CODES: 1052, 3300 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Cover > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Cover: > 90118 > May > 90 > Wheel Cover - Centers Damaged By Stones Wheel Cover: All Technical Service Bulletins Wheel Cover - Centers Damaged By Stones Article No. 90-11-8 WHEEL COVERS-16 INCH TURBINE WHEEL-CENTERS DAMAGED BY STONES LIGHT TRUCK: 1986-90 E-250, E-350, F-250, F-350 ISSUE: The wheel cover centers may be damaged by stones and debris hitting the cover. This condition is most noticeable during cold weather because the wheel cover material becomes very brittle. ACTION: Install new wheel covers made of a more durable plastic. The color of the new plastic material is gray which will help hide any stone chips. Refer to the following Wheel Cover Application Chart for correct parts usage. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION DESCRIPTION TIME 901108A Install Wheel Covers 0.2 Hr. DEALER CODING BASIC PART NO. CONDITION CODE 1130 01 OASIS CODES: 1052, 3300 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Axle Nut > Component Information > Technical Service Bulletins > Front Drive Axle - Retaining Nut Revision Axle Nut: Technical Service Bulletins Front Drive Axle - Retaining Nut Revision Article No. 85-21-13 AXLE - FRONT DRIVE (DANA 441FSHD, 501FS, 60F MONOBEAM) - NEW WHEEL BEARING LOCKNUTS LIGHT TRUCK 1985-86 F-250 HD/350 (4x4) Front axle hub and rotor assembly bearing adjusting and retaining nuts and lockwashers have been revised. Removal and installation procedures are the same as outlined in Section 11-12 of the 1985-86 Light Truck Shop Manual except the Front Wheel Bearing Adjusting Spanner, tool number D78T-1197-B (6-prong) is used with the old design adjusting nut (Dana part number 33732) and tool number D85T-1197-A (4- prong) is required for the new nuts (Dana part number 621029). OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > Customer Interest: > 87721 > Apr > 87 > Wheels- Lug Nuts Bind On Studs Wheel Fastener: Customer Interest Wheels- Lug Nuts Bind On Studs Article No. WHEEL - LUG NUTS BIND ON STUDS - VEHICLES 87-7-21 WITH 9/16" STUDS AND SINGLE REAR WHEELS LIGHT TRUCK: 1983-87 E-250/350, F-250/350 ISSUE: Some lug nuts may be difficult to remove due to nut crimping. The lug nuts are designed to be free-running as opposed to a "prevailing" torque style. The freerunning nuts may have "crimped in" against the stud when torqued. ACTION: To correct this, use new replacement nuts which will not "crimp in" when tightened to the recommended torque of 140 ft.lbs. (190 N-m). CAUTION: Lug nuts should be torqued by hand, not with an impact wrench, and retorqued at intervals specified in the Owner Guide. PART NUMBER PART NAME CLASS E7TZ-1120-A Lug Nut - R.H. Thread A - Package of 4 E7TZ-1121-A Lug Nut - L.H. Thread A - Package of 4 OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual OPERATION: SP870721A - Replace lug nuts TIME: 0.5 Hr. OPERATION: 1107B - Replace wheel studs TIME: Refer to the appropriate Service Labor Time Standards Manual OPERATION: "M" Time - Replace lug nut stuck on spinning stud, if required Requires District Authorization DLR. CODING: Basic Part No. 1120 - Code: 41 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Fastener: > 98-5A-4 > Mar > 98 > Lug Nuts - Proper Installation/Torqueing Procedure Wheel Fastener: All Technical Service Bulletins Lug Nuts - Proper Installation/Torqueing Procedure Article No. 98-5A-4 ^ BRAKES - PREVENTING BRAKE VIBRATION - SERVICE TIP ^ WHEELS - PROPER LUG TORQUE PROCEDURES - SERVICE TIP FORD: 1972-97 THUNDERBIRD 1976-86 LTD 1976-97 MUSTANG 1981-97 CROWN VICTORIA 1982-88 EXP 1982-98 ESCORT 1984-94 TEMPO 1986-97 TAURUS 1988-93 FESTIVA 1989-97 PROBE 1994-97 ASPIRE 1995-98 CONTOUR LINCOLN-MERCURY: 1979-83 MONARCH, ZEPHYR 1979-97 COUGAR 1980-83 MARK VI 1980-98 CONTINENTAL, TOWN CAR 1981-86 LYNX 1983-86 MARQUIS 1984-92 MARK VII 1984-94 TOPAZ 1986-97 SABLE 1987-89 TRACER 1987-97 GRAND MARQUIS 1991-94 CAPRI 1991-97 TRACER 1993-98 MARK VIII 1995-98 MYSTIQUE LIGHT TRUCK: 1979-96 BRONCO 1979-97 ECONOLINE, F-150-350 SERIES 1984-90 BRONCO II 1984-97 RANGER 1986-97 AEROSTAR 1988-97 F SUPER DUTY 1991-97 EXPLORER 1993-97 VILLAGER 1995-98 WINDSTAR 1997 EXPEDITION 1998 NAVIGATOR ISSUE: The use of air impact tools to tighten wheel lug nuts can lead to overtightened and/or unevenly tightened wheel lug nuts. Air impact tools typically used for wheel lug nut removal and installation can generate up to 475 N.m (350 lb-ft) of torque. Overtightened and/or unevenly torqued wheel lug nuts may cause: ^ Brake vibration ^ Distortion of the wheel hub ^ Distortion of the brake rotor Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Fastener: > 98-5A-4 > Mar > 98 > Lug Nuts - Proper Installation/Torqueing Procedure > Page 1372 ^ Brake rotor runout ^ Damage to the wheel ^ Damage to the wheel nuts and studs ACTION: All wheel lug nuts should only be tightened to specification using a torque wrench or by using the Rotunda ACCUTORO 164-R0314 or equivalent on a 1/2" drive air impact tool. The "ACCUTORO" lug nut sockets limit the torque of the air impact tool, preventing overtightening or uneven tightening of the wheel lug nuts. The torque limiting devices (regulators) on air impact tools will not reduce the output torque enough to prevent overtightening of the wheel lug nuts. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Fastener: > 98-5A-4 > Mar > 98 > Lug Nuts - Proper Installation/Torqueing Procedure > Page 1373 NOTE: REFER TO THE APPROPRIATE SERVICE MANUAL OR THE CHART IN FIGURE 1 FOR THE CORRECT WHEEL LUG NUT TORQUE SPECIFICATION. THE CHART IN FIGURE 1 ALSO PROVIDES THE CORRECT "ACCUTORO" LUG NUT SOCKET TO USE. The "ACCUTORO" socket is intended for lug nut installation, not removal. When using the "ACCUTORO" socket, the output torque of the air impact tool must be set to 217-339 N.m (160-250 lb-ft), usually this will be the lowest setting on the air impact tool. The "ACCUTORO" lug nut sockets are available through Rotunda Equipment. The four-piece set (164-R0314) fits most Ford Motor Company cars and light trucks. The tool set consists of four (4) lug nut sockets and a storage case. The set can be ordered by calling Rotunda Equipment at 1-800-ROT-UNDA (768-8632). CAUTION: AIR IMPACT TOOLS SHOULD NOT BE USED TO TIGHTEN WHEEL LUG NUTS UNLESS THE "ACCUTORO" LUG NUT SOCKET OF THE CORRECT SPECIFICATION IS USED. NOTE: DO NOT USE AIR IMPACT TOOLS ON LOCKING WHEEL LUG NUTS. THEY ARE TO BE HAND-TORQUED ONLY. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 97-17-6 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 301000, 303000, 306000 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Fastener: > 87721 > Apr > 87 > Wheels- Lug Nuts Bind On Studs Wheel Fastener: All Technical Service Bulletins Wheels- Lug Nuts Bind On Studs Article No. WHEEL - LUG NUTS BIND ON STUDS - VEHICLES 87-7-21 WITH 9/16" STUDS AND SINGLE REAR WHEELS LIGHT TRUCK: 1983-87 E-250/350, F-250/350 ISSUE: Some lug nuts may be difficult to remove due to nut crimping. The lug nuts are designed to be free-running as opposed to a "prevailing" torque style. The freerunning nuts may have "crimped in" against the stud when torqued. ACTION: To correct this, use new replacement nuts which will not "crimp in" when tightened to the recommended torque of 140 ft.lbs. (190 N-m). CAUTION: Lug nuts should be torqued by hand, not with an impact wrench, and retorqued at intervals specified in the Owner Guide. PART NUMBER PART NAME CLASS E7TZ-1120-A Lug Nut - R.H. Thread A - Package of 4 E7TZ-1121-A Lug Nut - L.H. Thread A - Package of 4 OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual OPERATION: SP870721A - Replace lug nuts TIME: 0.5 Hr. OPERATION: 1107B - Replace wheel studs TIME: Refer to the appropriate Service Labor Time Standards Manual OPERATION: "M" Time - Replace lug nut stuck on spinning stud, if required Requires District Authorization DLR. CODING: Basic Part No. 1120 - Code: 41 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Fastener: > 98-5A-4 > Mar > 98 > Lug Nuts - Proper Installation/Torqueing Procedure Wheel Fastener: All Technical Service Bulletins Lug Nuts - Proper Installation/Torqueing Procedure Article No. 98-5A-4 ^ BRAKES - PREVENTING BRAKE VIBRATION - SERVICE TIP ^ WHEELS - PROPER LUG TORQUE PROCEDURES - SERVICE TIP FORD: 1972-97 THUNDERBIRD 1976-86 LTD 1976-97 MUSTANG 1981-97 CROWN VICTORIA 1982-88 EXP 1982-98 ESCORT 1984-94 TEMPO 1986-97 TAURUS 1988-93 FESTIVA 1989-97 PROBE 1994-97 ASPIRE 1995-98 CONTOUR LINCOLN-MERCURY: 1979-83 MONARCH, ZEPHYR 1979-97 COUGAR 1980-83 MARK VI 1980-98 CONTINENTAL, TOWN CAR 1981-86 LYNX 1983-86 MARQUIS 1984-92 MARK VII 1984-94 TOPAZ 1986-97 SABLE 1987-89 TRACER 1987-97 GRAND MARQUIS 1991-94 CAPRI 1991-97 TRACER 1993-98 MARK VIII 1995-98 MYSTIQUE LIGHT TRUCK: 1979-96 BRONCO 1979-97 ECONOLINE, F-150-350 SERIES 1984-90 BRONCO II 1984-97 RANGER 1986-97 AEROSTAR 1988-97 F SUPER DUTY 1991-97 EXPLORER 1993-97 VILLAGER 1995-98 WINDSTAR 1997 EXPEDITION 1998 NAVIGATOR ISSUE: The use of air impact tools to tighten wheel lug nuts can lead to overtightened and/or unevenly tightened wheel lug nuts. Air impact tools typically used for wheel lug nut removal and installation can generate up to 475 N.m (350 lb-ft) of torque. Overtightened and/or unevenly torqued wheel lug nuts may cause: ^ Brake vibration ^ Distortion of the wheel hub ^ Distortion of the brake rotor Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Fastener: > 98-5A-4 > Mar > 98 > Lug Nuts - Proper Installation/Torqueing Procedure > Page 1383 ^ Brake rotor runout ^ Damage to the wheel ^ Damage to the wheel nuts and studs ACTION: All wheel lug nuts should only be tightened to specification using a torque wrench or by using the Rotunda ACCUTORO 164-R0314 or equivalent on a 1/2" drive air impact tool. The "ACCUTORO" lug nut sockets limit the torque of the air impact tool, preventing overtightening or uneven tightening of the wheel lug nuts. The torque limiting devices (regulators) on air impact tools will not reduce the output torque enough to prevent overtightening of the wheel lug nuts. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Fastener: > 98-5A-4 > Mar > 98 > Lug Nuts - Proper Installation/Torqueing Procedure > Page 1384 NOTE: REFER TO THE APPROPRIATE SERVICE MANUAL OR THE CHART IN FIGURE 1 FOR THE CORRECT WHEEL LUG NUT TORQUE SPECIFICATION. THE CHART IN FIGURE 1 ALSO PROVIDES THE CORRECT "ACCUTORO" LUG NUT SOCKET TO USE. The "ACCUTORO" socket is intended for lug nut installation, not removal. When using the "ACCUTORO" socket, the output torque of the air impact tool must be set to 217-339 N.m (160-250 lb-ft), usually this will be the lowest setting on the air impact tool. The "ACCUTORO" lug nut sockets are available through Rotunda Equipment. The four-piece set (164-R0314) fits most Ford Motor Company cars and light trucks. The tool set consists of four (4) lug nut sockets and a storage case. The set can be ordered by calling Rotunda Equipment at 1-800-ROT-UNDA (768-8632). CAUTION: AIR IMPACT TOOLS SHOULD NOT BE USED TO TIGHTEN WHEEL LUG NUTS UNLESS THE "ACCUTORO" LUG NUT SOCKET OF THE CORRECT SPECIFICATION IS USED. NOTE: DO NOT USE AIR IMPACT TOOLS ON LOCKING WHEEL LUG NUTS. THEY ARE TO BE HAND-TORQUED ONLY. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 97-17-6 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 301000, 303000, 306000 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > Page 1385 Wheel Fastener: Specifications 5 LUG WHEEL 1/2-20 .................................................................................................................................................. ........................................... 135 Nm (100 lb ft) 8 LUG WHEEL 9/16-18 ................................................................................................................................................ ........................................... 190 Nm (140 lb ft) NOTE: Torque specifications are for clean, dirt and paint free dry bolt and nut threads. Never use oil or grease on studs and nuts. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > Page 1386 Wheel Fastener: Service and Repair Lug Nut Torque Patterns IMPORTANT Check all parts, including rims, lug studs, lug nuts, and mating surfaces of hubs and tire rims for rust, damage, or dirt. Clean mating surfaces with a wire brush to remove any foreign material. Replace any damaged parts as needed. Careless installation of tire/rim assemblies in a vehicle is a major cause of tire installation problems. Proper installation, including fastener torque, is essential to economical, safe and trouble free service. Use only the proper sizes and types of fasteners for safe and proper service. Tighten the fasteners a quarter turn at a time using the tightening sequence diagram as a guide. This is very important to prevent misalignment of the wheel. Continue tightening the fasteners in sequence until the fasteners are tightened to the proper torque (See WHEEL FASTENER TORQUE). CAUTION: Improper torque or tightening sequence can cause distortion, fatigue cracks, or alignment problems. After driving the vehicle for a short distance, recheck the wheel fastener torque. Parts will usually seat naturally, reducing the torque on the fasteners. Retorque all fasteners to the proper torque. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Seal > Component Information > Technical Service Bulletins > Customer Interest for Wheel Seal: > 9167 > Mar > 91 > Rear Axle Hub Seal - Lubricant Leaks Wheel Seal: Customer Interest Rear Axle Hub Seal - Lubricant Leaks Article No. 91-6-7 03/18/91 ^ AXLE - NEW HUB SEAL AND HUB SEAL REPLACER TOOL - VEHICLES WITH 10.25 INCH RING GEAR, FULL - FLOATING REAR AXLES ^ LEAKS - AXLE LUBE - 10.25 INCH RING GEAR, FULL - FLOATING REAR AXLES LIGHT TRUCK: 1985-91 F-250, F-350 ISSUE: A new hub seal and a hub seal replacer tool are now available for service. The new hub seal is designed to improve sealing when properly installed using the new hub seal replacer tool. ACTION: Install a new hub seal (FOTZ-1177-A) with the new hub seal replacer tool (T91T-1175-A). Refer to the following inspection list and service procedure for details. NOTE: DO NOT USE THE OLD HUB SEAL REPLACER TOOL (T85T-1175-AH). IT IS NOT DESIGNED TO INSTALL THE NEW SEAL. THE NEW HUB SEAL REPLACER TOOL IS AVAILABLE IN THE 1991 DEALER ESSENTIAL SERVICE TOOL KIT AND IS THE ONLY TOOL APPROVED TO INSTALL THE NEW SEAL. INSPECTION PRIOR TO SEAL INSTALLATION Prior to seal installation, make sure that the following items are checked and servicing action taken where indicated. ^ Inspect the outer diameter of the hub seal to be sure that it is dry and free of oil and grease. ^ Check the hub bore to be sure it is free of grease, dirt and debris. ^ Remove any nicks or burrs from the hub bore. ^ Inspect the inner and outer bearing for damage and replace as required. ^ Pack each hub bearing cone and roller with a bearing packing tool using XG-1-C grease. ^ Make sure that no residual grease from freshly greased bearings gets into the hub bore. ^ Prior to installing the hub assembly, clean the spindle thoroughly and inspect the seal and bearing journals for nicks and/or scratches. Remove nicks or scratches using crocus cloth or similar material. ^ Wipe spindle clean and lightly oil with clean axle lube or engine oil. Figure 1 REMOVAL & INSTALLATION PROCEDURE 1. Install the hub in a soft jawed vice. 2. Remove the hub seal as shown in Figure 1. CAUTION: CARE MUST BE TAKEN NOT TO DAMAGE THE HUB SEAL BORE WITH THE SEAL REMOVAL TOOL. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Seal > Component Information > Technical Service Bulletins > Customer Interest for Wheel Seal: > 9167 > Mar > 91 > Rear Axle Hub Seal - Lubricant Leaks > Page 1395 Figure 2 3. Thoroughly clean and inspect the hub bore, Figure 2. CAUTION: MAKE SURE THE HUB BORE IS FREE OF DIRT, GREASE, BURRS OR NICKS. NOTE: HUB BEARINGS MUST BE PRELUBED WITH GREASE PRIOR TO INSTALLATION. USE XG-1-C GREASE OR EQUIVALENT. 4. Pack each bearing cone and roller assembly with a bearing packing tool. Figure 3 5. Install the seal in the hub with the Ford logo facing up, Figure 3. CAUTION: HUB SEAL MUST BE FREE OF DIRT OR GREASE. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Seal > Component Information > Technical Service Bulletins > Customer Interest for Wheel Seal: > 9167 > Mar > 91 > Rear Axle Hub Seal - Lubricant Leaks > Page 1396 Figure 4 6. Install the hub oil seal on the hub seal installer tool, T91T-1175-A, Figure 4. Figure 5 7. Insert the tool with the seal squarely into the hub, Figure 5. Figure 6 8. Hold the tool straight. Strike the handle until the hub seal is fully seated (until tool strikes hub), Figure 6. CAUTION: INSTALL NEW SEAL IF SEAL IS MISALIGNED DURING OR AFTER INSTALLATION. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Seal > Component Information > Technical Service Bulletins > Customer Interest for Wheel Seal: > 9167 > Mar > 91 > Rear Axle Hub Seal - Lubricant Leaks > Page 1397 It is extremely important that the 1991 F-Series Shop Manual procedures be followed when installing the hub assembly. CAUTION: THE SPECIFIED TORQUING AND BACKING OFF OF THE HUB NUT IS CRITICAL IN ORDER TO PERFORM THE REPAIR CORRECTLY. NOTE: ALWAYS TURN THE HUB WHILE TIGHTENING THE HUB NUT. ONCE THE SPECIFIED TORQUE 55-65 LB.FT., (75-88 N-m) IS ACHIEVED, RATCHETING BACK ON THE HUB NUT VARIES DEPENDING ON WHETHER THE HUB BEARINGS ARE NEW OR USED. BACK OFF 5 CLICKS FOR NEW BEARING AND 8 CLICKS FOR USED BEARINGS. Make sure hub nut wrench tool (T85T-4252-AH) is used as shown in the Shop Manual procedure. Consult The 1991 F-Series Light Truck Shop Manual, Section 05-02B, for service procedures and torque specifications. PART NUMBER PART NAME CLASS FOTZ-1177-A Hub Seal B XG-1-C Grease (14 oz. cartridge, Pkg. V 60) OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 509000 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Seal > Component Information > Technical Service Bulletins > Customer Interest for Wheel Seal: > 862223 > Nov > 86 > Axle - Rear Axle Hub Seals Leak Wheel Seal: Customer Interest Axle - Rear Axle Hub Seals Leak Article No. 86-22-23 AXLE (10.25") - REAR - HUB SEALS LEAK - VENT PLUGGED LIGHT TRUCK 1985-86 F-250/350 A plugged rear axle vent may cause water to be sucked in through the seals and grease to be pushed out. This happens when pressures rise and fall inside the axle during various driving conditions and temperatures. The purpose of the vent is to relieve those pressures. If the vent is plugged with mud or other foreign materials, the axle cannot "breathe". To eliminate this concern, perform the following procedure: Figure 17 1. Remove the vent from the axle (Figure 17). 2. Place the vent in a vise so as not to damage the threads. 3. Drill out the vent using a 3/16 inch drill bit. Clean all shavings from vent. 4. Install vent. 5. Make sure entire vent hose is clear of dirt and mud, etc. 6. Install hose. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION: SP4022A86 TIME: 0.5 Hr. DLR. CODING: Basic Part No. 4022 - Code: 55 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Seal > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Seal: > 9167 > Mar > 91 > Rear Axle Hub Seal - Lubricant Leaks Wheel Seal: All Technical Service Bulletins Rear Axle Hub Seal - Lubricant Leaks Article No. 91-6-7 03/18/91 ^ AXLE - NEW HUB SEAL AND HUB SEAL REPLACER TOOL - VEHICLES WITH 10.25 INCH RING GEAR, FULL - FLOATING REAR AXLES ^ LEAKS - AXLE LUBE - 10.25 INCH RING GEAR, FULL - FLOATING REAR AXLES LIGHT TRUCK: 1985-91 F-250, F-350 ISSUE: A new hub seal and a hub seal replacer tool are now available for service. The new hub seal is designed to improve sealing when properly installed using the new hub seal replacer tool. ACTION: Install a new hub seal (FOTZ-1177-A) with the new hub seal replacer tool (T91T-1175-A). Refer to the following inspection list and service procedure for details. NOTE: DO NOT USE THE OLD HUB SEAL REPLACER TOOL (T85T-1175-AH). IT IS NOT DESIGNED TO INSTALL THE NEW SEAL. THE NEW HUB SEAL REPLACER TOOL IS AVAILABLE IN THE 1991 DEALER ESSENTIAL SERVICE TOOL KIT AND IS THE ONLY TOOL APPROVED TO INSTALL THE NEW SEAL. INSPECTION PRIOR TO SEAL INSTALLATION Prior to seal installation, make sure that the following items are checked and servicing action taken where indicated. ^ Inspect the outer diameter of the hub seal to be sure that it is dry and free of oil and grease. ^ Check the hub bore to be sure it is free of grease, dirt and debris. ^ Remove any nicks or burrs from the hub bore. ^ Inspect the inner and outer bearing for damage and replace as required. ^ Pack each hub bearing cone and roller with a bearing packing tool using XG-1-C grease. ^ Make sure that no residual grease from freshly greased bearings gets into the hub bore. ^ Prior to installing the hub assembly, clean the spindle thoroughly and inspect the seal and bearing journals for nicks and/or scratches. Remove nicks or scratches using crocus cloth or similar material. ^ Wipe spindle clean and lightly oil with clean axle lube or engine oil. Figure 1 REMOVAL & INSTALLATION PROCEDURE 1. Install the hub in a soft jawed vice. 2. Remove the hub seal as shown in Figure 1. CAUTION: CARE MUST BE TAKEN NOT TO DAMAGE THE HUB SEAL BORE WITH THE SEAL REMOVAL TOOL. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Seal > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Seal: > 9167 > Mar > 91 > Rear Axle Hub Seal - Lubricant Leaks > Page 1407 Figure 2 3. Thoroughly clean and inspect the hub bore, Figure 2. CAUTION: MAKE SURE THE HUB BORE IS FREE OF DIRT, GREASE, BURRS OR NICKS. NOTE: HUB BEARINGS MUST BE PRELUBED WITH GREASE PRIOR TO INSTALLATION. USE XG-1-C GREASE OR EQUIVALENT. 4. Pack each bearing cone and roller assembly with a bearing packing tool. Figure 3 5. Install the seal in the hub with the Ford logo facing up, Figure 3. CAUTION: HUB SEAL MUST BE FREE OF DIRT OR GREASE. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Seal > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Seal: > 9167 > Mar > 91 > Rear Axle Hub Seal - Lubricant Leaks > Page 1408 Figure 4 6. Install the hub oil seal on the hub seal installer tool, T91T-1175-A, Figure 4. Figure 5 7. Insert the tool with the seal squarely into the hub, Figure 5. Figure 6 8. Hold the tool straight. Strike the handle until the hub seal is fully seated (until tool strikes hub), Figure 6. CAUTION: INSTALL NEW SEAL IF SEAL IS MISALIGNED DURING OR AFTER INSTALLATION. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Seal > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Seal: > 9167 > Mar > 91 > Rear Axle Hub Seal - Lubricant Leaks > Page 1409 It is extremely important that the 1991 F-Series Shop Manual procedures be followed when installing the hub assembly. CAUTION: THE SPECIFIED TORQUING AND BACKING OFF OF THE HUB NUT IS CRITICAL IN ORDER TO PERFORM THE REPAIR CORRECTLY. NOTE: ALWAYS TURN THE HUB WHILE TIGHTENING THE HUB NUT. ONCE THE SPECIFIED TORQUE 55-65 LB.FT., (75-88 N-m) IS ACHIEVED, RATCHETING BACK ON THE HUB NUT VARIES DEPENDING ON WHETHER THE HUB BEARINGS ARE NEW OR USED. BACK OFF 5 CLICKS FOR NEW BEARING AND 8 CLICKS FOR USED BEARINGS. Make sure hub nut wrench tool (T85T-4252-AH) is used as shown in the Shop Manual procedure. Consult The 1991 F-Series Light Truck Shop Manual, Section 05-02B, for service procedures and torque specifications. PART NUMBER PART NAME CLASS FOTZ-1177-A Hub Seal B XG-1-C Grease (14 oz. cartridge, Pkg. V 60) OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 509000 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Seal > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Seal: > 862223 > Nov > 86 > Axle - Rear Axle Hub Seals Leak Wheel Seal: All Technical Service Bulletins Axle - Rear Axle Hub Seals Leak Article No. 86-22-23 AXLE (10.25") - REAR - HUB SEALS LEAK - VENT PLUGGED LIGHT TRUCK 1985-86 F-250/350 A plugged rear axle vent may cause water to be sucked in through the seals and grease to be pushed out. This happens when pressures rise and fall inside the axle during various driving conditions and temperatures. The purpose of the vent is to relieve those pressures. If the vent is plugged with mud or other foreign materials, the axle cannot "breathe". To eliminate this concern, perform the following procedure: Figure 17 1. Remove the vent from the axle (Figure 17). 2. Place the vent in a vise so as not to damage the threads. 3. Drill out the vent using a 3/16 inch drill bit. Clean all shavings from vent. 4. Install vent. 5. Make sure entire vent hose is clear of dirt and mud, etc. 6. Install hose. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION: SP4022A86 TIME: 0.5 Hr. DLR. CODING: Basic Part No. 4022 - Code: 55 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Compression Check > System Information > System Diagnosis Compression Check: Testing and Inspection COMPRESSION TEST 1. Ensure oil in crankcase is of the correct viscosity and at proper level and battery is properly charged. Operate vehicle until engine is at normal operating temperature. Turn OFF ignition switch, then remove all spark plugs. 2. Set throttle plates (and choke plates, if equipped) in wide-open position. 3. Install a compression gauge such as Rotunda Compression Tester 059-00009 or equivalent in No. 1 cylinder. 4. Install an auxiliary starter switch in starting circuit. With ignition switch in the OFF position, and using auxiliary starter switch, crank engine at least five compression strokes and record highest reading. Note the approximate number of compression strokes required to obtain the highest reading. 5. Repeat test on each cylinder cranking the engine approximately the same number of compression strokes. TEST CONCLUSION 1. The indicated compression pressures are considered within specification if the lowest reading cylinder is within 75 percent of the highest. 2. If one or more cylinders read low, squirt approximately one tablespoon of heavy SAE 50 weight or equivalent engine oil on top of the pistons in the low reading cylinders. Repeat compression pressure check on these cylinders. a. If compression improves considerably, piston rings are at fault. b. If compression does not improve, valves are sticking or seating poorly. c. If two adjacent cylinders indicate low compression pressures and squirting oil on pistons does not increase compression, cause may be a cylinder head gasket leak between cylinders. Engine oil and/or coolant in cylinders could result from this problem. Compression Pressure Limit Chart NOTE: Refer to the compression pressure limit chart for pressure specifications. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Specifications Camshaft: Specifications Camshaft Clearance Specifications Camshaft Clearance Specifications Camshaft Journal Diameter No. 1 2.0805-2.0815 in No. 2 2.0655-2.0665 in No. 3 2.0505-2.0515 in No. 4 2.0355-2.0365 in No. 5 2.0205-2.0215 in Camshaft Bearing Inside Diameter No. 1 2.0825-2.0835 in No. 2 2.0675-2.0685 in No. 3 2.0525-2.0535 in No. 4 2.0375-2.0385 in No. 5 2.0225-2.0235 in Camshaft Bearing Clearance .001-.003 in Note: Service Limit -- 0.006 in Camshaft End Play .001-.007 in Note: Service Limit -- 0.009 in Camshaft Runout Max. 0.005 in Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Specifications > Page 1423 Camshaft: Service and Repair V8 ENGINES 1. On Econoline models except V8-351M and 400 engines, remove grille. 2. On all models, drain cooling system, then disconnect all lines and hoses from radiator and remove radiator. 3. Remove intake manifold, then the rocker arm covers. 4. Loosen rocker arms, then remove pushrods and valve lifters in sequence. 5. Remove timing case cover and timing chain as previously described. 6. On models equipped with A/C, remove A/C condenser attaching bolts and position condenser aside. 7. On all models, remove camshaft thrust plate and carefully slide camshaft out through front of engine. 8. Reverse procedure to install. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Specifications Lifter / Lash Adjuster: Specifications Lifter Bore Diameter .8752-.8767 in Lifter Diameter .8740-.8745 in Lifter To Bore Clearance .0007-.0027 in Note: Service Limit -- 0.005 in Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Specifications > Page 1427 Lifter / Lash Adjuster: Service and Repair V6-232, V8-255, 302, 351, 400, & 460 1. Remove intake manifold. 2. Remove rocker arm covers. Loosen rocker arm stud nuts or bolts and rotate rocker arms to the side. 3. Remove pushrods in sequence so they can be installed in their original bores. 4. Using a magnet, remove the lifters and place them in a numbered rack so they can be installed in their original bores. If lifters are stuck in their bores, it may be necessary to use a plier-type tool to remove them. 5. The internal parts of each lifter are matched sets. Do not intermix parts. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Specifications Rocker Arm Assembly: Specifications Rocker Arm To Cylinder Head Bolts 18-25 ft.lb Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Specifications > Page 1431 Rocker Arm Assembly: Service and Repair Fig. 23 Rocker arm assembly Fig. 24 Rocker Arm Assembly V6-232, V8-255, 302, 351M, 351W, 400 & 460 & 1985-87 6-300 The rocker arm is supported by a fulcrum bolt which fits through the fulcrum seat and threads into the cylinder head. To disassemble, remove the bolt, oil deflector, fulcrum seat and rocker arm, Figs. 26 and 27. 1981-82 models equipped with V8-255, 302 and 351W engines with low profile rocker arm fulcrums (part No. E1TZ-6A528-A) may experience excessive oil displacement when engine is operated for extended periods during high ambient temperatures. This problem may be corrected by replacing original rocker arm fulcrums with part No. D7AZ-6A528-A. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Specifications Connecting Rod: Specifications Connecting Rod Cap Bolts 40-45 ft.lb Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Specifications > Page 1436 Connecting Rod: Service and Repair Fig. 28 Piston & rod assembly Fig. 29 Piston & rod assembly Fig. 35 Piston & rod assembly. V6-232 Lubricate all parts with light engine oil. Position the connecting rod in the piston and push the pin into place, Figs. 33, 34 and 35. Insert new piston pin retainers (when used) by spiralling them into the piston with the fingers. Do not use pliers. Replacement pistons for the following 6-300 equipped vehicles have an increased ring land, which raises the top compression ring .035 inch: Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Specifications > Page 1437 1980-81 E & F-100-250 & Bronco except heavy duty. Before installing the new piston, the cylinder ridge must be removed to ensure that the top compression ring does not contact the ridge or deposits formed at the top of the cylinder bore. When removing the ridge, do not cut into the ring travel area more than {1/32} inch. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Specifications Crankshaft: Specifications Main Cap Torque Main Cap Torque Main Bearing Cap Bolts 95- 105 ft.lb Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications Harmonic Balancer - Crankshaft Pulley: Specifications Crankshaft Pulley 70-90 ft.lb Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Specifications Piston: Specifications Piston Diameter coded red 3.9978 - 3.9984 in coded blue 3.9990 - 3.9996 in Piston Clearance .0018-.0026 in Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Specifications > Page 1447 Piston: Service and Repair Fig. 28 Piston & rod assembly Fig. 29 Piston & rod assembly Fig. 35 Piston & rod assembly. V6-232 Lubricate all parts with light engine oil. Position the connecting rod in the piston and push the pin into place, Figs. 33, 34 and 35. Insert new piston pin retainers (when used) by spiralling them into the piston with the fingers. Do not use pliers. Replacement pistons for the following 6-300 equipped vehicles have an increased ring land, which raises the top compression ring .035 inch: Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Specifications > Page 1448 1980-81 E & F-100-250 & Bronco except heavy duty. Before installing the new piston, the cylinder ridge must be removed to ensure that the top compression ring does not contact the ridge or deposits formed at the top of the cylinder bore. When removing the ridge, do not cut into the ring travel area more than {1/32} inch. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Pin, Engine > Component Information > Specifications Piston Pin: Specifications Piston Pin Diameter .9119-.9124 in Pin to Piston Bore Clearance .0003-.0005 in Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Ring, Engine > Component Information > Specifications Piston Ring: Specifications End Gap, Compression Ring 0.01 in End Gap, Oil Ring 0.015 in Side Clearance, Top Compression Ring 0.0013 - 0.0033 in Side Clearance, Second Compression Ring 0.002 - 0.004 in Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Rear Engine Plate > Component Information > Technical Service Bulletins > Customer Interest for Rear Engine Plate: > 86814 > Apr > 86 > Engine/Transmission Area - Grinding/Scraping Noise Rear Engine Plate: Customer Interest Engine/Transmission Area - Grinding/Scraping Noise Article No. 86-8-14 NOISE - GRINDING OR SCRAPING FROM ENGINE OR TRANSMISSION AREA (5.0L AND 5.8L WITH AUTOMATIC TRANSMISSION) LIGHT TRUCK 1986 E-, FSERIES, BRONCO During high speed or heavy load conditions, a loud metallic grinding or scraping noise may be heard coming from the engine or transmission area. Some vehicles built between 11/6/85 and 1/7/86 may have engines with a rear cover plate (equipped with a foam rubber dust seal) that may expand and make contact with the flywheel, which could result in the above concern. 1. Remove engine rear cover plate, by referring to the procedure in the 1986 Light Truck Shop Manual. Figure 16 2. Examine rear cover plate for damage, i.e., circular grind marks, loose metallic particles, etc. (See Figure 16) 3. If damage to rear cover plate is evident, replace existing plate with new plate (part number D8DZ- 7007-A). New plate does not have rubber dust seal. (Rubber dust seal is not required.) 4. If damage to rear cover plate is not evident, continue investigation for source of noise. PART NUMBER PART NAME CLASS D8DZ-7007-A Cover Plate C OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION: SP7007A86 - Plate assembly engine rear - remove and install or inspect. TIME: F Series Bronco Econoline 4x2 - C6-5.0L 2.8 Hrs. C6 - 5.8L 3.1 Hrs. 2.9 Hrs. AOD - 5.0L 3.0 Hrs. 2.8 Hrs. 4x4- C6-5.8L 4.6 Hrs. 4.6 Hrs. AOD - 5.0L 4.3 Hrs. 4.3 Hrs. OPERATION: SP7007S1 - Extra time if equipped with skid plate under transfer case. TIME: 0.2 Hr. - F-Series and Bronco only DLR. CODING: Basic Part No. 7007 - Code 56 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Rear Engine Plate > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Engine Plate: > 86814 > Apr > 86 > Engine/Transmission Area - Grinding/Scraping Noise Rear Engine Plate: All Technical Service Bulletins Engine/Transmission Area - Grinding/Scraping Noise Article No. 86-8-14 NOISE - GRINDING OR SCRAPING FROM ENGINE OR TRANSMISSION AREA (5.0L AND 5.8L WITH AUTOMATIC TRANSMISSION) LIGHT TRUCK 1986 E-, FSERIES, BRONCO During high speed or heavy load conditions, a loud metallic grinding or scraping noise may be heard coming from the engine or transmission area. Some vehicles built between 11/6/85 and 1/7/86 may have engines with a rear cover plate (equipped with a foam rubber dust seal) that may expand and make contact with the flywheel, which could result in the above concern. 1. Remove engine rear cover plate, by referring to the procedure in the 1986 Light Truck Shop Manual. Figure 16 2. Examine rear cover plate for damage, i.e., circular grind marks, loose metallic particles, etc. (See Figure 16) 3. If damage to rear cover plate is evident, replace existing plate with new plate (part number D8DZ- 7007-A). New plate does not have rubber dust seal. (Rubber dust seal is not required.) 4. If damage to rear cover plate is not evident, continue investigation for source of noise. PART NUMBER PART NAME CLASS D8DZ-7007-A Cover Plate C OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION: SP7007A86 - Plate assembly engine rear - remove and install or inspect. TIME: F Series Bronco Econoline 4x2 - C6-5.0L 2.8 Hrs. C6 - 5.8L 3.1 Hrs. 2.9 Hrs. AOD - 5.0L 3.0 Hrs. 2.8 Hrs. 4x4- C6-5.8L 4.6 Hrs. 4.6 Hrs. AOD - 5.0L 4.3 Hrs. 4.3 Hrs. OPERATION: SP7007S1 - Extra time if equipped with skid plate under transfer case. TIME: 0.2 Hr. - F-Series and Bronco only DLR. CODING: Basic Part No. 7007 - Code 56 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Clearance > System Information > Specifications Valve Clearance: Specifications ENGINE YEAR CLEARANCE V6-232 82-83 .088-.189 V8-255 81-82 .123-.173 6-300 80-87 .125-.175 V8-302 80-87 .096-.165 V8-351M 80-81 .125 V8-351W 80-87 .123-.173 V8-400 80-82 .175 V8-460 80-87 .100-.150 On engines with hydraulic lifters, clearance specified is at valve stem tip with lifter collapsed. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Clearance > System Information > Specifications > Page 1472 Valve Clearance: Locations FRONT TO REAR 6-300 E-I-E-I-E-I-E-I-E-I-E-I V6-232 Right I-E-I-E-I-E V6-232 Left E-I-E-I-E-I V8-255, 302 Left Bank E-I-E-I-E-I-E-I V8-255, 302 Right Bank I-E-I-E-I-E-I-E V8-351, 400 Right Bank I-E-I-E-I-E-I-E V8-351, 400 Left Bank E-I-E-I-E-I-E-I V8-460 Left Bank E-I-E-I-E-I-E-I V8-460 Right Bank I-E-I-E-I-E-I-E Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Clearance > System Information > Specifications > Page 1473 Valve Clearance: Adjustments Fig. 2 Positioning crankshaft for valve clearance check Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Clearance > System Information > Specifications > Page 1474 Fig. 3 Checking collapsed tappet clearance Valves, Adjust To provide a means to compensate for dimensional changes in the valve train and provide for valve adjustment, .060 inch shorter or longer pushrods are available. If the valve clearance is less than the minimum, the .060 inch shorter pushrod should be used. If the clearance is more than the maximum, the longer pushrod should be used. To check the valve clearance, proceed as follows: 1. Mark crankshaft pulley at three locations, with No. 1 location at TDC timing mark (end of compression stroke), location No. 2 one full turn (360°) clockwise from TDC and No. 3 location one quarter turn clockwise (90°) from position No. 2, Fig. 2. 2. Turn crankshaft to number 1 location, then compress valve lifter using tool T71P-6513-A or equivalent, Fig. 3, and check the clearance on the following valves: a. On V8-302 and 460 engines, check intake valve Nos. 1 , 7 and 8; exhaust valve Nos. 1, 4 and 5. b. On V8-351, check intake valve Nos. 1, 4 and No. 8; exhaust valve Nos. 1, 3 and 7. 3. Turn crankshaft to number 2 location, then compress valve lifter using tool T71P-6513-A or equivalent, Fig. 3, and check the clearance on the following valves: a. On V8-301 and 460 engines check intake valve Nos. 4 and 5; exhaust valve Nos. 2 and 6. b. On V8-351 engines, check intake valve Nos. 3 and 7; exhaust valve Nos. 2 and 6. 4. Turn crankshaft to number 3 location, then compress valve lifter using tool T71P-6513-A or equivalent and check the clearance on the following valves: a. V8-302 and 460 engines check intake valve Nos. 2, 3 and 6; exhaust valve Nos. 3, 7 and 8. b. On V8-351 engines, check intake valve Nos. 2, 5 and 6; exhaust valve Nos. 4, 5 and 8. Valve Arrangement Front to Rear V8-302 Left Bank.................................................................................................................................. ...........................................................E-I-E-I-E-I-E-I V8-302 Right Bank............................................. ..............................................................................................................................................I-E-I-E-IE-I-E V8-351 Right Bank...................................................................................................................... .....................................................................I-E-I-E-I-E-I-E V8-351 Left Bank...................................... .......................................................................................................................................................E-IE-I-E-I-E-I V8-460 Left Bank................................................................................................................. ............................................................................E-I-E-I-E-I-E-I V8-460 Right Bank............................ .............................................................................................................................................................. .I-E-I-E-I-E-I-E Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Specifications Rocker Arm Assembly: Specifications Rocker Arm To Cylinder Head Bolts 18-25 ft.lb Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Specifications > Page 1478 Rocker Arm Assembly: Service and Repair Fig. 23 Rocker arm assembly Fig. 24 Rocker Arm Assembly V6-232, V8-255, 302, 351M, 351W, 400 & 460 & 1985-87 6-300 The rocker arm is supported by a fulcrum bolt which fits through the fulcrum seat and threads into the cylinder head. To disassemble, remove the bolt, oil deflector, fulcrum seat and rocker arm, Figs. 26 and 27. 1981-82 models equipped with V8-255, 302 and 351W engines with low profile rocker arm fulcrums (part No. E1TZ-6A528-A) may experience excessive oil displacement when engine is operated for extended periods during high ambient temperatures. This problem may be corrected by replacing original rocker arm fulcrums with part No. D7AZ-6A528-A. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Specifications Valve Cover: Specifications Rocker Arm Cover 3-5 ft/lb ft.lb Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Guide > Component Information > Specifications Valve Guide: Specifications Guide, Inside Diameter .3433-.3443 in Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Guide > Component Information > Specifications > Page 1485 Valve Guide: Service and Repair Valve guides in these engines are an integral part of the head and, therefore, cannot be removed. For service, guides can be reamed oversize to accommodate one of three service valves with oversize stems (.003 inch, .015 inch and .030 inch). Check the valve stem clearance of each valve (after cleaning) in its respective valve guide. If the clearance exceeds the service limits of .004 inch of the intake or .005 inch on the exhaust, ream the valve guides to accommodate the next oversize diameter valve. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Seat > Component Information > Specifications Valve Seat: Specifications Seat Width, Intake .060-.080 in Seat Width, Exhaust .060-.080 in Runout 0.002 in Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Specifications Valve Spring: Specifications Free Length Intake 2.04 in Free Length Exhaust 1.85 in Out Of Square Limit 0.078 in Installed Height Intake 1.765-1.797 in Installed Height Exhaust 1.578-1.609 in Spring Pressure, Closed, Intake 74-82 lbf at 1.78 in Spring Pressure, Closed, Exhaust 76-84 lbf at 1.60 in Spring Pressure, Open, Intake 190-210 lbf at 1.36 in Spring Pressure, Open, Exhaust 190-210 lbf at 1.20 in Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Specifications Valve: Specifications Stem Diameter Intake .3416-.3423 in Stem Diameter Exhaust .3411-.3418 in Maximum Tip Refinish 0.01 in Face Angle 44 deg Margin Intake 1/32 in Margin Exhaust 1/32 in Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > Customer Interest for Drive Belt: > 87531 > Mar > 87 > Accessory Drive Belt - Squealing Noise Drive Belt: Customer Interest Accessory Drive Belt - Squealing Noise ^ ACCESSORY DRIVE BELT - SQUEALS Article No. 87-5-31 ^ NOISE - ACCESSORY DRIVE "V" BELT SQUEALS LIGHT TRUCK 1985-87 E SERIES, F SERIES ISSUE: Accessory drive "V" belt squeals on F Series and E-250/350 vehicles 8500 lbs. GVW with dual thermactors and a 5.8L 4V engine equipped with power steering may be caused by the design of the current production belt. ACTION: To correct this, two new high profile "V" belts, E6TZ-8620-C and E6TZ- 8620-D, with an increased surface area and improved qualities less likely to stretch during normal service, are now available. Refer to the Truck Shop Manual for "V" belt installation and adjustment specifications. NOTE: When installing a now "V" belt, a belt tension gauge should be used. Refer to the following application chart for the proper "V" belt application. ACCESSORY DRIVE "V" BELT APPLICATION CHART Service Part No. Vehicle Application E6TZ-8620-C * 1985-87 F-250/350 over 8500 lbs. GVW with dual thermactors and 5.8L 4V engine - power steering and water pump drive. E6TZ-8620-D * 1985-87 E-250/350 over 8500 lbs. GVW with dual thermactors and 5.8L 4V engine - power steering and water pump drive. C9PZ-8620-CP 1985-87 F Series and Bronco with 5.8L engine without A/C - power steering and water pump drive. D9PZ-8620-P 1985-87 Econoline with 5.8L engine without A/C - power steering and water pump drive. D9PZ-8620-P 1985-87 F Series and Bronco with 5.8L engine and A/C (except F/B- 250/350 over 8500 lbs. GVW with A/C and dual thermactor) - power steering and water pump drive. D9PZ-8620-U 1985-87 Econoline with 5.8L engine and A/C (except E-250/350 over 8500 lbs. GVW with A/C and dual thermactor) - power steering and water pump drive. * Now high profile "V" belts. PART NUMBER PART NAME CLASS E6TZ-8620-C V-Drive Belt B E6TZ-8620-D V-Drive Belt B C9PZ-8620-CP V-Drive Belt AM D9PZ-8620-P V-Drive Belt AM D9PZ-8620-U V-Drive Belt AQ OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Drive Belt: > 87531 > Mar > 87 > Accessory Drive Belt - Squealing Noise Drive Belt: All Technical Service Bulletins Accessory Drive Belt - Squealing Noise ^ ACCESSORY DRIVE BELT - SQUEALS Article No. 87-5-31 ^ NOISE - ACCESSORY DRIVE "V" BELT SQUEALS LIGHT TRUCK 1985-87 E SERIES, F SERIES ISSUE: Accessory drive "V" belt squeals on F Series and E-250/350 vehicles 8500 lbs. GVW with dual thermactors and a 5.8L 4V engine equipped with power steering may be caused by the design of the current production belt. ACTION: To correct this, two new high profile "V" belts, E6TZ-8620-C and E6TZ- 8620-D, with an increased surface area and improved qualities less likely to stretch during normal service, are now available. Refer to the Truck Shop Manual for "V" belt installation and adjustment specifications. NOTE: When installing a now "V" belt, a belt tension gauge should be used. Refer to the following application chart for the proper "V" belt application. ACCESSORY DRIVE "V" BELT APPLICATION CHART Service Part No. Vehicle Application E6TZ-8620-C * 1985-87 F-250/350 over 8500 lbs. GVW with dual thermactors and 5.8L 4V engine - power steering and water pump drive. E6TZ-8620-D * 1985-87 E-250/350 over 8500 lbs. GVW with dual thermactors and 5.8L 4V engine - power steering and water pump drive. C9PZ-8620-CP 1985-87 F Series and Bronco with 5.8L engine without A/C - power steering and water pump drive. D9PZ-8620-P 1985-87 Econoline with 5.8L engine without A/C - power steering and water pump drive. D9PZ-8620-P 1985-87 F Series and Bronco with 5.8L engine and A/C (except F/B- 250/350 over 8500 lbs. GVW with A/C and dual thermactor) - power steering and water pump drive. D9PZ-8620-U 1985-87 Econoline with 5.8L engine and A/C (except E-250/350 over 8500 lbs. GVW with A/C and dual thermactor) - power steering and water pump drive. * Now high profile "V" belts. PART NUMBER PART NAME CLASS E6TZ-8620-C V-Drive Belt B E6TZ-8620-D V-Drive Belt B C9PZ-8620-CP V-Drive Belt AM D9PZ-8620-P V-Drive Belt AM D9PZ-8620-U V-Drive Belt AQ OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > Page 1509 Drive Belt: Specifications A belt in operation 10 minutes is considered a used belt. 1988-89 Automatic tensioner used. Deflection method: Table lists deflection at midpoint of belt segment. Strand Tension method: Use a strand tension gauge. Measurements are in pounds. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > Page 1510 Drive Belt: Adjustments A belt in operation 10 minutes is considered a used belt. 1988-89 Automatic tensioner used. Deflection method: Table lists deflection at midpoint of belt segment. Strand Tension method: Use a strand tension gauge. Measurements are in pounds. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Accessory Bracket > Component Information > Technical Service Bulletins > Alternator Bracket - Parts Return Engine Accessory Bracket: Technical Service Bulletins Alternator Bracket - Parts Return Number: 52786 To: All Ford and Lincoln-Mercury Dealers Subject: Request for Return of Bracket Assembly E3SZ-10A313-A and Bracket Assembly E5SZ-10A313-B Because the subject parts may not meet Ford's high quality requirements, they should be witbdrawn from all inventories. All unused E3SZ-10A313-A and E5SZ-10A313-B should be returned to your facing PDC within 30 days from the date of this letter. Use the least expensive mode of transportation for your return. The subject parts are obsolete and replaced by E7SZ-10A313-A, which is available for ordering immediately. You are requested to complete a separate FPS-340 form for each part number in accordance with the instructions on the front of the form. Annotate "Returned Per FPSD Instructions Purge No. PN 1017" in the Customer's Detail Explanation Section and use Reason Code J (Unsatisfactory Service Stock). You will receive full credit in your parts statement for the price of each unused part returned, plus the prepaid transportation cost. In order to receive return credit, all parts must be received at the Parts Distribution Center within 30 days of the date of this letter. Material other than subject parts received on this return will be sent back to you freight collect. Any questions should be referred to your Zone Manager or facing PDC Manager. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair Engine Mount: Service and Repair Fig. 7 Engine mounts. F-100---350 & Bronco w/V8-255, 302, 351W engine F-100-350 & Bronco 1. Remove fan shroud attaching bolts and position shroud over fan. 2. Remove insulator-to-chassis bracket attaching nut and washer. 3. Raise engine slightly, then remove insulator attaching bolts and the insulator, Fig. 7. When removing lefthand insulator, the heat shield must also be removed. 4. Reverse procedure to install. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Dip Stick - Dip Stick Tube > Component Information > Technical Service Bulletins > Engine - Oil Dipstick May Not Be Read Correctly Engine Oil Dip Stick - Dip Stick Tube: Technical Service Bulletins Engine - Oil Dipstick May Not Be Read Correctly Article No. 88-8-9 FORD: 1984-88 ALL CAR LINES LINCOLN-MERCURY: 1984-88 ALL CAR LINES MERKUR: 1985-88 ALL CAR LINES LIGHT TRUCK: 1984-88 ALL LIGHT TRUCK LINES ISSUE: The "markings" on the engine oil level dipstick (indicator) may not be read correctly or could possibly be misinterpreted. This can result in overfilling the engine with oil in newly delivered vehicles or thinking that the engine has been overfilled with the specified amount of oil during oil and filter changes. ACTION: If service is required, use the following guidelines to make sure of correct oil fill. NOTE: PROPER OIL FILL IS BASED ON A SPECIFIED VOLUME AND IS LISTED IN THE "VEHICLE ENGINE OIL LEVEL CAPACITY SPECIFICATION CHART" AND THE "FLUID REFILL CAPACITIES CHART" OF THE VEHICLE OWNERS GUIDE. USE THESE RECOMMENDED VOLUMES WHENEVER REFILLING THE ENGINE WITH OIL. FIGURE 6 Old Style Design Dipstick On "MAX/ADD" style dipsticks the "MAX" line represents an allowable tolerance limit of approximately 1/2 quart above the specified (normal) engine operating level, Figure 6. The oil level of a properly filled engine should indicate an oil level reading in the upper crosshatched area of the dipstick. NOTE: DO NOT "TOP OFF" TO THE "MAX" LINE. IF THE OIL LEVEL GOES ABOVE THE "MAX" LINE, A SUFFICIENT AMOUNT OF OIL SHOULD BE REMOVED TO BRING THE OIL LEVEL READING BACK INTO THE CROSSHATCHED AREA OF THE DIPSTICK. New Style Design Dipstick On "FULL/ADD", "FULL/ADD 1 QUART" or "F" style dipsticks the oil level of an engine filled with the correct amount of oil, as listed in the "Vehicle Oil Capacity Specification Chart" will normally occur slightly above the "FULL" line, Figure 6. This occurs because the "FULL" mark on the dipstick Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Dip Stick - Dip Stick Tube > Component Information > Technical Service Bulletins > Engine - Oil Dipstick May Not Be Read Correctly > Page 1523 represents the lowest level of oil that could occur when an engine is filled with the specified volume of oil. This variation in oil level is due to manufacturing tolerances and oil level checking conditions. 1987-88 ENGINE OIL CAPACITY SPECIFICATION CHART Oil Fill With Filter Engine Models Change Car 1.3L All 3.9 Qts. 1.6L All 3.9 Qts. 1.9L All 4.0 Qts. 2.2L All 4.9 Qts. 2.3L OHC N.A. EFI/TC 5.0 Qts. 2.3L/2.5L HSC/PENTA 4.5 Qts. 2.9L Scorpio 5.0 Qts. 3.0L All 4.5 Qts. 3.8L All 5.0 Qts. 5.0L All 5.0 Qts. 5.8L All 5.0 Qts. Truck 2.0L Ranger 5.0 Qts. 2.3L Ranger 5.0 Qts. 2.9L Ranger 5.0 Qts. 3.0L Aerostar 4.5 Qts. 4.9L All 6.0 Qts. 5.0L All 6.0 Qts. 5.8L All 6.0 Qts. 6.1L/7.0L All 9.0 Qts. 7.5L All 6.0 Qts. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Technical Service Bulletins > Engine - Oil Level Checking Procedure Engine Oil: Technical Service Bulletins Engine - Oil Level Checking Procedure Article No. 85-25-20 OIL DIPSTICK - ENGINE OIL LEVEL CHECKING PROCEDURE - GASOLINE ENGINES LIGHT TRUCK 1986 AND PRIOR MEDIUM/HEAVY TRUCK 1986 AND PRIOR Figure 17 - Dipstick To correctly check the engine oil level, the vehicle must be parked on a level surface. Allow a few minutes after shutting the engine off for oil to drain down before checking. For consistent oil level readings, insert the dipstick with the loop of the handle as shown in Figure 17. Figure 18 - Dipstick - Calibration Figure 19 - Dipstick - Calibration Dipsticks in Ford vehicles do not incorporate a Full mark. Instead, the dipstick will have marks indicating a Safe range and an Add range as shown in Figure 18 or 19. When the correct amount of oil is in the engine, the oil level indication will be in the Safe range or above the Minimum mark, but not necessarily at the top of the Safe range or at the Maximum mark. When the indicated oil level is in the Add range put one quart of oil in the engine. Recheck the oil level to determine if the oil level is now in the Safe range or above the Minimum mark. Add and recheck oil level one quart at a time until the oil level indicator moves into the Safe range or above the Minimum mark. Do not add additional oil to bring the level to the top of the Safe range or to the Maximum mark since this may result in overfill and increased oil consumption. If the accuracy of the engine oil dipstick is in doubt, it may be verified in the following manner: ^ Drain the oil and install a new filter. ^ Put in the specified amount of oil for an oil and filter change. (See owner guide) ^ Start the engine and operate a few minutes. ^ Shut off the engine and allow a few minutes for the oil to drain down. ^ Check the oil level with the dipstick. ^ If the oil level does not indicate in the Safe range or above the Minimum mark, rework or replace the dipstick. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Capacity Specifications Engine Oil: Capacity Specifications Engine oil capacity ............................................................................................................................... ........................................................... 5.0 Qts.(4.7L) Note: Add 1 Qt. with filter change. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Capacity Specifications > Page 1530 Engine Oil: Fluid Type Specifications BL Self-adjusting Brake Lubricant EC Ethylene Glycol Coolant Mix 50/50 with water to at least -20°F (-29°C) protection EP Extreme Pressure Gear Lubricant Ford Part No. D8DZ-19C547-A FA Automatic Transmission Fluid, Type F GL-5 Gear Oil, API Service GL-5 HBH Hydraulic Brake Fluid, Extra Heavy-Duty HP Hypoid Gear Oil Ford Part No. E0AZ-19580-A HP* Hypoid Gear Oil for Limited-Slip or Traction-Lok Differential LM Lithium Grease, with Polyethylene LS Steering Gear Lubricant MA MERCONAutomatic Transmission Fluid MH Manifold Heat Valve Solvent SG Motor Oil, API Service SG Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Warning Indicator > Component Information > Technical Service Bulletins > Customer Interest for Oil Level Warning Indicator: > 932410 > Nov > 93 > Instrument Cluster Warning Lights - Dimly Lit Oil Level Warning Indicator: Customer Interest Instrument Cluster Warning Lights - Dimly Lit Article No. 93-24-10 11/24/93 ^ LAMP - MALFUNCTION OF FOUR PIN LOW OIL LEVEL RELAY - VEHICLES BUILT AFTER 8/1/92 OR 1983-1993 VEHICLES THAT HAVE HAD SERVICE REPLACEMENT IGNITION SWITCHES AFTER 8/1/92 ^ LAMPS - INSTRUMENT CLUSTER WARNING LIGHTS DIMLY LIT - VEHICLES BUILT AFTER 8/1/92 OR 1983-1993 VEHICLES THAT HAVE HAD SERVICE REPLACEMENT IGNITION SWITCHES AFTER 8/1/92 FORD: 1983 FAIRMONT 1983-89 CROWN VICTORIA, ESCORT 1983-93 MUSTANG, THUNDERBIRD 1983-94 PROBE 1984-86 LTD 1984-94 TEMPO LINCOLN-MERCURY: 1983 LN7, ZEPHYR 1983-87 CONTINENTAL, LYNX 1983-89 GRAND MARQUIS, TOWN CAR 1983-93 COUGAR 1984-86 CAPRI, MARQUIS 1984-94 TOPAZ LIGHT TRUCK: 1983-91 BRONCO 1983-93 ECONOLINE, F-150-350 SERIES, RANGER 1986-91 AEROSTAR 1991-93 EXPLORER ISSUE: The instrument cluster warning light(s) may be dimly lit or there may be a malfunction of the four pin low oil relay on vehicles so equipped. This could be due to the ignition switch. ACTION: If the vehicle displays the subject symptoms and meets the following conditions, replace the ignition switch. Refer to the appropriate Car or Light Truck Service Manual (Section 13-04 for 1983-1990 Cars, Section 11-04 for 1991-1993 Cars and Section 13-05 for 1983-1990 Light Trucks, Section 11-05 for 1991-1993 Light Trucks) for removal and installation procedures. Refer to the Parts Block in this article for correct parts usage. CONDITIONS ^ The vehicle has 14401 wiring attached to the P2 terminal of the ignition switch. Refer to the wiring schematic and/or Electrical And Vacuum Troubleshooting Manual (EVTM) for the concern vehicle. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Warning Indicator > Component Information > Technical Service Bulletins > Customer Interest for Oil Level Warning Indicator: > 932410 > Nov > 93 > Instrument Cluster Warning Lights - Dimly Lit > Page 1539 ^ The vehicle is equipped with one of the ignition switches identified in the Ignition Switch Part Number Chart. NOTE: THE SERVICE PART NUMBERS FOR THE REPLACEMENT IGNITION SWITCHES WILL HAVE THE SAME PART NUMBERS AS THOSE REPLACED. THE NEW SWITCH HAS BEEN IMPROVED TO CORRECT THE SUBJECT ISSUE. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of The Bumper To Bumper For 1992/93 Models, Basic Warranty Coverage For All Other Models Except Lincolns. Major Component Warranty Coverage For Lincolns OPERATION DESCRIPTION TIME 932410A Replace Ignition Switch - 0.5 Hr. All Light and Compact Trucks DEALER CODING BASIC PART NO. CONDITION CODE 11572 X1 OASIS CODES: 201000, 201100, 206000 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Warning Indicator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oil Level Warning Indicator: > 932410 > Nov > 93 > Instrument Cluster Warning Lights - Dimly Lit Oil Level Warning Indicator: All Technical Service Bulletins Instrument Cluster Warning Lights Dimly Lit Article No. 93-24-10 11/24/93 ^ LAMP - MALFUNCTION OF FOUR PIN LOW OIL LEVEL RELAY - VEHICLES BUILT AFTER 8/1/92 OR 1983-1993 VEHICLES THAT HAVE HAD SERVICE REPLACEMENT IGNITION SWITCHES AFTER 8/1/92 ^ LAMPS - INSTRUMENT CLUSTER WARNING LIGHTS DIMLY LIT - VEHICLES BUILT AFTER 8/1/92 OR 1983-1993 VEHICLES THAT HAVE HAD SERVICE REPLACEMENT IGNITION SWITCHES AFTER 8/1/92 FORD: 1983 FAIRMONT 1983-89 CROWN VICTORIA, ESCORT 1983-93 MUSTANG, THUNDERBIRD 1983-94 PROBE 1984-86 LTD 1984-94 TEMPO LINCOLN-MERCURY: 1983 LN7, ZEPHYR 1983-87 CONTINENTAL, LYNX 1983-89 GRAND MARQUIS, TOWN CAR 1983-93 COUGAR 1984-86 CAPRI, MARQUIS 1984-94 TOPAZ LIGHT TRUCK: 1983-91 BRONCO 1983-93 ECONOLINE, F-150-350 SERIES, RANGER 1986-91 AEROSTAR 1991-93 EXPLORER ISSUE: The instrument cluster warning light(s) may be dimly lit or there may be a malfunction of the four pin low oil relay on vehicles so equipped. This could be due to the ignition switch. ACTION: If the vehicle displays the subject symptoms and meets the following conditions, replace the ignition switch. Refer to the appropriate Car or Light Truck Service Manual (Section 13-04 for 1983-1990 Cars, Section 11-04 for 1991-1993 Cars and Section 13-05 for 1983-1990 Light Trucks, Section 11-05 for 1991-1993 Light Trucks) for removal and installation procedures. Refer to the Parts Block in this article for correct parts usage. CONDITIONS ^ The vehicle has 14401 wiring attached to the P2 terminal of the ignition switch. Refer to the wiring schematic and/or Electrical And Vacuum Troubleshooting Manual (EVTM) for the concern vehicle. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Warning Indicator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oil Level Warning Indicator: > 932410 > Nov > 93 > Instrument Cluster Warning Lights - Dimly Lit > Page 1545 ^ The vehicle is equipped with one of the ignition switches identified in the Ignition Switch Part Number Chart. NOTE: THE SERVICE PART NUMBERS FOR THE REPLACEMENT IGNITION SWITCHES WILL HAVE THE SAME PART NUMBERS AS THOSE REPLACED. THE NEW SWITCH HAS BEEN IMPROVED TO CORRECT THE SUBJECT ISSUE. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of The Bumper To Bumper For 1992/93 Models, Basic Warranty Coverage For All Other Models Except Lincolns. Major Component Warranty Coverage For Lincolns OPERATION DESCRIPTION TIME 932410A Replace Ignition Switch - 0.5 Hr. All Light and Compact Trucks DEALER CODING BASIC PART NO. CONDITION CODE 11572 X1 OASIS CODES: 201000, 201100, 206000 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Warning Indicator > Component Information > Technical Service Bulletins > Page 1546 Oil Level Warning Indicator: Description and Operation This system is used to indicate a low engine oil level condition. The lamp will be illuminated during engine starting. If oil level is sufficient, the lamp will go off when engine is operating. If oil level is low the lamp will remain on until engine oil is added and the ignition switch is placed in the Off position. The module may take a few minutes to reset. If the engine is started during this period, the last recorded reading will be displayed. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Service and Repair > Removal Oil Pan: Service and Repair Removal 1. Remove the oil dipstick (on pan entry models only). 2. Remove the bolts attaching the fan shroud to the radiator and position the shroud over the fan. 3. Remove the nuts and lock washers attaching the engine support insulators to the chassis bracket. 4. If equipped with an automatic transmission, disconnect the oil cooler line at the LH side of the radiator. 5. Raise the engine and place wood blocks under the engine supports. 6. Remove muffler inlet pipe. 7. Drain the crankcase. 8. Remove the oil pan attaching bolts and lower the oil pan onto the crossmember. 9. Remove the two bolts attaching the oil pump pickup tube to the oil pump. Remove nut attaching oil pump pickup tube to the number 3 main bearing cap stud. Lower the pickup tube and screen into the oil pan. 10. Remove the oil pan from the vehicle. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Service and Repair > Removal > Page 1551 Oil Pan: Service and Repair Installation 1. Clean oil pan, inlet tube and gasket surfaces. Inspect the gasket sealing surface for damages and distortion due to overtightening of the bolts. Repair and straighten as required. 2. Position a new oil pan gasket and seals to the cylinder block. 3. Position the oil pickup tube and screen to the oil pump, and install the lower attaching bolt and gasket loosely. Install nut attaching to number 3 main bearing cap stud. 4. Place the oil pan on the crossmember. lnstall the upper pickup tube bolt Tighten the pickup tube bolts to specifications. 5. Position the oil pan to the cylinder block and install the attaching bolts. Tighten to 13 - 14 N.m (9 - 11 ft. lb.). 6. Raise the engine and remove the wood blocks. Lower the engine and install the insulator to chassis bracket nuts and washers. Tighten the nuts to 73 - 100 N.m (54 - 74 ft. lb.). 7. Install muffler inlet pipe. 8. If equipped with an automatic transmission, connect the oil cooler line at the radiator. 9. install the fan shroud attaching bolts. 10. Fill the crankcase with the proper grade and quantity of engine oil. Install the oil dipstick. Start the engine and operate it until it reaches normal operating temperature, then check for leaks. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Gauge > Component Information > Testing and Inspection Oil Pressure Gauge: Testing and Inspection This oil pressure indicating system incorporates an instrument voltage regulator, electrical oil pressure gauge and a sending unit which are connected in series. The sending unit consists of a diaphragm, contact and a variable resistor. As oil pressure increases or decreases, the diaphragm actuated the contact on the variable resistor, in turn controlling current flow to the gauge. When oil pressure is low, the resistance of the variable resistor is high, restricting current flow to the gauge, in turn indicating low oil pressure. As oil pressure increases, the resistance of the variable resistor is lowered, permitting an increased current flow to the gauge, resulting in an increased gauge reading. TROUBLESHOOTING A special tester is required to diagnose this type gauge. Follow instructions included with the tester. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Switch <--> [Oil Pressure Sender] > Component Information > Locations Oil Pressure Switch: Locations LH Side Of V8-351/5. LH Front Of Engine Applicable to: 8L Engine Less EEC-IV Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Warning Lamp/Indicator > Component Information > Testing and Inspection Oil Pressure Warning Lamp/Indicator: Testing and Inspection Many trucks utilize a warning light on the instrument panel in place of the conventional dash indicating gauge to warn the driver when the oil pressure is dangerously low. The warning light is wired in series with the ignition switch and the engine unit--which is an oil pressure switch. The oil pressure switch contains a diaphragm and a set of contacts. When the ignition switch is turned on, the warning light circuit is energized and the circuit is completed through the closed contacts in the pressure switch. When the engine is started, build-up of oil pressure compresses the diaphragm, opening the contacts, thereby breaking the circuit and putting out the light. TROUBLESHOOTING The oil pressure warning light should go on when the ignition is turned on. If it does not light, disconnect the wire from the engine unit and ground the wire to the frame or cylinder block. Then if the warning light still does not go on with the ignition switch on, replace the bulb. If the warning light goes on when the wire is grounded to the frame or cylinder block, the engine unit should be checked for being loose or poorly grounded. If the unit is found to be tight and properly grounded, it should be removed and a new one installed. (The presence of sealing compound on the threads of the engine unit will cause a poor ground). If the warning light remains lit when it normally should be out, replace the engine unit before proceeding further to determine the cause for a low pressure indication. The warning light will sometimes light up or flicker when the engine is idling, even though the oil pressure is adequate. However, the light should go out when the engine speed is increased. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Component Information > Specifications Oil Pump: Specifications Rotor Backlash 0.012 in Note: Maximum inner and outer rotor tip clearance. Rotor To Body Clearance 0.001-0.003 in Rotor End Clearance 0.004 in Note: Measured between pump cover mounting surface & end of gear using suitable straightedge & feeler gauges. Maximum Maximum Cover Flatness Variation N/A Note: Pump should be replaced if cover is damaged, scored or worn. Driveshaft To Pump Body Clearance 0.0015-0.0030 in Relief Valve To Body Clearance 0.0015-0.0030 in Relief Spring Pressure 18.2-20.2 lbf at 2.49 in Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Component Information > Service and Repair > Removal and Installation Oil Pump: Service and Repair Removal and Installation V8 ENGINES On some models, the oil pump must be removed when removing the oil pan. These models are indicated in the ``Oil Pan, Replace'' procedures. 1. Remove oil pan as previously described. 2. Remove oil pump attaching bolts and the oil pump. 3. To install, prime pump with engine oil and apply sealant to gasket. 4. Insert distributor intermediate shaft, making sure that it is properly seated, then install oil pump. Do not force pump into place if it will not readily seat, as the intermediate shaft may be misaligned with distributor shaft. To align, rotate intermediate shaft until pump can be seated without applying force. 5. Install oil pan. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Component Information > Service and Repair > Removal and Installation > Page 1566 Oil Pump: Service and Repair Service Fig. 42 Oil pump. 6-300 Fig. 43 Oil pump. V8-255, 302, 351W Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Component Information > Service and Repair > Removal and Installation > Page 1567 Fig. 44 Oil pump assembly. 351M & 400 ROTOR TYPE PUMP 1. To disassemble, Figs. 42, 43 and 44, remove cover, inner rotor and shaft assembly and outer race. Remove staking marks at relief valve chamber cap. Insert a self-threading sheet metal screw of proper diameter into oil pressure relief valve chamber cap and pull cap out of chamber. Then remove spring and plunger. 2. To assemble, install pressure relief valve plunger, spring and a new cap. Stake cap in place. Install outer race, inner rotor and shaft. Be sure identification dimple mark on outer race is facing outward and on the same side as dimple on rotor. Inner rotor and shaft and outer race are furnished only as a unit. One part should not be replaced without replacing the other. 3. Install pump cover. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > Engine - Lack of Power/No Start Diagnosis Intake Manifold: Technical Service Bulletins Engine - Lack of Power/No Start Diagnosis Article No. 91-12-11 06/12/91 LACK OF POWER 7.5L, 5.8L, 5.0L, 4.9L - CATALYTIC CONVERTER DIAGNOSTIC TIPS LIGHT TRUCK: 1986-91 BRONCO, ECONOLINE, F-150-350 SERIES 1988-91 F SUPER DUTY, F47 ISSUE: Lack of power or a no start condition may be diagnosed as an exhaust restriction caused by a plugged catalytic converter. A plugged catalytic converter (internal deterioration) is usually caused by abnormal engine operation. ACTION: Diagnose the catalytic converter to confirm internal failure. Refer to the Catalyst and Exhaust System Diagnostic Section, in the Engine/Emissions Diagnostic Shop Manual and the following procedures for service details. 1. Lack of proper HEGO operation may cause, or be the result of a rich or lean fuel condition, which could cause additional heat in the catalyst. Perform self test KOEO and KOER, service any codes. NOTE: IF TWO DIGIT CODES 41, 42, 85 OR THREE DIGIT CODES 171, 172, 173, 179, 181, 182, 183 AND 565 ARE RECEIVED, CHECK FOR PROPER HEGO GROUND. If the HEGO ground is good, the following areas may be at fault: ^ Ignition Coil ^ Distributor Cap ^ Distributor Rotor ^ Fouled Spark Plug ^ Spark Plug Wires ^ Air Filter ^ Stuck Open Injector ^ Fuel Contamination Engine OIL ^ Manifold Leaks Intake/ Exhaust ^ Fuel Pressure ^ Poor Power Ground ^ Engine Not At Normal Operating Temperature ^ HEGO Sensor 2. Spark timing that is retarded from specification may increase exhaust gas temperature and shorten catalyst life. Refer to the following procedure for service details. a. Check spark timing. Check base timing with spout disconnected. Set base timing to the specification on the vehicle emission decal. b. Check computed timing with spout connected. NOTE: COMPUTED TIMING IS EQUAL TO BASE TIMING PLUS 20~ BTDC +/- 3~. 3. Misfiring spark plugs may cause an unburned fuel air mixture to pass through the catalyst, which could cause higher than normal catalyst temperatures. Refer to the following procedure for service details. a. Check secondary ignition, hook the vehicle up to an engine analyzer and check for a secondary ignition misfire. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > Engine - Lack of Power/No Start Diagnosis > Page 1572 NOTE: SERVICE ANY ITEM THAT IS NOT PERFORMING AT PROPER SPECIFICATIONS BEFORE CONTINUING. 4. Fuel pressure that is too high may cause rich air fuel mixtures to pass through the catalyst which could cause higher than normal catalyst temperatures. Refer to the following procedure for service details. a. Check fuel pressure, install fuel pressure gauge, start and run the engine at idle. Fuel pressures between 28 and 34 PSI are typical (4.9L typically is 15 PSI higher). b. Disconnect the vacuum line going to the fuel pressure regulator. Fuel pressure typically jumps to 40 PSI +/- 3 PSI (4.9L typically is 15 PSI higher). Visually inspect vacuum line for raw fuel. NOTE: FUEL PRESSURES ABOVE THESE VALUES SHOULD BE CORRECTED. HOWEVER, THIS MAY NOT BE THE CAUSE OF THE CONCERN. SERVICE AS NECESSARY. 5. Throttle plates in the throttle body not returning to the proper closed position may cause excessive catalyst temperatures during downhill grades. Refer to the following procedure for service details. a. Visually inspect the throttle body and linkage for: ^ Binding or sticking throttle linkage. ^ Tight speed control linkage or cable. ^ Vacuum line interference. ^ Electrical harness interference. NOTE: AFTERMARKET GOVERNORS, THROTTLE LINKAGE AND CABLES ASSOCIATED WITH POWER TAKE-OFF UNITS, MAY ALSO INTERFERE WITH PROPER THROTTLE RETURN. SERVICE AS NECESSARY. 6. It is extremely important that all systems related to the engine and emission systems operate properly. a. Visually inspect the engine compartment to make sure all vacuum hoses and spark plug wires are properly routed and securely connected. b. Inspect all wiring harnesses and connectors for insulation damage, burned, overheated, loose or broken conditions. c. Verify proper operation of the thermactor system. Thermactor systems that fail to dump thermactor air to the atmosphere properly or at the correct time can cause high catalyst temperatures. d. Visually inspect thermactor system for damaged or kinked hoses and perform a function test on following components: air control valve, check valve, silencer, filter and the air bypass solenoid. e. Verify proper operation of the engine cooling system thermostat. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under Basic Warranty Coverage, Emissions Warranty Coverage OPERATION DESCRIPTION TIME 911211A Diagnostics - Perform 0.5 Hrs. KOEO And KOER Self Tests 911211B Timing - Check Or Adjust 0.5 Hrs. Spark Timing, Check Computed Timing And Check Secondary Ignition System With Engine Analyzer. 911211C Check - Fuel Pressure And 0.2 Hrs. Inspect Vacuum Line For Raw Fuel. 911211D Inspect - Throttle Body And 0.1 Hrs. Linkage. 911211E Inspect - Vacuum Hoses, 0.1 Hrs. Electrical Harnesses, Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > Engine - Lack of Power/No Start Diagnosis > Page 1573 Connectors And Spark Plug Wires For Routing Damage. 911211F Thermactor System - 0.3 Hrs. Inspect For Proper Operation And Damaged Component. Includes Function Check Of Air Control Valve, Thermactor Air Bypass Solenoid, Check Valves, Silencer And Filter. 911211G Thermostat - Check For 0.2 Hrs. Proper Operation. DEALER CODING BASIC PART NO. CONDITION CODE 5E212 25 OASIS CODES: 403000, 603300, 614000 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > Page 1574 Intake Manifold: Specifications Intake Manifold 23-25 ft.lb Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > Page 1575 Intake Manifold: Service and Repair Fig. 13 Intake manifold tightening sequence. V8-255, 302 & V8-351W Fig. 20 Intake manifold installation. V8 engines V8-255, 302 & 351W 1. Drain cooling system, then remove air cleaner with intake duct assembly and crankcase ventilation hose. 2. Disconnect accelerator cable and speed control linkage (if equipped) from carburetor or throttle body. Remove accelerator cable bracket, then disconnect kickdown rod from carburetor or throttle body on models equipped with automatic transmission. Disconnect electric choke, carburetor solenoid electrical connectors or EEC connector, if equipped. 3. Disconnect high tension lead and wires from ignition coil. 4. Disconnect ignition wires from spark plugs, then remove wires and bracket assembly from rocker arm cover attaching stud. 5. Remove distributor cap and ignition wires as an assembly. 6. Disconnect fuel inlet line from carburetor or throttle body. 7. Disconnect vacuum hoses from distributor, then remove distributor and disconnect evaporative hoses, if equipped. 8. Disconnect upper radiator hose from coolant outlet housing. 9. Disconnect electrical connector from coolant temperature sending unit, then remove heater hose from intake manifold. 10. Remove water pump bypass hose from coolant outlet housing, then disconnect crankcase vent hose from rocker arm cover. 11. Remove intake manifold attaching bolts, then the intake manifold, carburetor or throttle body as an assembly. 12. Reverse procedure to install. Apply sealer as shown in Fig. 20. Torque manifold attaching bolts to 23-25 ft-lbs in sequence as shown in Fig. 13. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Level Warning Indicator > Component Information > Technical Service Bulletins > Customer Interest: > 932410 > Nov > 93 > Instrument Cluster Warning Lights - Dimly Lit Oil Level Warning Indicator: Customer Interest Instrument Cluster Warning Lights - Dimly Lit Article No. 93-24-10 11/24/93 ^ LAMP - MALFUNCTION OF FOUR PIN LOW OIL LEVEL RELAY - VEHICLES BUILT AFTER 8/1/92 OR 1983-1993 VEHICLES THAT HAVE HAD SERVICE REPLACEMENT IGNITION SWITCHES AFTER 8/1/92 ^ LAMPS - INSTRUMENT CLUSTER WARNING LIGHTS DIMLY LIT - VEHICLES BUILT AFTER 8/1/92 OR 1983-1993 VEHICLES THAT HAVE HAD SERVICE REPLACEMENT IGNITION SWITCHES AFTER 8/1/92 FORD: 1983 FAIRMONT 1983-89 CROWN VICTORIA, ESCORT 1983-93 MUSTANG, THUNDERBIRD 1983-94 PROBE 1984-86 LTD 1984-94 TEMPO LINCOLN-MERCURY: 1983 LN7, ZEPHYR 1983-87 CONTINENTAL, LYNX 1983-89 GRAND MARQUIS, TOWN CAR 1983-93 COUGAR 1984-86 CAPRI, MARQUIS 1984-94 TOPAZ LIGHT TRUCK: 1983-91 BRONCO 1983-93 ECONOLINE, F-150-350 SERIES, RANGER 1986-91 AEROSTAR 1991-93 EXPLORER ISSUE: The instrument cluster warning light(s) may be dimly lit or there may be a malfunction of the four pin low oil relay on vehicles so equipped. This could be due to the ignition switch. ACTION: If the vehicle displays the subject symptoms and meets the following conditions, replace the ignition switch. Refer to the appropriate Car or Light Truck Service Manual (Section 13-04 for 1983-1990 Cars, Section 11-04 for 1991-1993 Cars and Section 13-05 for 1983-1990 Light Trucks, Section 11-05 for 1991-1993 Light Trucks) for removal and installation procedures. Refer to the Parts Block in this article for correct parts usage. CONDITIONS ^ The vehicle has 14401 wiring attached to the P2 terminal of the ignition switch. Refer to the wiring schematic and/or Electrical And Vacuum Troubleshooting Manual (EVTM) for the concern vehicle. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Level Warning Indicator > Component Information > Technical Service Bulletins > Customer Interest: > 932410 > Nov > 93 > Instrument Cluster Warning Lights - Dimly Lit > Page 1585 ^ The vehicle is equipped with one of the ignition switches identified in the Ignition Switch Part Number Chart. NOTE: THE SERVICE PART NUMBERS FOR THE REPLACEMENT IGNITION SWITCHES WILL HAVE THE SAME PART NUMBERS AS THOSE REPLACED. THE NEW SWITCH HAS BEEN IMPROVED TO CORRECT THE SUBJECT ISSUE. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of The Bumper To Bumper For 1992/93 Models, Basic Warranty Coverage For All Other Models Except Lincolns. Major Component Warranty Coverage For Lincolns OPERATION DESCRIPTION TIME 932410A Replace Ignition Switch - 0.5 Hr. All Light and Compact Trucks DEALER CODING BASIC PART NO. CONDITION CODE 11572 X1 OASIS CODES: 201000, 201100, 206000 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Level Warning Indicator > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 932410 > Nov > 93 > Instrument Cluster Warning Lights - Dimly Lit Oil Level Warning Indicator: All Technical Service Bulletins Instrument Cluster Warning Lights Dimly Lit Article No. 93-24-10 11/24/93 ^ LAMP - MALFUNCTION OF FOUR PIN LOW OIL LEVEL RELAY - VEHICLES BUILT AFTER 8/1/92 OR 1983-1993 VEHICLES THAT HAVE HAD SERVICE REPLACEMENT IGNITION SWITCHES AFTER 8/1/92 ^ LAMPS - INSTRUMENT CLUSTER WARNING LIGHTS DIMLY LIT - VEHICLES BUILT AFTER 8/1/92 OR 1983-1993 VEHICLES THAT HAVE HAD SERVICE REPLACEMENT IGNITION SWITCHES AFTER 8/1/92 FORD: 1983 FAIRMONT 1983-89 CROWN VICTORIA, ESCORT 1983-93 MUSTANG, THUNDERBIRD 1983-94 PROBE 1984-86 LTD 1984-94 TEMPO LINCOLN-MERCURY: 1983 LN7, ZEPHYR 1983-87 CONTINENTAL, LYNX 1983-89 GRAND MARQUIS, TOWN CAR 1983-93 COUGAR 1984-86 CAPRI, MARQUIS 1984-94 TOPAZ LIGHT TRUCK: 1983-91 BRONCO 1983-93 ECONOLINE, F-150-350 SERIES, RANGER 1986-91 AEROSTAR 1991-93 EXPLORER ISSUE: The instrument cluster warning light(s) may be dimly lit or there may be a malfunction of the four pin low oil relay on vehicles so equipped. This could be due to the ignition switch. ACTION: If the vehicle displays the subject symptoms and meets the following conditions, replace the ignition switch. Refer to the appropriate Car or Light Truck Service Manual (Section 13-04 for 1983-1990 Cars, Section 11-04 for 1991-1993 Cars and Section 13-05 for 1983-1990 Light Trucks, Section 11-05 for 1991-1993 Light Trucks) for removal and installation procedures. Refer to the Parts Block in this article for correct parts usage. CONDITIONS ^ The vehicle has 14401 wiring attached to the P2 terminal of the ignition switch. Refer to the wiring schematic and/or Electrical And Vacuum Troubleshooting Manual (EVTM) for the concern vehicle. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Level Warning Indicator > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 932410 > Nov > 93 > Instrument Cluster Warning Lights - Dimly Lit > Page 1591 ^ The vehicle is equipped with one of the ignition switches identified in the Ignition Switch Part Number Chart. NOTE: THE SERVICE PART NUMBERS FOR THE REPLACEMENT IGNITION SWITCHES WILL HAVE THE SAME PART NUMBERS AS THOSE REPLACED. THE NEW SWITCH HAS BEEN IMPROVED TO CORRECT THE SUBJECT ISSUE. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of The Bumper To Bumper For 1992/93 Models, Basic Warranty Coverage For All Other Models Except Lincolns. Major Component Warranty Coverage For Lincolns OPERATION DESCRIPTION TIME 932410A Replace Ignition Switch - 0.5 Hr. All Light and Compact Trucks DEALER CODING BASIC PART NO. CONDITION CODE 11572 X1 OASIS CODES: 201000, 201100, 206000 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Level Warning Indicator > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oil Level Warning Indicator: > 88141 > Jul > 88 > Vent Windows - May Stick to Weatherstrip Window Seal: All Technical Service Bulletins Vent Windows - May Stick to Weatherstrip GLASS - VENT WINDOWS - MANUAL - GLASS STICKS TO WEATHERSTRIP - VEHICLES BUILT BEFORE 4/04/88 Article No. 88-14-1 FORD: 1984-88 ALL CAR LINES LINCOLN-MERCURY: 1984-88 ALL CAR LINES MERKUR: 1985-88 ALL CAR LINES LIGHT TRUCK: 1984-88 ALL LIGHT TRUCK LINES MEDIUM/HEAVY TRUCK: 1984-88 ALL MEDIUM/HEAVY TRUCK LINES ISSUE: Manual vent windows that are not opened very often may stick to the vent window weatherstrip making them hard to open. In some cases, the high opening efforts may cause the weatherstrip to pull out of the vent division bar. ACTION: To correct this, apply "Krytox" oil to the vent window weatherstrip using the following service procedure. FIGURE 1 1. Open the vent window all the way. 2. From inside of vehicle, apply "Krytox" oil on the weatherstrip sealing lips of vent window, Figure 1. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Level Warning Indicator > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oil Level Warning Indicator: > 88141 > Jul > 88 > Vent Windows - May Stick to Weatherstrip > Page 1597 FIGURE 2 3. From outside of vehicle, apply "Krytox" oil on the weatherstrip sealing lips of vent window, Figure 2. 4. Close and open vent window to make sure window operates correctly. NOTE: CONTACT EXCEL INDUSTRIES, INC. TO ORDER "KRYTOX" OIL: (904) 286-8300 EXTENSION 305 REPRESENTATIVE: RACHEL FLYNN. OTHER APPLICABLE ARTICLES: Supersedes 87-11-2 WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION: 881401A TIME: 0.3 Hr. DLR. CODING: Basic Part No. 7022296 - Car 7021448 - Truck Condition Code: 41 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Level Warning Indicator > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oil Level Warning Indicator: > 88141 > Jul > 88 > Vent Windows - May Stick to Weatherstrip > Page 1603 FIGURE 2 3. From outside of vehicle, apply "Krytox" oil on the weatherstrip sealing lips of vent window, Figure 2. 4. Close and open vent window to make sure window operates correctly. NOTE: CONTACT EXCEL INDUSTRIES, INC. TO ORDER "KRYTOX" OIL: (904) 286-8300 EXTENSION 305 REPRESENTATIVE: RACHEL FLYNN. OTHER APPLICABLE ARTICLES: Supersedes 87-11-2 WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION: 881401A TIME: 0.3 Hr. DLR. CODING: Basic Part No. 7022296 - Car 7021448 - Truck Condition Code: 41 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Level Warning Indicator > Component Information > Technical Service Bulletins > Page 1604 Oil Level Warning Indicator: Description and Operation This system is used to indicate a low engine oil level condition. The lamp will be illuminated during engine starting. If oil level is sufficient, the lamp will go off when engine is operating. If oil level is low the lamp will remain on until engine oil is added and the ignition switch is placed in the Off position. The module may take a few minutes to reset. If the engine is started during this period, the last recorded reading will be displayed. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Gauge > Component Information > Testing and Inspection Oil Pressure Gauge: Testing and Inspection This oil pressure indicating system incorporates an instrument voltage regulator, electrical oil pressure gauge and a sending unit which are connected in series. The sending unit consists of a diaphragm, contact and a variable resistor. As oil pressure increases or decreases, the diaphragm actuated the contact on the variable resistor, in turn controlling current flow to the gauge. When oil pressure is low, the resistance of the variable resistor is high, restricting current flow to the gauge, in turn indicating low oil pressure. As oil pressure increases, the resistance of the variable resistor is lowered, permitting an increased current flow to the gauge, resulting in an increased gauge reading. TROUBLESHOOTING A special tester is required to diagnose this type gauge. Follow instructions included with the tester. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Warning Lamp/Indicator > Component Information > Testing and Inspection Oil Pressure Warning Lamp/Indicator: Testing and Inspection Many trucks utilize a warning light on the instrument panel in place of the conventional dash indicating gauge to warn the driver when the oil pressure is dangerously low. The warning light is wired in series with the ignition switch and the engine unit--which is an oil pressure switch. The oil pressure switch contains a diaphragm and a set of contacts. When the ignition switch is turned on, the warning light circuit is energized and the circuit is completed through the closed contacts in the pressure switch. When the engine is started, build-up of oil pressure compresses the diaphragm, opening the contacts, thereby breaking the circuit and putting out the light. TROUBLESHOOTING The oil pressure warning light should go on when the ignition is turned on. If it does not light, disconnect the wire from the engine unit and ground the wire to the frame or cylinder block. Then if the warning light still does not go on with the ignition switch on, replace the bulb. If the warning light goes on when the wire is grounded to the frame or cylinder block, the engine unit should be checked for being loose or poorly grounded. If the unit is found to be tight and properly grounded, it should be removed and a new one installed. (The presence of sealing compound on the threads of the engine unit will cause a poor ground). If the warning light remains lit when it normally should be out, replace the engine unit before proceeding further to determine the cause for a low pressure indication. The warning light will sometimes light up or flicker when the engine is idling, even though the oil pressure is adequate. However, the light should go out when the engine speed is increased. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Technical Service Bulletins > Crankshaft Seal - Leaks, Air Pressure Test Crankshaft Main Bearing Seal: Technical Service Bulletins Crankshaft Seal - Leaks, Air Pressure Test Article No. 86-3-14 LEAK OIL - CRANKSHAFT SEAL - AIR PRESSURE TEST FORD 1986 and Prior FORD, THUNDERBIRD, LTD, ESCORT, FAIRMONT, MUSTANG, EXP, TAURUS LINCOLN-MERCURY 1986 and Prior LINCOLN, MARK, CONTINENTAL, MERCURY, MARQUIS, COUGAR, CAPRI, LYNX, LN7, SABLE LIGHT TRUCK 1986 and Prior RANGER, BRONCO II, AEROSTAR, E AND F SERIES To prevent repeat servicing on engines suspected of oil leakage at the crankshaft seal, determine if the leak is actually from the seal or from another source such as the rear pan seal or galley plugs. The one-piece rear crankshaft seal is released for all passenger car and light truck engines and has proven to be more reliable than the rope or split lip design formerly used. Performing the oil leak air pressure check outlined in all Car and Truck Powertrain Shop Manuals, Section 21- 01 will accurately identify the location of the leak and can verify correction after servicing before the transmission is reinstalled. OTHER APPLICABLE ARTICLES: 80-15-5, 83-14-8 WARRANTY STATUS: "INFORMATION ONLY" Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Technical Service Bulletins > Page 1616 Crankshaft Main Bearing Seal: Specifications Main Bearing Cap Bolt Torque ................................................................................................................................................. 129-142 Nm (95-105 ft-lbs) Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Service and Repair > Removal Crankshaft Main Bearing Seal: Service and Repair Removal NOTE: If crankshaft rear oil seal replacement is the only operation being performed, it can be done in the vehicle. If the oil seal is being replaced in conjunction with a rear main bearing replacement, the engine must be removed from the vehicle. To replace the seal only, proceed as follows: 1. Disconnect battery ground cable from battery, then remove the starter motor. 2. Disconnect the transmission from the engine and slide it back. 3. On a manual shift transmission, remove the pressure plate and cover assembly and the clutch disc. 4. Remove flywheel attaching bolts and remove the flywheel and engine rear cover plate. CAUTION: Avoid scratching or damaging the oil seal surface. 5. Use an awl to punch one hole into the seal metal surface between the seal lip and block. Screw the threaded end of a Jet Plug Remover or equivalent into the hole, and remove the seal. 6. Clean the oil seal recess in the cylinder block and main bearing cap. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Service and Repair > Removal > Page 1619 Crankshaft Main Bearing Seal: Service and Repair Installation 1. Clean, inspect, and polish the rear oil seal rubbing surface on the crankshaft. 2. Coat new oil seal and crankshaft with a light film of engine oil. Crankshaft Rear Oil Seal. CAUTION: Do not apply grease on seal for lubrication. 3. Start the seal into the recess with the seal lip facing FORWARD and install it with a rear oil seal replacer tool. Keep the tool straight with the centerline of the crankshaft and install the seal until the tool contacts the cylinder block surface. Remove the tool and inspect the seal to ensure it was not damaged during installation. 4. Install the engine rear cover plate. Position the flywheel on the crankshaft flange. Coat the threads of the flywheel attaching bolts with Pipe Sealant with TEFLON(R) or equivalent, and install the bolts. Tighten the bolts in sequence across from each other to 102-115 Nm (75-85 ft-lbs). 5. On a manual shift transmission, install the clutch disc and the pressure plate assembly. 6. Install the transmission. On an automatic transmission, do not adjust the transmission linkage. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Service and Repair > Page 1620 Crankshaft Main Bearing Seal: Tools and Equipment Special Service Tool(s) Required: Rear Oil Seal Replacer Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Switch <--> [Oil Pressure Sender] > Component Information > Locations Oil Pressure Switch: Locations LH Side Of V8-351/5. LH Front Of Engine Applicable to: 8L Engine Less EEC-IV Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair Timing Chain: Service and Repair Fig. 27 Valve timing alignment marks Fig. 32 Timing marks aligned for correct valve timing. 1982 V6-232 V6-232, V8-255, 302, 351, 400 & 460 After removing the cover as outlined previously, remove the crankshaft front oil slinger, if equipped. On V6-232 engines, remove camshaft thrust button and spring from end of camshaft. Crank the engine until the timing marks are aligned as shown in Figs. 31 and 32. Remove camshaft sprocket retaining bolt, washer and fuel pump eccentric. Slide sprockets and chain forward and remove them as an assembly. Reverse the order of the foregoing procedure to install the chain and sprockets, being sure the timing marks are properly aligned. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Service and Repair Timing Cover: Service and Repair F-100-150 & Bronco 1. Drain cooling system, then remove fan shroud attaching bolts and position shroud over fan. 2. Disconnect hoses from water pump, then remove drive belts, fan, fan spacer and pulley. 3. Loosen alternator pivot bolt and the alternator adjusting arm-to-water pump attaching bolt. 4. Remove crankshaft pulley and vibration damper. 5. Disconnect fuel outlet line from fuel pump, then remove fuel pump attaching bolts and position pump aside. 6. On all models, remove timing case cover-to-oil pan attaching bolts. 7. Cut oil pan gasket flush with cylinder block face, then remove timing case cover and water pump as an assembly. 8. Reverse procedure to install. Apply RTV sealant to oil pan gasket surfaces. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Technical Service Bulletins > By Symptom Fuel Pressure: By Symptom Technical Service Bulletin # 911211 Date: 910612 Engine - Lack of Power/No Start Diagnosis Article No. 91-12-11 06/12/91 LACK OF POWER 7.5L, 5.8L, 5.0L, 4.9L - CATALYTIC CONVERTER DIAGNOSTIC TIPS LIGHT TRUCK: 1986-91 BRONCO, ECONOLINE, F-150-350 SERIES 1988-91 F SUPER DUTY, F47 ISSUE: Lack of power or a no start condition may be diagnosed as an exhaust restriction caused by a plugged catalytic converter. A plugged catalytic converter (internal deterioration) is usually caused by abnormal engine operation. ACTION: Diagnose the catalytic converter to confirm internal failure. Refer to the Catalyst and Exhaust System Diagnostic Section, in the Engine/Emissions Diagnostic Shop Manual and the following procedures for service details. 1. Lack of proper HEGO operation may cause, or be the result of a rich or lean fuel condition, which could cause additional heat in the catalyst. Perform self test KOEO and KOER, service any codes. NOTE: IF TWO DIGIT CODES 41, 42, 85 OR THREE DIGIT CODES 171, 172, 173, 179, 181, 182, 183 AND 565 ARE RECEIVED, CHECK FOR PROPER HEGO GROUND. If the HEGO ground is good, the following areas may be at fault: ^ Ignition Coil ^ Distributor Cap ^ Distributor Rotor ^ Fouled Spark Plug ^ Spark Plug Wires ^ Air Filter ^ Stuck Open Injector ^ Fuel Contamination Engine OIL ^ Manifold Leaks Intake/ Exhaust ^ Fuel Pressure ^ Poor Power Ground ^ Engine Not At Normal Operating Temperature ^ HEGO Sensor 2. Spark timing that is retarded from specification may increase exhaust gas temperature and shorten catalyst life. Refer to the following procedure for service details. a. Check spark timing. Check base timing with spout disconnected. Set base timing to the specification on the vehicle emission decal. b. Check computed timing with spout connected. NOTE: COMPUTED TIMING IS EQUAL TO BASE TIMING PLUS 20~ BTDC +/- 3~. 3. Misfiring spark plugs may cause an unburned fuel air mixture to pass through the catalyst, which could cause higher than normal catalyst Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Technical Service Bulletins > By Symptom > Page 1637 temperatures. Refer to the following procedure for service details. a. Check secondary ignition, hook the vehicle up to an engine analyzer and check for a secondary ignition misfire. NOTE: SERVICE ANY ITEM THAT IS NOT PERFORMING AT PROPER SPECIFICATIONS BEFORE CONTINUING. 4. Fuel pressure that is too high may cause rich air fuel mixtures to pass through the catalyst which could cause higher than normal catalyst temperatures. Refer to the following procedure for service details. a. Check fuel pressure, install fuel pressure gauge, start and run the engine at idle. Fuel pressures between 28 and 34 PSI are typical (4.9L typically is 15 PSI higher). b. Disconnect the vacuum line going to the fuel pressure regulator. Fuel pressure typically jumps to 40 PSI +/- 3 PSI (4.9L typically is 15 PSI higher). Visually inspect vacuum line for raw fuel. NOTE: FUEL PRESSURES ABOVE THESE VALUES SHOULD BE CORRECTED. HOWEVER, THIS MAY NOT BE THE CAUSE OF THE CONCERN. SERVICE AS NECESSARY. 5. Throttle plates in the throttle body not returning to the proper closed position may cause excessive catalyst temperatures during downhill grades. Refer to the following procedure for service details. a. Visually inspect the throttle body and linkage for: ^ Binding or sticking throttle linkage. ^ Tight speed control linkage or cable. ^ Vacuum line interference. ^ Electrical harness interference. NOTE: AFTERMARKET GOVERNORS, THROTTLE LINKAGE AND CABLES ASSOCIATED WITH POWER TAKE-OFF UNITS, MAY ALSO INTERFERE WITH PROPER THROTTLE RETURN. SERVICE AS NECESSARY. 6. It is extremely important that all systems related to the engine and emission systems operate properly. a. Visually inspect the engine compartment to make sure all vacuum hoses and spark plug wires are properly routed and securely connected. b. Inspect all wiring harnesses and connectors for insulation damage, burned, overheated, loose or broken conditions. c. Verify proper operation of the thermactor system. Thermactor systems that fail to dump thermactor air to the atmosphere properly or at the correct time can cause high catalyst temperatures. d. Visually inspect thermactor system for damaged or kinked hoses and perform a function test on following components: air control valve, check valve, silencer, filter and the air bypass solenoid. e. Verify proper operation of the engine cooling system thermostat. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under Basic Warranty Coverage, Emissions Warranty Coverage OPERATION DESCRIPTION TIME 911211A Diagnostics - Perform 0.5 Hrs. KOEO And KOER Self Tests 911211B Timing - Check Or Adjust 0.5 Hrs. Spark Timing, Check Computed Timing And Check Secondary Ignition System With Engine Analyzer. 911211C Check - Fuel Pressure And 0.2 Hrs. Inspect Vacuum Line For Raw Fuel. 911211D Inspect - Throttle Body And 0.1 Hrs. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Technical Service Bulletins > By Symptom > Page 1638 Linkage. 911211E Inspect - Vacuum Hoses, 0.1 Hrs. Electrical Harnesses, Connectors And Spark Plug Wires For Routing Damage. 911211F Thermactor System - 0.3 Hrs. Inspect For Proper Operation And Damaged Component. Includes Function Check Of Air Control Valve, Thermactor Air Bypass Solenoid, Check Valves, Silencer And Filter. 911211G Thermostat - Check For 0.2 Hrs. Proper Operation. DEALER CODING BASIC PART NO. CONDITION CODE 5E212 25 OASIS CODES: 403000, 603300, 614000 Technical Service Bulletin # 911211 Date: 910612 Engine - Lack of Power/No Start Diagnosis Article No. 91-12-11 06/12/91 LACK OF POWER 7.5L, 5.8L, 5.0L, 4.9L - CATALYTIC CONVERTER DIAGNOSTIC TIPS LIGHT TRUCK: 1986-91 BRONCO, ECONOLINE, F-150-350 SERIES 1988-91 F SUPER DUTY, F47 ISSUE: Lack of power or a no start condition may be diagnosed as an exhaust restriction caused by a plugged catalytic converter. A plugged catalytic converter (internal deterioration) is usually caused by abnormal engine operation. ACTION: Diagnose the catalytic converter to confirm internal failure. Refer to the Catalyst and Exhaust System Diagnostic Section, in the Engine/Emissions Diagnostic Shop Manual and the following procedures for service details. 1. Lack of proper HEGO operation may cause, or be the result of a rich or lean fuel condition, which could cause additional heat in the catalyst. Perform self test KOEO and KOER, service any codes. NOTE: IF TWO DIGIT CODES 41, 42, 85 OR THREE DIGIT CODES 171, 172, 173, 179, 181, 182, 183 AND 565 ARE RECEIVED, CHECK FOR PROPER HEGO GROUND. If the HEGO ground is good, the following areas may be at fault: ^ Ignition Coil ^ Distributor Cap ^ Distributor Rotor ^ Fouled Spark Plug ^ Spark Plug Wires ^ Air Filter ^ Stuck Open Injector ^ Fuel Contamination Engine OIL ^ Manifold Leaks Intake/ Exhaust Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Technical Service Bulletins > By Symptom > Page 1639 ^ Fuel Pressure ^ Poor Power Ground ^ Engine Not At Normal Operating Temperature ^ HEGO Sensor 2. Spark timing that is retarded from specification may increase exhaust gas temperature and shorten catalyst life. Refer to the following procedure for service details. a. Check spark timing. Check base timing with spout disconnected. Set base timing to the specification on the vehicle emission decal. b. Check computed timing with spout connected. NOTE: COMPUTED TIMING IS EQUAL TO BASE TIMING PLUS 20~ BTDC +/- 3~. 3. Misfiring spark plugs may cause an unburned fuel air mixture to pass through the catalyst, which could cause higher than normal catalyst temperatures. Refer to the following procedure for service details. a. Check secondary ignition, hook the vehicle up to an engine analyzer and check for a secondary ignition misfire. NOTE: SERVICE ANY ITEM THAT IS NOT PERFORMING AT PROPER SPECIFICATIONS BEFORE CONTINUING. 4. Fuel pressure that is too high may cause rich air fuel mixtures to pass through the catalyst which could cause higher than normal catalyst temperatures. Refer to the following procedure for service details. a. Check fuel pressure, install fuel pressure gauge, start and run the engine at idle. Fuel pressures between 28 and 34 PSI are typical (4.9L typically is 15 PSI higher). b. Disconnect the vacuum line going to the fuel pressure regulator. Fuel pressure typically jumps to 40 PSI +/- 3 PSI (4.9L typically is 15 PSI higher). Visually inspect vacuum line for raw fuel. NOTE: FUEL PRESSURES ABOVE THESE VALUES SHOULD BE CORRECTED. HOWEVER, THIS MAY NOT BE THE CAUSE OF THE CONCERN. SERVICE AS NECESSARY. 5. Throttle plates in the throttle body not returning to the proper closed position may cause excessive catalyst temperatures during downhill grades. Refer to the following procedure for service details. a. Visually inspect the throttle body and linkage for: ^ Binding or sticking throttle linkage. ^ Tight speed control linkage or cable. ^ Vacuum line interference. ^ Electrical harness interference. NOTE: AFTERMARKET GOVERNORS, THROTTLE LINKAGE AND CABLES ASSOCIATED WITH POWER TAKE-OFF UNITS, MAY ALSO INTERFERE WITH PROPER THROTTLE RETURN. SERVICE AS NECESSARY. 6. It is extremely important that all systems related to the engine and emission systems operate properly. a. Visually inspect the engine compartment to make sure all vacuum hoses and spark plug wires are properly routed and securely connected. b. Inspect all wiring harnesses and connectors for insulation damage, burned, overheated, loose or broken conditions. c. Verify proper operation of the thermactor system. Thermactor systems that fail to dump thermactor air to the atmosphere properly or at the correct time can cause high catalyst temperatures. d. Visually inspect thermactor system for damaged or kinked hoses and perform a function test on following components: air control valve, check valve, silencer, filter and the air bypass solenoid. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Technical Service Bulletins > By Symptom > Page 1640 e. Verify proper operation of the engine cooling system thermostat. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under Basic Warranty Coverage, Emissions Warranty Coverage OPERATION DESCRIPTION TIME 911211A Diagnostics - Perform 0.5 Hrs. KOEO And KOER Self Tests 911211B Timing - Check Or Adjust 0.5 Hrs. Spark Timing, Check Computed Timing And Check Secondary Ignition System With Engine Analyzer. 911211C Check - Fuel Pressure And 0.2 Hrs. Inspect Vacuum Line For Raw Fuel. 911211D Inspect - Throttle Body And 0.1 Hrs. Linkage. 911211E Inspect - Vacuum Hoses, 0.1 Hrs. Electrical Harnesses, Connectors And Spark Plug Wires For Routing Damage. 911211F Thermactor System - 0.3 Hrs. Inspect For Proper Operation And Damaged Component. Includes Function Check Of Air Control Valve, Thermactor Air Bypass Solenoid, Check Valves, Silencer And Filter. 911211G Thermostat - Check For 0.2 Hrs. Proper Operation. DEALER CODING BASIC PART NO. CONDITION CODE 5E212 25 OASIS CODES: 403000, 603300, 614000 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Pressure: > 911211 > Jun > 91 > Engine - Lack of Power/No Start Diagnosis Fuel Pressure: All Technical Service Bulletins Engine - Lack of Power/No Start Diagnosis Article No. 91-12-11 06/12/91 LACK OF POWER 7.5L, 5.8L, 5.0L, 4.9L - CATALYTIC CONVERTER DIAGNOSTIC TIPS LIGHT TRUCK: 1986-91 BRONCO, ECONOLINE, F-150-350 SERIES 1988-91 F SUPER DUTY, F47 ISSUE: Lack of power or a no start condition may be diagnosed as an exhaust restriction caused by a plugged catalytic converter. A plugged catalytic converter (internal deterioration) is usually caused by abnormal engine operation. ACTION: Diagnose the catalytic converter to confirm internal failure. Refer to the Catalyst and Exhaust System Diagnostic Section, in the Engine/Emissions Diagnostic Shop Manual and the following procedures for service details. 1. Lack of proper HEGO operation may cause, or be the result of a rich or lean fuel condition, which could cause additional heat in the catalyst. Perform self test KOEO and KOER, service any codes. NOTE: IF TWO DIGIT CODES 41, 42, 85 OR THREE DIGIT CODES 171, 172, 173, 179, 181, 182, 183 AND 565 ARE RECEIVED, CHECK FOR PROPER HEGO GROUND. If the HEGO ground is good, the following areas may be at fault: ^ Ignition Coil ^ Distributor Cap ^ Distributor Rotor ^ Fouled Spark Plug ^ Spark Plug Wires ^ Air Filter ^ Stuck Open Injector ^ Fuel Contamination Engine OIL ^ Manifold Leaks Intake/ Exhaust ^ Fuel Pressure ^ Poor Power Ground ^ Engine Not At Normal Operating Temperature ^ HEGO Sensor 2. Spark timing that is retarded from specification may increase exhaust gas temperature and shorten catalyst life. Refer to the following procedure for service details. a. Check spark timing. Check base timing with spout disconnected. Set base timing to the specification on the vehicle emission decal. b. Check computed timing with spout connected. NOTE: COMPUTED TIMING IS EQUAL TO BASE TIMING PLUS 20~ BTDC +/- 3~. 3. Misfiring spark plugs may cause an unburned fuel air mixture to pass through the catalyst, which could cause higher than normal catalyst temperatures. Refer to the following procedure for service details. a. Check secondary ignition, hook the vehicle up to an engine analyzer and check for a secondary ignition misfire. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Pressure: > 911211 > Jun > 91 > Engine - Lack of Power/No Start Diagnosis > Page 1646 NOTE: SERVICE ANY ITEM THAT IS NOT PERFORMING AT PROPER SPECIFICATIONS BEFORE CONTINUING. 4. Fuel pressure that is too high may cause rich air fuel mixtures to pass through the catalyst which could cause higher than normal catalyst temperatures. Refer to the following procedure for service details. a. Check fuel pressure, install fuel pressure gauge, start and run the engine at idle. Fuel pressures between 28 and 34 PSI are typical (4.9L typically is 15 PSI higher). b. Disconnect the vacuum line going to the fuel pressure regulator. Fuel pressure typically jumps to 40 PSI +/- 3 PSI (4.9L typically is 15 PSI higher). Visually inspect vacuum line for raw fuel. NOTE: FUEL PRESSURES ABOVE THESE VALUES SHOULD BE CORRECTED. HOWEVER, THIS MAY NOT BE THE CAUSE OF THE CONCERN. SERVICE AS NECESSARY. 5. Throttle plates in the throttle body not returning to the proper closed position may cause excessive catalyst temperatures during downhill grades. Refer to the following procedure for service details. a. Visually inspect the throttle body and linkage for: ^ Binding or sticking throttle linkage. ^ Tight speed control linkage or cable. ^ Vacuum line interference. ^ Electrical harness interference. NOTE: AFTERMARKET GOVERNORS, THROTTLE LINKAGE AND CABLES ASSOCIATED WITH POWER TAKE-OFF UNITS, MAY ALSO INTERFERE WITH PROPER THROTTLE RETURN. SERVICE AS NECESSARY. 6. It is extremely important that all systems related to the engine and emission systems operate properly. a. Visually inspect the engine compartment to make sure all vacuum hoses and spark plug wires are properly routed and securely connected. b. Inspect all wiring harnesses and connectors for insulation damage, burned, overheated, loose or broken conditions. c. Verify proper operation of the thermactor system. Thermactor systems that fail to dump thermactor air to the atmosphere properly or at the correct time can cause high catalyst temperatures. d. Visually inspect thermactor system for damaged or kinked hoses and perform a function test on following components: air control valve, check valve, silencer, filter and the air bypass solenoid. e. Verify proper operation of the engine cooling system thermostat. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under Basic Warranty Coverage, Emissions Warranty Coverage OPERATION DESCRIPTION TIME 911211A Diagnostics - Perform 0.5 Hrs. KOEO And KOER Self Tests 911211B Timing - Check Or Adjust 0.5 Hrs. Spark Timing, Check Computed Timing And Check Secondary Ignition System With Engine Analyzer. 911211C Check - Fuel Pressure And 0.2 Hrs. Inspect Vacuum Line For Raw Fuel. 911211D Inspect - Throttle Body And 0.1 Hrs. Linkage. 911211E Inspect - Vacuum Hoses, 0.1 Hrs. Electrical Harnesses, Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Pressure: > 911211 > Jun > 91 > Engine - Lack of Power/No Start Diagnosis > Page 1647 Connectors And Spark Plug Wires For Routing Damage. 911211F Thermactor System - 0.3 Hrs. Inspect For Proper Operation And Damaged Component. Includes Function Check Of Air Control Valve, Thermactor Air Bypass Solenoid, Check Valves, Silencer And Filter. 911211G Thermostat - Check For 0.2 Hrs. Proper Operation. DEALER CODING BASIC PART NO. CONDITION CODE 5E212 25 OASIS CODES: 403000, 603300, 614000 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Technical Service Bulletins > Page 1648 Fuel Pressure: Specifications FUEL PRESSURE Pump Pressure .................................................................................................................................... ...................................................................... 6 - 8 psi Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Test Fuel Pressure: Testing and Inspection Fuel Pressure Test NOTE: Perform Fuel System Capacity Test prior to performing Pressure Test. See: Fuel System Capacity Test PRESSURE TEST 1. Connect a suitable pressure gauge (0-15 PSI) to the carburetor end of the fuel line. WARNING: Use care to prevent combustion of spilled fuel. 2. Start the engine (it should be able to run for over 30 seconds on the fuel in the carburetor bowl) and read the pressure after 10 seconds. If pump pressure is too low or too high install a new fuel pump. Fuel Pump Pressure ............................................................................................................................ ................................................. 6.0-8.0 PSI 3. Reconnect fuel line at filter and install air cleaner. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Test > Page 1651 Fuel Pressure: Testing and Inspection Fuel System Capacity Test FUEL CAPACITY (VOLUME) TEST - Remove the carburetor air cleaner. - Slowly (fuel line is pressurized) disconnect the fuel line at the fuel filter. WARNING: Use care to prevent combustion of spilled fuel. - Place a suitable non-breakable container (1/2 liter or 1 pint minimum) at the end of the disconnected fuel line (a piece of hose may be needed on the fuel line end). - Disconnect high tension wire from coil. - Crank engine 10 seconds, the fuel pump should deliver 0.158 liters (1/3 pint) of fuel or more. - If fuel flow is to specification perform pressure test. See: Fuel Pressure Test - If fuel flow is low repeat procedure using a non-breakable container of gasoline connected to the fuel pump inlet. If fuel pressure is to specification, the problem is either a plugged in-tank filter, or a kinked or leaking fuel pump inlet hose. - If fuel flow is still below specification, replace fuel pump. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air/Fuel Mixture > System Information > Technical Service Bulletins > Idle Fuel Mixture - Manual Revision Technical Service Bulletin # 8912A26 Date: 890627 Idle Fuel Mixture - Manual Revision ENGINE EMISSIONS DIAGNOSIS SHOP MANUAL- 1986-SECTION 4-IDLE FUEL MIXTURE-PROPANE ENRICHMENT METHOD ENGINE EMISSIONS DIAGNOSIS SHOP MANUAL- 1987-SECTION 4-IDLE FUEL MIXTURE-PROPANE ENRICHMENT METHOD Article No. 89-12A-26 FORD: 1986 ESCORT, LTD, MUSTANG 1986-87 TEMPO 1986 THUNDERBIRD LINCOLN-MERCURY: 1986 CAPRI, COUGAR, MARQUIS 1986-87 TOPAZ LIGHT TRUCK: 1986 AEROSTAR 1986-87 BRONCO, ECONOLINE, F-150, F-250, F-350, RANGER ISSUE: The tachometer reference "or equivalent" as shown in procedure I.-B in both 1986 and 1987 Engine Emissions Diagnosis Manuals is incorrect. This also applies to procedure I.-H in the 1986 Engine Emissions Diagnosis Manual. ACTION: Refer to the pages following this TSB article for the revised Volume H pages which show the correct tachometer designation as: "Connect an analog tachometer, Rotunda 059-000010 or an equivalent analog tachometer." This information should be inserted in your 1986 Engine Emissions Diagnosis Manual, pages 4-83, 4-87, 4-90, 4-93 and the 1987 Manual, pages 4-66 and 4-69. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 680000 Pages 4-83, 4-84 1986 Carburetors, Fuel Charging Assemblies and Throttle Bodies 4-83 Idle Mixture Setting Procedures IDLE FUEL MIXTURE-PROPANE ENRICHMENT METHOD Passenger Car. 1.9L w/740-2V, 2.3L OHC w/YFA-IV FB, 2.3L HSC w/1949-IV, 3.8L w/2150-A-2V and 5.0L w/4180C-4V. Truck, Under 8500 GVW: 5.8L w/4180C-4V. NOTE: This procedure is applicable to the above engines only. If CO and HC are not within specification, perform appropriate electrical diagnostic procedure in Section 15. I. Vehicle Preparation: All Carburetors as noted above. A. Apply the parking brake, and block the wheels. Disconnect the automatic brake release, if so equipped, and plug the vacuum connection. B. Connect an analog tachometer, Rotunda 059-000010 or an equivalent analog tachometer. C. If so equipped, insure that the hot idle compensator is in a closed position and remains so throughout the test. Idle vehicle on kickdown step of fast idle cam for three to five minutes to insure that HIC valve is closed. D. If so equipped, disconnect the fuel evaporative purge hose at the engine or the carburetor, (1.9L engines) and plug the connection. (Not applicable to 5.0L and 5.8L Truck and 5.0L Passenger Car engines). E. If so equipped, disconnect the fuel evaporative purge hose at the air cleaner and plug the nipple. (Not applicable to 5.0L and 5.8L Truck and 5.0L Passenger car engines). F. Disconnect the flexible fresh air tube from the air cleaner duct or adaptor. Using propane enrichment Tool T75L-9600-A or equivalent, insert the tool hose approximately 3/4 of the way into the duct or fresh air tube. If necessary, secure the hose with tape. G. For vehicles equipped with thermactor systems, revise the dump valve vacuum hoses as follows: (Not applicable to 1.9L engines). 1. For dump valves with two vacuum fittings, disconnect and plug the hose(s). Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air/Fuel Mixture > System Information > Technical Service Bulletins > Idle Fuel Mixture - Manual Revision > Page 1656 2. For dump valves with one fitting or combination air bypass/air control valve, remove the hose at the dump valve and plug it. Connect a slave hose from the dump valve vacuum fitting to an intake manifold vacuum fitting. (Not applicable to 5.0L and 5.8L Truck engines with 2150A-2VFB). 3. For 2.3L OHC engines: a. Equipped with a dump valve with two vacuum fittings: Disconnect and plug the hoses. b. Equipped with a combination dump valve and air diverter valve: Disconnect and plug the hoses (2-port) from the dump valve portion. c. Equipped with feedback carburetor: Disconnect electric lead wire from electric PVS. 4. On 3.8L engine Canadian 2150A-2V applications, do not make any thermactor system modifications. 5. For 5.8L 4180C-4V Truck Disconnect and Plug Vacuum Hose to Dump Valve. 1986 4-84 Carburetors, Fuel Charging Assemblies and Throttle Bodies Idle Mixture Setting Procedures H. For 1.9L ATX/MTX vehicles equipped with (Mechanical Vacuum) Idle Speed Control (ISC): 1. With engine off: a. Disconnect and plug the vacuum hose at the MVISC. b. Connect an alternate vacuum source (hand vacuum pump) capable of maintaining 22 inches Hg. to the ISC diaphragm on carburetor, and apply vacuum (retracting ISC plunger clear of throttle linkage). 2. With engine running and transmission in Drive (ATX) or Neutral (MTX): ^ Idle speed should be equal to the ISC retracted speed specified on the emission decal, if not readjust throttle stop adjustment screw under choke housing to specification, (fan On, A/C Off). I. When the above Steps have been completed, proceed to Section II. II. Propane Enrichment Method (Except as Noted) NOTE: Leave all vacuum signal hoses attached to the air cleaner assembly when relocating the assembly to perform carburetor adjustments. The air cleaner assembly must be in place however, when measuring engine speeds. CAUTION: Prolonged engine idling can result in catalyst overheating and excessive underbody temperatures. A. Verify that the timing is set to specification; reset if necessary, Section 15. B. Check engine curb idle rpm or A/C-off rpm, and, if necessary, reset to specification, Section 4. NOTE: Even If the vehicle has less than 160.9 km (100 miles) of operation, set the speed to the normal engine specification. NOTE: Remove PCV valve from grommet, and allow PCV valve to draw underhood air during idle fuel mixture check. (PCV should remain in vertical position). NOTE: Escort/Lynx, has an in-line fixed orifice crankcase vent, not a conventional PCV valve. The fixed orifice is located in the crankcase vent hose located between the vacuum fitting on the intake manifold and the plastic fitting attached to the air cleaner tray. Locate the crankcase vent hose and disconnect at the air cleaner end, allowing the hose to vent to underhood air during idle fuel/air mixture check. C. With the transmission in Neutral, run the engine at approximately 2500 rpm for 15 seconds before each mixture check. NOTE: On Escort/Lynx and Tempo/Topaz, run engine until electric fan comes On. Pages 4-87 Thru 4-90 1986 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air/Fuel Mixture > System Information > Technical Service Bulletins > Idle Fuel Mixture - Manual Revision > Page 1657 Carburetors, Fuel Charging Assemblies and Throttle Bodies 4-87 Idle Mixture Setting Procedures IDLE FUEL MIXTURE-PROPANE ENRICHMENT METHOD 2.0L TRUCK UNDER 8600 GVW w/YFA-IV NOTE: This procedure is for 2.0L Truck engines only, it is not for trucks over 8500 GVW. Propane specifications are not listed for these applications. If CO and HC are not within specification, perform appropriate electrical diagnostic procedure, Section 15. I. Vehicle Preparation A. Apply the parking brake and block the wheels. B. Connect an analog tachometer, Rotunda 059-000010 or an equivalent analog tachometer. C. Disconnect the flexible fresh air tube from the air cleaner duct or adaptor. Using propane enrichment Tool T75L-9600-A or equivalent, insert the tool hose approximately 3/4 of the way into the duct or fresh air tube. If necessary, secure the hose with tape. D. Disconnect and plug the hose at the air bypass valve. E. Disconnect and plug the hose between the purge valve and the spacer at the purge valve. F. When the above Steps have been completed, proceed to Section II. II. Propane Enrichment Method (Except as Noted) NOTE: Leave all vacuum signal hoses attached to the air cleaner assembly when relocating the assembly to perform carburetor adjustments. The air cleaner assembly must be in place, however, when measuring engine speeds. CAUTION: Prolonged engine idling can result in catalyst overheating and excessive underbody temperatures. A. Verify engine timing is set to specification - reset if necessary, Section 15. B. Verify that the curb idle speed is being controlled to specification. Then, electrically disconnect idle speed control (ISC) motor from wiring harness. C. Place A/C-heat selector in the Off position and verify that lamps are Off. NOTE: Remove PCV valve from grommet, locate the crankcase closure hose and disconnect at the air cleaner end (allowing the PCV valve and closure hose to vent to underhood air during idle fuel mixture check). D. With the transmission in Neutral, run the engine at approximately 2500 rpm for 15 seconds before each mixture check. If check is not completed within 60 seconds, repeat this cleanout Step. 1986 4-88 Carburetors, Fuel Charging Assemblies and Throttle Bodies Idle Mixture Setting Procedures E. With the engine idling at normal operating temperature gradually open the propane tool valve and watch for engine speed gain, on the tachometer. When the engine speed reaches a maximum and then begins to drop off, note the amount of speed gain. (Propane cartridge must be in vertical position). NOTE: If the engine speed will not drop off check the propane cartridge gas supply. If necessary repeat Steps D & E with a new propane cartridge gas supply. F. Compare measured speed gain to specified speed gain.* 1. If the measured speed gain is within specification, proceed to Step H. NOTE: The carburetor assembly is equipped with a tamper-resistant idle adjustment feature, the carburetor must be removed from the vehicle. Refer to Shop Manual, Group 24 for removal of the above feature. NOTE: If it is determined that idle fuel mixture adjustment will be necessary, adjust the mixture according to the reset rpm specification. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air/Fuel Mixture > System Information > Technical Service Bulletins > Idle Fuel Mixture - Manual Revision > Page 1658 2. If the measured speed gain is higher than the speed gain specification:* Turn the mixture screw counterclockwise (rich) and simultaneously repeat Steps D and E until the measured speed rise meets the reset rpm specification.* After final adjustment, proceed to Step G. 3. If the measured speed gain is lower than the speed gain specification:* Turn the mixture screw clockwise (lean) and simultaneously repeat Steps D and E until the measured speed rise meets the reset rpm specification.* After final adjustment, proceed to Step G. 4. If there is no rpm rise and the minimum speed gain specification is "0" rpm, perform the following speed drop test: NOTE: Speed drop test information is specified with the artificial enrichment requirements whenever the minimum speed gain specification is "0" rpm. * a. While watching the tachometer, adjust the mixture screw 1/4 turn clockwise (lean). Note the drop in engine speed. b. If the measured speed drop is greater "0" and less than or equal to 30 rpm, proceed to Step G. c. If the measured speed drop is more than 30 rpm, return the mixture screw to the position before adjustment. Proceed to Step G. d. If the measured speed drop is still "0" rpm repeat steps a, b, and c. G. The carburetor fuel air adjustment must have the tamper-resistant feature reinstalled, see Section III. *Refer to the Special Specifications Issue TSB Publications. 1986 Carburetors, Fuel Charging Assemblies and Throttle Bodies 4-89 Idle Mixture Setting Procedures H. Reinstall PCV valve in grommet. Reconnect air bypass valve, purge valve and crankcase closure hose. Reconnect ISC motor to wiring harness. I. Remove all test equipment. Reconnect all system components, reinstall air cleaner, and tighten the air cleaner wing nut(s) to specification. III. Removal and Installation for Tamper-Resistant Fuel Air Adjustment Feature: A. See appropriate carburetor disassembly instructions in Shop Manual, Group 24. 1986 4-90 Carburetors, Fuel Charging Assemblies and Throttle Bodies Idle Mixture Setting Procedures IDLE FUEL MIXTURE-PROPANE ENRICHMENT METHOD 2.8L AEROSTAR w/2150A FB NOTE: This procedure is for the 2.8L engine only. It is not for trucks over 8500 GVW. I. Vehicle Preparation A. Apply the parking brake and block the wheels. B. Verify that timing is set to specification. C. Remove the air cleaner assembly. D. Disconnect wiring harness from carburetor feedback solenoid, located in the rear of carburetor. E. Remove the PCV valve from the rocker cover grommet and move away from the crankcase vapors. F. Disconnect the fuel evaporating purge line (from the intake manifold spacer at the purge solenoid). Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air/Fuel Mixture > System Information > Technical Service Bulletins > Idle Fuel Mixture - Manual Revision > Page 1659 G. Install purge line tester (Tool T84T-9600-A) into the end of purge line that is still connected to the intake manifold spacer. H. Disconnect ISC motor from wiring harness as follows: Simultaneously: 1. Connect tachometer, Rotunda Model 059-00001, 099-00001 or equivalent. 2. Start engine. 3. Manually hold throttle above 1000 rpm. 4. Push ISC plunger until it retracts fully. 5. After plunger retracts, release throttle and quickly unplug the connection. NOTE: Before proceeding, verify that the throttle lever is resting on the speed screw and that the engine idles at specification for anti-dieseling rpm (750 rpm in neutral). I. Install air cleaner assembly, but do not connect the flexible fresh air tube to the air cleaner duct and valve assembly. Using a propane enrichment Tool T75L-9600-A or equivalent, insert the tool hose approximately 3/4 of the way into the duct and valve assembly. If necessary, secure the hose with tape. J. When the above Steps have been completed, proceed to Section II. Pages 4-93 & 4-94 1986 Carburetors, Fuel Charging Assemblies and Throttle Bodies 4-93 Idle Mixture Setting Procedures IDLE FUEL MIXTURE-PROPANE ENRICHMENT METHOD 4.9L TRUCK UNDER 8500 GVW w/YFA-IV FB NOTE: This procedure is for the 4.9L engine only. It is not for trucks over 8600 GVW. Propane specifications are not listed for these applications. If CO and HC are not within specification, perform appropriate electrical diagnostic procedure, Section 15. I. Vehicle Preparation A. Apply the parking brake and block the wheels. Disconnect the automatic brake release (if so equipped), and plug the vacuum connection. B. Connect an analog tachometer, Rotunda 059-000010 or an equivalent analog tachometer. C. Disconnect the flexible fresh air tube from the air cleaner duct or adapter. Using propane enrichment Tool T75L-9600-A or equivalent, insert the tool hose approximately 3/4 of the way into the duct or fresh air tube. If necessary, secure the hose with tape. D. When the above Steps have been completed, proceed to Section II. II. Propane Enrichment Method (Except as Noted) NOTE: Leave all vacuum signal hoses attached to the air cleaner assembly when relocating the assembly to perform carburetor adjustments. The air cleaner assembly must be in place, however, when measuring engine speeds. CAUTION: Prolonged engine idling can result in catalyst overheating and excessive underbody temperatures. A. Verify engine timing is set to specification-reset if necessary, Section 15. B. Place A/C-heat selector in the Off position and verify that all accessories (lamps, defrost, etc.) are Off. 1986 4-94 Carburetors, Fuel Charging Assemblies and Throttle Bodies Idle Mixture Setting Procedures Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air/Fuel Mixture > System Information > Technical Service Bulletins > Idle Fuel Mixture - Manual Revision > Page 1660 Figure 1 - In-Line Base Timing Connector NOTE: Remove PCV valve from grommet locate the crankcase closure hose and disconnect at the air cleaner end (allowing the PCV valve and closure hose to vent to underhood air during idle fuel mixture check). C. Verify that the idle speed control motor and the single wire connector near the distributor (sometimes called the In-Line Base timing connector, Figure 1) are connected electrically. With the transmission in Neutral, run the engine at approximately 2500 rpm for 15 seconds before each mixture check. If check is not completed within 60 seconds, repeat this cleanout Step. D. Return engine to idle and disconnect idle speed control motor from wiring harness. Disconnect single wire connector near the distributor (Fig. 1). With the engine idling at normal operating temperature, place the transmission selector in the position specified for the idle fuel mixture check. Gradually open the propane tool valve and watch for engine speed gain, on the tachometer. When the engine speed reaches a maximum and then begins to drop off, note the amount of speed gain. (Propane cartridge must be in vertical position). NOTE: If the engine speed will not drop off check the propane cartridge gas supply. If necessary repeat Steps C and D with a new propane cartridge gas supply. E. Compare measured speed gain to specified speed gain.* 1. If the measured speed gain is within specification, proceed to Step G. NOTE: The carburetor assembly is equipped with a tamper-resistant idle adjustment feature, the carburetor must be removed from the vehicle. Refer to Group 24, Powertrain Shop manual for removal of the above feature. NOTE: If it is determined that idle fuel mixture adjustment will be necessary, adjust the mixture according to the reset rpm specification. 2. If the measured speed gain is higher than the speed gain specification:* Turn the mixture screw counterclockwise (rich) and simultaneously repeat Steps C and D until the measured speed rise meets the reset rpm specification,* After final adjustment, proceed to Step F. 3. If the measured speed gain is lower than the speed gain specification:* Turn the mixture screw clockwise (lean) and simultaneously repeat Steps C and D until the measured speed rise meets the reset rpm specification.* After final adjustment, proceed to Step F. F. The carburetor fuel air adjustment must have the tamper-resistant feature reinstalled. Refer to appropriate carburetor assembly instructions in Shop Manual, Group 24. G. Reinstall PCV valve in grommet. Reconnect idle speed control motor and crankcase closure system, and the single wire connector near the distributor. H. Remove all test equipment. Reconnect all system components, reinstall air cleaner, and tighten the air cleaner wing nut(s) to specification, *Specified speed gain is 10 to 70 rpm, specified reset is 30 rpm. Pages 4-65 & 4-66 1987 Carburetors, Fuel Charging Assemblies and Throttle Bodies 4-65 Idle Mixture Setting Procedures Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air/Fuel Mixture > System Information > Technical Service Bulletins > Idle Fuel Mixture - Manual Revision > Page 1661 IDLE FUEL MIXTURE-PROPANE ENRICHMENT METHOD Propane Enrichment Procedures Are Not Applicable For The Following: ^ CFI Applications. ^ EFI Applications. ^ Truck Over 8500 GVW Applications. ^ 5.8L MCU Police and Trailer Tow Vehicles w/7200 Carburetors. 1987 4-66 Carburetors, Fuel Charging Assemblies and Throttle Bodies Idle Mixture Setting Procedures IDLE FUEL MIXTURE-PROPANE ENRICHMENT METHOD Passenger Car. 2.3L HSC w/1949-IV Truck, Under 8500 GVW: 5.8L w/418OC-4V. NOTE: This procedure is applicable to the above engines only. If CO and HC are not within specificatlon, perform appropriate electrical diagnostic procedure in Section 15. I. Vehicle Preparation: All Carburetors as noted above. A. Apply the parking brake, and block the wheels, Disconnect the automatic brake release, If so equipped, and plug the vacuum connection. B. Connect an analog tachometer, Rotunda 059-000010 or equivalent analog tachometer. C. If so equipped, ensure that the hot idle compensator is in a closed position and remains so throughout the test. Idle vehicle on kickdown step of fast idle cam for three to five minutes to ensure that HIC valve is closed. D. If so equipped, disconnect the fuel evaporative purge hose at the engine or the carburetor, (1.9L engines) and plug the connection. (Not applicable to 5.8L Truck engines). E. If so equipped, disconnect the fuel evaporative purge hose at the air cleaner and plug the nipple. (Not applicable 5.8L Truck engines.) F. Disconnect the flexible fresh air tube from the air cleaner duct or adaptor. Using propane enrichment Tool T75L-9600-A or equivalent, insert the tool hose approximately 3/4 of the way into the duct or fresh air tube. If necessary, secure the hose with tape. G. For vehicles equipped with Thermactor systems, revise the dump valve vacuum hoses as follows: 1. For dump valves with two vacuum fittings, disconnect and plug the hose(s). 2. For dump valves with one fitting or combination air bypass/air control valve, remove the hose at the dump valve and plug it. Connect a slave hose from the dump valve vacuum fitting to an intake manifold vacuum fitting. (Not applicable to 5.0L and 5.8L Truck engines with 2150A-2VFB). 3. For 5.8L 4180C-4V Truck Disconnect and Plug Vacuum Hose to Dump Valve. H. When the above Steps have been completed, proceed to Section II. Pages 4-69 & 4-70 1987 Carburetors, Fuel Charging Assemblies and Throttle Bodies 4-69 Idle Mixture Setting Procedures IDLE FUEL MIXTURE-PROPANE ENRICHMENT METHOD 2.0L TRUCK UNDER 8500 GVW w/Aisan Carburetor NOTE: This procedure is for 2.0L Truck engines only, it is not for trucks over 8500 GVW. Propane specifications are not listed for these applications. If CO and HC are not within specification, perform appropriate electrical diagnostic procedure, Section 15. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air/Fuel Mixture > System Information > Technical Service Bulletins > Idle Fuel Mixture - Manual Revision > Page 1662 I. Vehicle Preparation A. Apply the parking brake and block the wheels. B. Connect an analog tachometer, Rotunda 059-000010 or an equivalent analog tachometer. C. Disconnect the flexible fresh air tube from the air cleaner duct or adaptor. Using propane enrichment Tool T75L-9600-A or equivalent, insert the tool hose approximately 3/4 of the way into the duct or fresh air tube. If necessary, secure the hose with tape. D. Disconnect and plug the hose at the air bypass valve. E. Disconnect and plug the hose between the purge valve and the spacer at the purge valve. F. When the above Steps have been completed, proceed to Section II. II. Propane Enrichment Method (Except as Noted) NOTE: Leave all vacuum signal hoses attached to the air cleaner assembly when relocating the assembly to perform carburetor adjustments. The air cleaner assembly must be in place, however, when measuring engine speeds. CAUTION: Prolonged engine idling can result in catalyst overheating and excessive underbody temperatures. A. Verify engine timing is set to specification-reset if necessary, Section 15. B. Verify that the curb idle speed is being controlled to specification. Then, electrically disconnect idle speed control (ISC) motor from wiring harness. C. Place A/C-heat selector in the Off position and verify that lamps are Off. NOTE: Remove PCV valve from grommet, locate the crankcase closure hose and disconnect at the air cleaner end (allowing the PCV valve and closure hose to vent to underhood air during idle fuel mixture check). D. With the transmission in Neutral, run the engine at approximately 2500 rpm for 15 seconds before each mixture check. If check is not completed within 60 seconds, repeat this cleanout Step. 1987 4-70 Carburetors, Fuel Charging Assemblies and Throttle Bodies Idle Mixture Setting Procedures E. With the engine idling at normal operating temperature gradually open the propane tool valve and watch for engine speed gain, on the tachometer. When the engine speed reaches a maximum and then begins to drop off, note the amount of speed gain. (Propane cartridge must be in vertical position). NOTE: If the engine speed will not drop off check the propane cartridge gas supply. If necessary repeat Steps D & E with a new propane cartridge gas supply. F. Compare measured speed gain to specified speed gain.* 1. If the measured speed gain is within specification, proceed to Step H. NOTE: The carburetor assembly is equipped with a tamper-resistant idle adjustment feature, the carburetor must be removed from the vehicle. Refer to Shop Manual, Group 24 for removal of the above feature. NOTE: If it is determined that idle fuel mixture adjustment will be necessary, adjust the mixture according to the reset rpm specification. 2. If the measured speed gain is higher than the speed gain specification:* Turn the mixture screw counterclockwise (rich) and simultaneously repeat Steps D and E until the measured speed rise meets the reset rpm specification.* After final adjustment, proceed to Step G. 3. If the measured speed gain is lower than the speed gain specification:* Turn the mixture screw clockwise (lean) and simultaneously repeat Steps D and E until the measured speed rise meets the reset rpm specification.* After final adjustment, proceed to Step G. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air/Fuel Mixture > System Information > Technical Service Bulletins > Idle Fuel Mixture - Manual Revision > Page 1663 4. If there is no rpm rise and the minimum speed gain specification is "0" rpm, perform the following speed drop test: NOTE: Speed drop test information is specified with the artificial enrichment requirements whenever the minimum speed gain specification is "0" rpm.* a. While watching the tachometer, adjust the mixture screw 1/4 turn clockwise (lean). Note the drop in engine speed. b. If the measured speed drop is greater than "0" and less than or equal to 40 rpm, proceed to Step G. c. If the measured speed drop is more than 40 rpm, return the mixture screw to the position before adjustment. Proceed to Step G. d. If the measured speed drop is still "0" rpm repeat steps a, b, and c. G. The carburetor fuel air adjustment must have the tamper-resistant feature reinstalled, see Section III. *Refer to the Special Specifications Issue TSB Publications. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > Customer Interest: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up Technical Service Bulletin # 91257 Date: 911213 Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up Article No. 91-25-7 12/13/91 ^ HARD COLD START - DURING INITIAL START-UP, IDLE OR DECEL - EFI ENGINES SLUDGE IN THROTTLE BODY AND/OR IDLE AIR BY-PASS VALVE ^ HESITATION/STALLS - DURING INITIAL START-UP, IDLE OR DECEL - EFI ENGINES SLUDGE IN THROTTLE BODY AND/OR IDLE AIR BY-PASS VALVE FORD: 1983-87 EXP 1983-91 ESCORT 1984-90 MUSTANG, THUNDERBIRD 1986-90 TAURUS 1986-91 CROWN VICTORIA 1988-90 TEMPO LINCOLN-MERCURY: 1983-85 LN7 1983-87 LYNX 1984-88 CAPRI 1984-90 COUGAR 1986-90 CONTINENTAL, MARK VII, SABLE 1986-91 GRAND MARQUIS, TOWN CAR 1988-90 TOPAZ 1991 TRACER LIGHT TRUCK: 1985-90 BRONCO II, BRONCO 1985-91 ECONOLINE, F-150-350 SERIES 1985-92 RANGER 1986-91 AEROSTAR 1991 EXPLORER ISSUE: Hard cold starts, hesitation and stalls on initial start-up or during idle or decel may be caused by sludge in the throttle body and/or idle by-pass valve. Sludge deposits or oil film on the throttle body bore and plate or the idle air by-pass valve may cause one or more of the following conditions. ^ Hard Cold Start ^ Stall On Initial Start-Up ^ Stall During Idle ^ Stall During Decel ^ Rough Idle ^ Rolling Idle ^ Hesitation During Acceleration ACTION: A new idle air by-pass service kit (F2PZ-9F939-A) is now available for service use to correct sludge contamination concerns of the throttle bore and plate only. It eliminates the need to clean the majority of past model throttle body applications. Cleaning is not required on sludge tolerant throttle body designs released for 1991 and newer model years. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > Customer Interest: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 1672 Figure 1 Install an idle air by-pass service kit (F2PZ-9F939-A) as applicable to provide a permanent correction for symptoms caused by throttle body sludge deposits. Refer to the instruction sheet included in the kit for installation details. Refer to Figure 1 for a specific application list of EFI (port fuel Injection) engines involved in this TSB article. The idle air by-pass service kit (F2PZ-9F939-A) includes the following items. ^ One (1) Idle Adjust Spacer ^ Two (2) Gaskets Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > Customer Interest: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 1673 ^ Two (2) Attaching Bolts ^ One (1) "Attention" Sticker ^ One (1) Instruction Sheet Figure 2 Refer to Figure 2 for a pictorial of the kits components. NOTE: EFFECTIVE WITH THIS TSB, THROTTLE BODY CLEANING IS NO LONGER COVERED UNDER 5/50 EMISSIONS WARRANTY, UNLESS AS SPECIFIED IN THE FOLLOWING APPLICATION CHARTS. FAILURE TO FOLLOW THE CORRECT PROCEDURE MAY RESULT IN THE CLAIM BEING DISALLOWED. The idle air adjust spacer incorporates sludge tolerant design features that eliminate throttle body sludge related conditions. Once installed, throttle body cleaning is not allowed and periodic adjustment of the throttle body is not required. Procedures, Warranty and Labor CHECKS TO MAKE PRIOR TO SERVICE KIT INSTALLATION Confirm that the following items are not causing the idle quality concern before proceeding with the service kit installation. ^ Contamination within the idle air by-pass solenoid ^ Lack of fuel system control (excessively rich or lean) ^ Ignition timing change ^ Incorrect or malfunctioning EGR system ^ Incorrect or malfunctioning cooling system ^ Vacuum leaks (air intake manifold, vacuum hoses, vacuum reservoirs, power brake booster where applicable) ^ EEC diagnostics have been performed and vehicle malfunction indicated service output codes have been resolved and cleared. If any of the areas listed above are found to be at fault, correct them before proceeding with the service kit installation. Idle Speed Adjustment Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > Customer Interest: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 1674 WARNING: BEFORE PROCEEDING WITH THE IDLE SPEED ADJUSTMENT, VERIFY THAT THE FOLLOWING ITEMS ARE TAKEN CARE OF PROPERLY. ^ The transmission is in PARK or Neutral. ^ The parking brake is applied. ^ The wheels are properly blocked. ^ The engine is at operating temperature. ^ The heater, A/C, cooling fan and other accessories are OFF. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > Customer Interest: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 1675 Figure 3 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > Customer Interest: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 1676 Figure 4 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > Customer Interest: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 1677 Figure 5 The EFI throttle body idle speed adjustment procedures for the various model year passenger cars and light trucks are outlined in step-by-step procedures featured in Figures 3, 4 and 5. Select the appropriate procedure for the vehicle involved and adjust the throttle body idle RPM accordingly, after service kit installation. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > Customer Interest: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 1678 Figure 6 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > Customer Interest: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 1679 Figure 7 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > Customer Interest: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 1680 Figure 8 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > Customer Interest: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 1681 Figure 9 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > Customer Interest: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 1682 Figure 10 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > Customer Interest: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 1683 Figure 11 THROTTLE BODY AND IDLE AIR BY-PASS SOLENOID SERVICE PROCEDURE Detailed application charts for throttle body and idle air by-pass solenoid service procedures by engine VIN # /engine displacement/vehicle application and model year are shown in Figures 6 through 11. Refer to these charts to see if the service kit is to be installed and which service cleaning procedure, if any, is to be used. SERVICE CLEANING PROCEDURES The following items should be noted prior to beginning the service cleaning procedure. ^ Confirm that the correct service cleaning procedure is identified in the Application Charts, Figures 6-11, for the vehicle/engine combination being Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > Customer Interest: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 1684 serviced. ^ Do not clean throttle bodies identified to accept service kit (F2PZ-9F939-A), IDLE AIR ADJUST SPACER. ^ Use a 1" (25.4 mm) to 1-1/2" (38.1 mm) wire stemmed horse hair or nylon bottle cleaner type brush. ^ Use rubber gloves and eye protection. ^ Do not clean throttle bodies identified with a yellow/black "ATTENTION" label. ^ Do not clean "Black" plastic air by-pass valves. Refer to TSB 89-13-8 for service details. ^ Do not run vehicles with air flow meters when the air duct is removed. ^ Do not use carburetor cleaner as a cleaning solvent. Use Carburetor Tune-up Cleaner (D9AZ-19579-AA). Procedure # 1 THROTTLE BODY AND IDLE AIR BY-PASS VALVE CLEANING CAUTION: DO NOT RUN VEHICLES EQUIPPED WITH AIR FLOW METERS DURING THE CLEANING PROCEDURE. IF THERE IS A YELLOW/BLACK "ATTENTION" LABEL ON THE THROTTLE BODY ADVISING NOT TO CLEAN, OR IF THE VEHICLE IS IDENTIFIED AS ACCEPTING SERVICE KIT (F2PZ-9F939-A), USE PROCEDURE # 2 FOR IDLE AIR BY-PASS VALVE CLEANING ONLY. 1. Plug the actuator into the connector in the Rotunda Cleaner/Tester, Tool 113-00009. 2. Remove the air duct to the throttle body inlet. 3. Disoonnect the idle air by-pass valve signal lead. 4. Attach the actuator harness plug to the idle air by-pass valve. 5. Start the actuator and then start the engine. Do not start engines that have air flow meters. 6. Spray just enough Carburetor Tune-up Cleaner (D9AZ-19579-AA) into the throttle bore to wet the bore and throttle plate. 7. Spray the Carburetor Tune-up Cleaner for about five (5) seconds into the idle air by-pass valve inlet passage while the actuator is operating. 8. Stop the engine and actuator. Let everything soak for fifteen (15) minutes. 9. After a fifteen (15) minute soak, saturate the cleaning brush with solvent and scrub between the throttle body bore and plate while holding the throttle wide open. NOTE: IT IS NECESSARY TO APPLY SOME PRESSURE ON THE BRUSH WHILE SCRUBBING. 10. Repeat saturating the brush and scrubbing for one (1) to two (2) minutes, making sure to reach into the corners where the throttle shaft meets the bore wall. 11. Start the actuator and the start the engine. Do not start engines that have air flow meters. 12. Spray Carburetor Tune-up Cleaner into the throttle bore for up to one (1) minute to wash away residue. Do not spray for longer than six (6) continuous seconds on engines that have air flow meters and are not running. 13. Spray Carburetor Tune-up Cleaner into the idle by-pass valve passage leading to the inlet of the valve for up to one (1) minute. Do not spray for longer than six (6) continuous seconds on engines that have air flow meters and are not running. 14. Stop actuator and stop engine, if running. NOTE: MAKE SURE THE THROTTLE PLATES OPERATE FREELY AND CLOSE PROPERLY. 15. Reinstall the air duct. 16. Start and run the engine for about one (1) minute to dry out the solvent residue. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > Customer Interest: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 1685 17. Operate the actuator to make sure the solvent is purged from the idle by-pass valve. 18. Disconnect the actuator from the idle air by-pass valve. 19. Reattach the control signal lead to the air by-pass valve. 20. Check engine for normal operation. It may be necessary to reset the idle speed due to a previous adjustment for an idle concern. (Refer to the respective Powertrain/Emissions Diagnosis Service Manual, Throttle Body Section, for idle speed adjust procedure.) Procedure # 2 Idle Air By-Pass Valve Cleaning Only CAUTION: THIS CLEANING PROCEDURE MAY BE USED WITH SLUDGE TOLERANT THROTTLE BODIES WHICH ARE IDENTIFIED WITH A YELLOW/BLACK "ATTENTION" LABEL AND THOSE USING SERVICE KIT (F2PZ-9F939-A). NO ATTEMPT SHOULD BE MADE TO CLEAN THROTTLE BODY BORE/PLATE AREA BY DIRECT SPRAYING OR SCRUBBING. DO NOT RUN VEHICLES WITH AIR FLOW METERS DURING CLEANING PROCEDURE. 1. Plug the actuator into the connector in the Rotunda Air By-Pass Valve Adapter 113-00009, or equivalent. 2. Remove the air duct to the throttle body inlet. 3. Disconnect the idle air by-pass valve signal lead. 4. Attach the actuator harness plug to the idle air by-pass valve. 5. Start the actuator and then start the engine. NOTE: DO NOT START ENGINES THAT HAVE AIR FLOW METERS. 6. Spray the Carburetor Tune-up Cleaner for about five (5) seconds into the idle air by-pass valve inlet passage while the actuator is operating. CAUTION: AVOID DIRECT SPRAYING ON THROTTLE PLATE/BORE AREA. 7. Stop the engine and actuator. Let everything soak for fifteen (15) minutes. 8. Start the actuator and the start the engine. CAUTION: DO NOT START ENGINES THAT HAVE AIR FLOW METERS. 9. Spray Carburetor Tune-up Cleaner into the throttle bore for up to one (1) minute. CAUTION: DO NOT SPRAY FOR LONGER THAN SIX (6) CONTINUOUS SECONDS ON ENGINES THAT HAVE AIR FLOW METERS AND ARE NOT RUNNING. 10. Stop actuator and stop engine if running. 11. Reinstall the air duct. 12. Start and run the engine for about one (1) minute to dry out the solvent residue. 13. Operate the actuator to make sure the solvent is purged from the idle by-pass valve. 14. Disconnect the actuator from the idle air by-pass valve. 15. Reattach the control signal lead to the air by-pass valve. 16. Check engine for normal operation. NOTE: IT SHOULD NOT BE NECESSARY TO RESET THE IDLE SPEED SINCE ONLY THE IDLE AIR BY-PASS VALVE WAS SERVICED IN THIS PROCEDURE Warranty Coverage Throttle bodies and idle air by-pass valves on all EFI (Port Fuel Injection) engines through the 1992 model year that can be cleaned (as identified in the application charts) are covered under 5/50 Emissions Warranty Coverage. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > Customer Interest: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 1686 For those throttle bodies identified as having sludge tolerant designs or using service kit (F2PZ-9F939-A) where cleaning is not allowed per the application charts, the warranty claims for cleaning will not be reimbursed even within the 12/12 warranty coverage period. Cleaning is not allowed. Service kit installation (single time) is covered under 5/50 emission warranty. Labor Standards Operations The labor operations shown in the following Operation/Description/Time columns are identified by procedure number and vehicle line. Specific engines for various vehicles are identified in the sludge cleaning procedure application charts. The throttle body cleaning operations with combinations and the air by-pass valve cleaning combinations will appear in future Labor Manuals under the following operation numbers. ^ 9926 B - Throttle body and idle air by-pass valve cleaning ^ 9926 B2 - Adjust idle speed ^ 9715 A - Air by-pass valve cleaning only ^ 9715 A1 - Adjust idle speed PART NUMBER PART NAME CLASS F2PZ-9F939-A Idle Air By-pass Service Kit B D9AZ-19579-AA Carburstor Tune-Up Cleaner BG OTHER APPLICABLE ARTICLES: 89-13-8 SUPERSEDES: 88-24-5, 88-24-6, 89-16-5, 91-10-9, 91-7-4 Operation Description WARRANTY STATUS: Eligible Under Warranty Coverage As Stated In The Text Of This Article OPERATION DESCRIPTION TIME 912507A Idle Air By-Pass Valve 0.5 Hr. Cleaning - 1983-85 Escort, EXP, LN7, LYNX 1.6L EFI. 912507B Idle Air By-Pass Valve 0.5 Hr. Cleaning - 1986-91 Escort 1.9L EFI, 1986/87 EXP, Lynx 1.9L EFI, 1991 Tracer 1.9L EFI. 912507C Idle Air By Pass Valve 0.5 Hr. Cleaning - 1984-87 Mustang 2.3L T/C, 1986/87 Capri, Cougar 2.3L T/C, 1984-88 T-Bird 2.3L T/C, 1987/92 Mustang 2.3L EFI. 912507D Idle By-Pass Valve Cleaning 0.6 Hr. - 1988-91 Tempo, Topaz 2.3L HSC, 1985-92 Ranger 2.3L EFI. 912507E Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1986/87 Aerostar 2.3L EFI, 1985 Bronco II 2.3L EFI. 912507F Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1986-90 Bronco II 2.9L EFI, 1986-92 Ranger 2.9L EFI. 912507G Idle Air By-Pass Valve 0.6 Hr. Cleaning - 1991/92 Probe 3.0L EFI, 1986-91 Taurus 3.0L EFI, 1987-91 Sable 3.0L EFI. 912507H Idle Air By-Pass Valve 0.7 Hr. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > Customer Interest: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 1687 Cleaning - 1986-91 Aerostar 3.0L EFI, 1991 Ranger 3.0L EFI. 912507I Idle Air By-Pass Valve 0.6 Hr. Cleaning - 1988 Continental, Cougar, Taurus, T-Bird, Sable 3.8L EFI. 1988 Cougar, T-Bird 3.8L S/C. 912507J Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1990-92 Aerostar 4.0L EFI, 1990 Bronco II 4.0L EFI, 1991/92 Explorer 4.0L EFI, 1990-92 Ranger 4.0L EFI. 912507K Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1987-92 Bronco 4.9L EFI, 1987-92 F-Series 4.9L EFI, 1987/90 Econoline (Without Rear Heater) 4.9L EFI, 1991/92 Econoline (All) 4.9L EFI. 912507L Idle Air By-Pass Valve 0.6 Hr. Cleaning - 1986-88 Cougar, T-Bird 5.0L EFI, 1986-87 Continental, Mark VII 5.OL EFI, 1986/91 Crn - Victoria, Grn - Marquis 5.0L EFI, 1986-92 Mark VII 5.0L HO, 1982-92 Mustang 5.0L HO. 912507M Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1985-92 Bronco, E-Series, F-Series 5.0L EFI. 912507N Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1988-90 Bronco, F-Series 5.8L. 1991 Econo, F-Series, Bronco 5.8L (Do not Clean Solenoid, Calib; 1-64E-R10, 1-64H-R10, 1-64J-R10, 1-64K-R10, 1-64M-R10, 1-64P-R10, 1-64R-R10, 1-75A-R00, 1-76A-R00, 1-76B-R00, 1-76C-R00. 912507O Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1991/92 F And B Series, 7.0L EFI. 912507P Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1987-92 E-Series, F-Series 7.5L EFI. 912507Q Throttle Body And Idle Air 0.9 Hr. By-Pass Valve Cleaning - 1989/90 Probe 3.0L EFI. 912507R Throttle Body And Idle Air 0.8 Hr. By-Pass Valve Cleaning - 1987-90 Econoline (With Rear Heat) 4.9L EFI. 912507S Throttle Body And Idle Air 0.9 Hr. By-Pass Valve Cleaning - 1988-90 Econoline 5.8L EFI. 912507T Service Kit Install - All Cars 1.0 Hr. And Light Trucks (Except Aerostar And Econoline) - Refer To The Service Procedure Application Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > Customer Interest: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 1688 Charts, For Vehicle Application. 912507U Service Kit Install - 1.2 Hr. Aerostar, Econoline - Refer To Service Procedure Application Charts - For Vehicle Application. DEALER CODING BASIC PART NO. CONDITION CODE 9E926 49 OASIS CODES: 602300, 607000, 607400, 607700, 608400, 611500, 618400 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up Technical Service Bulletin # 91257 Date: 911213 Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up Article No. 91-25-7 12/13/91 ^ HARD COLD START - DURING INITIAL START-UP, IDLE OR DECEL - EFI ENGINES SLUDGE IN THROTTLE BODY AND/OR IDLE AIR BY-PASS VALVE ^ HESITATION/STALLS - DURING INITIAL START-UP, IDLE OR DECEL - EFI ENGINES SLUDGE IN THROTTLE BODY AND/OR IDLE AIR BY-PASS VALVE FORD: 1983-87 EXP 1983-91 ESCORT 1984-90 MUSTANG, THUNDERBIRD 1986-90 TAURUS 1986-91 CROWN VICTORIA 1988-90 TEMPO LINCOLN-MERCURY: 1983-85 LN7 1983-87 LYNX 1984-88 CAPRI 1984-90 COUGAR 1986-90 CONTINENTAL, MARK VII, SABLE 1986-91 GRAND MARQUIS, TOWN CAR 1988-90 TOPAZ 1991 TRACER LIGHT TRUCK: 1985-90 BRONCO II, BRONCO 1985-91 ECONOLINE, F-150-350 SERIES 1985-92 RANGER 1986-91 AEROSTAR 1991 EXPLORER ISSUE: Hard cold starts, hesitation and stalls on initial start-up or during idle or decel may be caused by sludge in the throttle body and/or idle by-pass valve. Sludge deposits or oil film on the throttle body bore and plate or the idle air by-pass valve may cause one or more of the following conditions. ^ Hard Cold Start ^ Stall On Initial Start-Up ^ Stall During Idle ^ Stall During Decel ^ Rough Idle ^ Rolling Idle ^ Hesitation During Acceleration ACTION: A new idle air by-pass service kit (F2PZ-9F939-A) is now available for service use to correct sludge contamination concerns of the throttle bore and plate only. It eliminates the need to clean the majority of past model throttle body applications. Cleaning is not required on sludge tolerant throttle body designs released for 1991 and newer model years. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 1694 Figure 1 Install an idle air by-pass service kit (F2PZ-9F939-A) as applicable to provide a permanent correction for symptoms caused by throttle body sludge deposits. Refer to the instruction sheet included in the kit for installation details. Refer to Figure 1 for a specific application list of EFI (port fuel Injection) engines involved in this TSB article. The idle air by-pass service kit (F2PZ-9F939-A) includes the following items. ^ One (1) Idle Adjust Spacer ^ Two (2) Gaskets Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 1695 ^ Two (2) Attaching Bolts ^ One (1) "Attention" Sticker ^ One (1) Instruction Sheet Figure 2 Refer to Figure 2 for a pictorial of the kits components. NOTE: EFFECTIVE WITH THIS TSB, THROTTLE BODY CLEANING IS NO LONGER COVERED UNDER 5/50 EMISSIONS WARRANTY, UNLESS AS SPECIFIED IN THE FOLLOWING APPLICATION CHARTS. FAILURE TO FOLLOW THE CORRECT PROCEDURE MAY RESULT IN THE CLAIM BEING DISALLOWED. The idle air adjust spacer incorporates sludge tolerant design features that eliminate throttle body sludge related conditions. Once installed, throttle body cleaning is not allowed and periodic adjustment of the throttle body is not required. Procedures, Warranty and Labor CHECKS TO MAKE PRIOR TO SERVICE KIT INSTALLATION Confirm that the following items are not causing the idle quality concern before proceeding with the service kit installation. ^ Contamination within the idle air by-pass solenoid ^ Lack of fuel system control (excessively rich or lean) ^ Ignition timing change ^ Incorrect or malfunctioning EGR system ^ Incorrect or malfunctioning cooling system ^ Vacuum leaks (air intake manifold, vacuum hoses, vacuum reservoirs, power brake booster where applicable) ^ EEC diagnostics have been performed and vehicle malfunction indicated service output codes have been resolved and cleared. If any of the areas listed above are found to be at fault, correct them before proceeding with the service kit installation. Idle Speed Adjustment Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 1696 WARNING: BEFORE PROCEEDING WITH THE IDLE SPEED ADJUSTMENT, VERIFY THAT THE FOLLOWING ITEMS ARE TAKEN CARE OF PROPERLY. ^ The transmission is in PARK or Neutral. ^ The parking brake is applied. ^ The wheels are properly blocked. ^ The engine is at operating temperature. ^ The heater, A/C, cooling fan and other accessories are OFF. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 1697 Figure 3 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 1698 Figure 4 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 1699 Figure 5 The EFI throttle body idle speed adjustment procedures for the various model year passenger cars and light trucks are outlined in step-by-step procedures featured in Figures 3, 4 and 5. Select the appropriate procedure for the vehicle involved and adjust the throttle body idle RPM accordingly, after service kit installation. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 1700 Figure 6 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 1701 Figure 7 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 1702 Figure 8 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 1703 Figure 9 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 1704 Figure 10 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 1705 Figure 11 THROTTLE BODY AND IDLE AIR BY-PASS SOLENOID SERVICE PROCEDURE Detailed application charts for throttle body and idle air by-pass solenoid service procedures by engine VIN # /engine displacement/vehicle application and model year are shown in Figures 6 through 11. Refer to these charts to see if the service kit is to be installed and which service cleaning procedure, if any, is to be used. SERVICE CLEANING PROCEDURES The following items should be noted prior to beginning the service cleaning procedure. ^ Confirm that the correct service cleaning procedure is identified in the Application Charts, Figures 6-11, for the vehicle/engine combination being Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 1706 serviced. ^ Do not clean throttle bodies identified to accept service kit (F2PZ-9F939-A), IDLE AIR ADJUST SPACER. ^ Use a 1" (25.4 mm) to 1-1/2" (38.1 mm) wire stemmed horse hair or nylon bottle cleaner type brush. ^ Use rubber gloves and eye protection. ^ Do not clean throttle bodies identified with a yellow/black "ATTENTION" label. ^ Do not clean "Black" plastic air by-pass valves. Refer to TSB 89-13-8 for service details. ^ Do not run vehicles with air flow meters when the air duct is removed. ^ Do not use carburetor cleaner as a cleaning solvent. Use Carburetor Tune-up Cleaner (D9AZ-19579-AA). Procedure # 1 THROTTLE BODY AND IDLE AIR BY-PASS VALVE CLEANING CAUTION: DO NOT RUN VEHICLES EQUIPPED WITH AIR FLOW METERS DURING THE CLEANING PROCEDURE. IF THERE IS A YELLOW/BLACK "ATTENTION" LABEL ON THE THROTTLE BODY ADVISING NOT TO CLEAN, OR IF THE VEHICLE IS IDENTIFIED AS ACCEPTING SERVICE KIT (F2PZ-9F939-A), USE PROCEDURE # 2 FOR IDLE AIR BY-PASS VALVE CLEANING ONLY. 1. Plug the actuator into the connector in the Rotunda Cleaner/Tester, Tool 113-00009. 2. Remove the air duct to the throttle body inlet. 3. Disoonnect the idle air by-pass valve signal lead. 4. Attach the actuator harness plug to the idle air by-pass valve. 5. Start the actuator and then start the engine. Do not start engines that have air flow meters. 6. Spray just enough Carburetor Tune-up Cleaner (D9AZ-19579-AA) into the throttle bore to wet the bore and throttle plate. 7. Spray the Carburetor Tune-up Cleaner for about five (5) seconds into the idle air by-pass valve inlet passage while the actuator is operating. 8. Stop the engine and actuator. Let everything soak for fifteen (15) minutes. 9. After a fifteen (15) minute soak, saturate the cleaning brush with solvent and scrub between the throttle body bore and plate while holding the throttle wide open. NOTE: IT IS NECESSARY TO APPLY SOME PRESSURE ON THE BRUSH WHILE SCRUBBING. 10. Repeat saturating the brush and scrubbing for one (1) to two (2) minutes, making sure to reach into the corners where the throttle shaft meets the bore wall. 11. Start the actuator and the start the engine. Do not start engines that have air flow meters. 12. Spray Carburetor Tune-up Cleaner into the throttle bore for up to one (1) minute to wash away residue. Do not spray for longer than six (6) continuous seconds on engines that have air flow meters and are not running. 13. Spray Carburetor Tune-up Cleaner into the idle by-pass valve passage leading to the inlet of the valve for up to one (1) minute. Do not spray for longer than six (6) continuous seconds on engines that have air flow meters and are not running. 14. Stop actuator and stop engine, if running. NOTE: MAKE SURE THE THROTTLE PLATES OPERATE FREELY AND CLOSE PROPERLY. 15. Reinstall the air duct. 16. Start and run the engine for about one (1) minute to dry out the solvent residue. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 1707 17. Operate the actuator to make sure the solvent is purged from the idle by-pass valve. 18. Disconnect the actuator from the idle air by-pass valve. 19. Reattach the control signal lead to the air by-pass valve. 20. Check engine for normal operation. It may be necessary to reset the idle speed due to a previous adjustment for an idle concern. (Refer to the respective Powertrain/Emissions Diagnosis Service Manual, Throttle Body Section, for idle speed adjust procedure.) Procedure # 2 Idle Air By-Pass Valve Cleaning Only CAUTION: THIS CLEANING PROCEDURE MAY BE USED WITH SLUDGE TOLERANT THROTTLE BODIES WHICH ARE IDENTIFIED WITH A YELLOW/BLACK "ATTENTION" LABEL AND THOSE USING SERVICE KIT (F2PZ-9F939-A). NO ATTEMPT SHOULD BE MADE TO CLEAN THROTTLE BODY BORE/PLATE AREA BY DIRECT SPRAYING OR SCRUBBING. DO NOT RUN VEHICLES WITH AIR FLOW METERS DURING CLEANING PROCEDURE. 1. Plug the actuator into the connector in the Rotunda Air By-Pass Valve Adapter 113-00009, or equivalent. 2. Remove the air duct to the throttle body inlet. 3. Disconnect the idle air by-pass valve signal lead. 4. Attach the actuator harness plug to the idle air by-pass valve. 5. Start the actuator and then start the engine. NOTE: DO NOT START ENGINES THAT HAVE AIR FLOW METERS. 6. Spray the Carburetor Tune-up Cleaner for about five (5) seconds into the idle air by-pass valve inlet passage while the actuator is operating. CAUTION: AVOID DIRECT SPRAYING ON THROTTLE PLATE/BORE AREA. 7. Stop the engine and actuator. Let everything soak for fifteen (15) minutes. 8. Start the actuator and the start the engine. CAUTION: DO NOT START ENGINES THAT HAVE AIR FLOW METERS. 9. Spray Carburetor Tune-up Cleaner into the throttle bore for up to one (1) minute. CAUTION: DO NOT SPRAY FOR LONGER THAN SIX (6) CONTINUOUS SECONDS ON ENGINES THAT HAVE AIR FLOW METERS AND ARE NOT RUNNING. 10. Stop actuator and stop engine if running. 11. Reinstall the air duct. 12. Start and run the engine for about one (1) minute to dry out the solvent residue. 13. Operate the actuator to make sure the solvent is purged from the idle by-pass valve. 14. Disconnect the actuator from the idle air by-pass valve. 15. Reattach the control signal lead to the air by-pass valve. 16. Check engine for normal operation. NOTE: IT SHOULD NOT BE NECESSARY TO RESET THE IDLE SPEED SINCE ONLY THE IDLE AIR BY-PASS VALVE WAS SERVICED IN THIS PROCEDURE Warranty Coverage Throttle bodies and idle air by-pass valves on all EFI (Port Fuel Injection) engines through the 1992 model year that can be cleaned (as identified in the application charts) are covered under 5/50 Emissions Warranty Coverage. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 1708 For those throttle bodies identified as having sludge tolerant designs or using service kit (F2PZ-9F939-A) where cleaning is not allowed per the application charts, the warranty claims for cleaning will not be reimbursed even within the 12/12 warranty coverage period. Cleaning is not allowed. Service kit installation (single time) is covered under 5/50 emission warranty. Labor Standards Operations The labor operations shown in the following Operation/Description/Time columns are identified by procedure number and vehicle line. Specific engines for various vehicles are identified in the sludge cleaning procedure application charts. The throttle body cleaning operations with combinations and the air by-pass valve cleaning combinations will appear in future Labor Manuals under the following operation numbers. ^ 9926 B - Throttle body and idle air by-pass valve cleaning ^ 9926 B2 - Adjust idle speed ^ 9715 A - Air by-pass valve cleaning only ^ 9715 A1 - Adjust idle speed PART NUMBER PART NAME CLASS F2PZ-9F939-A Idle Air By-pass Service Kit B D9AZ-19579-AA Carburstor Tune-Up Cleaner BG OTHER APPLICABLE ARTICLES: 89-13-8 SUPERSEDES: 88-24-5, 88-24-6, 89-16-5, 91-10-9, 91-7-4 Operation Description WARRANTY STATUS: Eligible Under Warranty Coverage As Stated In The Text Of This Article OPERATION DESCRIPTION TIME 912507A Idle Air By-Pass Valve 0.5 Hr. Cleaning - 1983-85 Escort, EXP, LN7, LYNX 1.6L EFI. 912507B Idle Air By-Pass Valve 0.5 Hr. Cleaning - 1986-91 Escort 1.9L EFI, 1986/87 EXP, Lynx 1.9L EFI, 1991 Tracer 1.9L EFI. 912507C Idle Air By Pass Valve 0.5 Hr. Cleaning - 1984-87 Mustang 2.3L T/C, 1986/87 Capri, Cougar 2.3L T/C, 1984-88 T-Bird 2.3L T/C, 1987/92 Mustang 2.3L EFI. 912507D Idle By-Pass Valve Cleaning 0.6 Hr. - 1988-91 Tempo, Topaz 2.3L HSC, 1985-92 Ranger 2.3L EFI. 912507E Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1986/87 Aerostar 2.3L EFI, 1985 Bronco II 2.3L EFI. 912507F Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1986-90 Bronco II 2.9L EFI, 1986-92 Ranger 2.9L EFI. 912507G Idle Air By-Pass Valve 0.6 Hr. Cleaning - 1991/92 Probe 3.0L EFI, 1986-91 Taurus 3.0L EFI, 1987-91 Sable 3.0L EFI. 912507H Idle Air By-Pass Valve 0.7 Hr. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 1709 Cleaning - 1986-91 Aerostar 3.0L EFI, 1991 Ranger 3.0L EFI. 912507I Idle Air By-Pass Valve 0.6 Hr. Cleaning - 1988 Continental, Cougar, Taurus, T-Bird, Sable 3.8L EFI. 1988 Cougar, T-Bird 3.8L S/C. 912507J Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1990-92 Aerostar 4.0L EFI, 1990 Bronco II 4.0L EFI, 1991/92 Explorer 4.0L EFI, 1990-92 Ranger 4.0L EFI. 912507K Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1987-92 Bronco 4.9L EFI, 1987-92 F-Series 4.9L EFI, 1987/90 Econoline (Without Rear Heater) 4.9L EFI, 1991/92 Econoline (All) 4.9L EFI. 912507L Idle Air By-Pass Valve 0.6 Hr. Cleaning - 1986-88 Cougar, T-Bird 5.0L EFI, 1986-87 Continental, Mark VII 5.OL EFI, 1986/91 Crn - Victoria, Grn - Marquis 5.0L EFI, 1986-92 Mark VII 5.0L HO, 1982-92 Mustang 5.0L HO. 912507M Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1985-92 Bronco, E-Series, F-Series 5.0L EFI. 912507N Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1988-90 Bronco, F-Series 5.8L. 1991 Econo, F-Series, Bronco 5.8L (Do not Clean Solenoid, Calib; 1-64E-R10, 1-64H-R10, 1-64J-R10, 1-64K-R10, 1-64M-R10, 1-64P-R10, 1-64R-R10, 1-75A-R00, 1-76A-R00, 1-76B-R00, 1-76C-R00. 912507O Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1991/92 F And B Series, 7.0L EFI. 912507P Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1987-92 E-Series, F-Series 7.5L EFI. 912507Q Throttle Body And Idle Air 0.9 Hr. By-Pass Valve Cleaning - 1989/90 Probe 3.0L EFI. 912507R Throttle Body And Idle Air 0.8 Hr. By-Pass Valve Cleaning - 1987-90 Econoline (With Rear Heat) 4.9L EFI. 912507S Throttle Body And Idle Air 0.9 Hr. By-Pass Valve Cleaning - 1988-90 Econoline 5.8L EFI. 912507T Service Kit Install - All Cars 1.0 Hr. And Light Trucks (Except Aerostar And Econoline) - Refer To The Service Procedure Application Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 1710 Charts, For Vehicle Application. 912507U Service Kit Install - 1.2 Hr. Aerostar, Econoline - Refer To Service Procedure Application Charts - For Vehicle Application. DEALER CODING BASIC PART NO. CONDITION CODE 9E926 49 OASIS CODES: 602300, 607000, 607400, 607700, 608400, 611500, 618400 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 861516 > Jul > 86 > Vehicle - High Altitude Modification Idle Speed: All Technical Service Bulletins Vehicle - High Altitude Modification Article No. 86-15-16 ALTITUDE (5.8L (W)) - MODIFICATION OF SEA LEVEL CALIBRATION FOR ALTITUDE APPLICATION - VEHICLES WITH 4V CARBURETORS ONLY - OVER 8500 LBS. GVWR LIGHT TRUCK 1986 E SERIES, F SERIES CALIBRATION: 5-76J-R17 (Manual Transmission) WARNING: This modification is authorized only for the listed engines. Performing this modification on other engine calibrations is unauthorized and could create liability under applicable federal or local laws. Customers who may have relocated and/or continually operate the subject vehicles in high altitude (above 4,000 ft. alt.) may have the following procedure performed to improve performance. 1. Remove existing PCV valve and replace with new PCV valve (part number D90Z-6A666-A). 2. Advance initial ignition timing 6~ from nominal setting of 8~ BTDC to 14~ BTDC. Refer to 1986 Light Truck Shop Manual, Volume B, Section 23-01. 3. Increase choke pull down hard gauge setting to .193". Refer to 1986 Light Truck Shop Manual, Volume B, Section 24-26. 4. Remove existing choke cap and replace with new choke cap 47R-776-A (part number E5PZ-9848-B). 5. Reset hi-cam and curb idle speeds to specification (refer to Vehicle Emission Control Information Decal). Obtain a Vehicle Emission Control Information Update Decal (available at all Ford or Lincoln-Mercury dealers) and fill in the appropriate information as indicated. If the vehicle is returned to continuous sea level (below 4,000 ft. alt.) operation, the above procedure should be reversed and the Vehicle Emission Control Information Update Decal should be removed from the vehicle. PART NUMBER PART NAME CLASS D90Z-6A666-A PCV Valve A E5PZ-9848-B Choke Cap C OTHER APPLICABLE ARTICLES: 85-21-16 WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION: SP9514A86 TIME: 1.3 Hrs. DLR. CODING: Basic Part No. DRIVE - Code: N4, P6, T5 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Other Service Bulletins for Idle Speed: > 861516 > Jul > 86 > Vehicle - High Altitude Modification Idle Speed: All Technical Service Bulletins Vehicle - High Altitude Modification Article No. 86-15-16 ALTITUDE (5.8L (W)) - MODIFICATION OF SEA LEVEL CALIBRATION FOR ALTITUDE APPLICATION - VEHICLES WITH 4V CARBURETORS ONLY - OVER 8500 LBS. GVWR LIGHT TRUCK 1986 E SERIES, F SERIES CALIBRATION: 5-76J-R17 (Manual Transmission) WARNING: This modification is authorized only for the listed engines. Performing this modification on other engine calibrations is unauthorized and could create liability under applicable federal or local laws. Customers who may have relocated and/or continually operate the subject vehicles in high altitude (above 4,000 ft. alt.) may have the following procedure performed to improve performance. 1. Remove existing PCV valve and replace with new PCV valve (part number D90Z-6A666-A). 2. Advance initial ignition timing 6~ from nominal setting of 8~ BTDC to 14~ BTDC. Refer to 1986 Light Truck Shop Manual, Volume B, Section 23-01. 3. Increase choke pull down hard gauge setting to .193". Refer to 1986 Light Truck Shop Manual, Volume B, Section 24-26. 4. Remove existing choke cap and replace with new choke cap 47R-776-A (part number E5PZ-9848-B). 5. Reset hi-cam and curb idle speeds to specification (refer to Vehicle Emission Control Information Decal). Obtain a Vehicle Emission Control Information Update Decal (available at all Ford or Lincoln-Mercury dealers) and fill in the appropriate information as indicated. If the vehicle is returned to continuous sea level (below 4,000 ft. alt.) operation, the above procedure should be reversed and the Vehicle Emission Control Information Update Decal should be removed from the vehicle. PART NUMBER PART NAME CLASS D90Z-6A666-A PCV Valve A E5PZ-9848-B Choke Cap C OTHER APPLICABLE ARTICLES: 85-21-16 WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION: SP9514A86 TIME: 1.3 Hrs. DLR. CODING: Basic Part No. DRIVE - Code: N4, P6, T5 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Other Service Bulletins for Idle Speed: > Page 1720 Idle Speed: By Symptom Technical Service Bulletin # 91257 Date: 911213 Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up Article No. 91-25-7 12/13/91 ^ HARD COLD START - DURING INITIAL START-UP, IDLE OR DECEL - EFI ENGINES SLUDGE IN THROTTLE BODY AND/OR IDLE AIR BY-PASS VALVE ^ HESITATION/STALLS - DURING INITIAL START-UP, IDLE OR DECEL - EFI ENGINES SLUDGE IN THROTTLE BODY AND/OR IDLE AIR BY-PASS VALVE FORD: 1983-87 EXP 1983-91 ESCORT 1984-90 MUSTANG, THUNDERBIRD 1986-90 TAURUS 1986-91 CROWN VICTORIA 1988-90 TEMPO LINCOLN-MERCURY: 1983-85 LN7 1983-87 LYNX 1984-88 CAPRI 1984-90 COUGAR 1986-90 CONTINENTAL, MARK VII, SABLE 1986-91 GRAND MARQUIS, TOWN CAR 1988-90 TOPAZ 1991 TRACER LIGHT TRUCK: 1985-90 BRONCO II, BRONCO 1985-91 ECONOLINE, F-150-350 SERIES 1985-92 RANGER 1986-91 AEROSTAR 1991 EXPLORER ISSUE: Hard cold starts, hesitation and stalls on initial start-up or during idle or decel may be caused by sludge in the throttle body and/or idle by-pass valve. Sludge deposits or oil film on the throttle body bore and plate or the idle air by-pass valve may cause one or more of the following conditions. ^ Hard Cold Start ^ Stall On Initial Start-Up ^ Stall During Idle ^ Stall During Decel ^ Rough Idle ^ Rolling Idle ^ Hesitation During Acceleration ACTION: A new idle air by-pass service kit (F2PZ-9F939-A) is now available for service use to correct sludge contamination concerns of the throttle bore and plate only. It eliminates the need to clean the majority of past model throttle body applications. Cleaning is not required on sludge tolerant throttle body designs released for 1991 and newer model years. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Other Service Bulletins for Idle Speed: > Page 1721 Figure 1 Install an idle air by-pass service kit (F2PZ-9F939-A) as applicable to provide a permanent correction for symptoms caused by throttle body sludge deposits. Refer to the instruction sheet included in the kit for installation details. Refer to Figure 1 for a specific application list of EFI (port fuel Injection) engines involved in this TSB article. The idle air by-pass service kit (F2PZ-9F939-A) includes the following items. ^ One (1) Idle Adjust Spacer ^ Two (2) Gaskets Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Other Service Bulletins for Idle Speed: > Page 1722 ^ Two (2) Attaching Bolts ^ One (1) "Attention" Sticker ^ One (1) Instruction Sheet Figure 2 Refer to Figure 2 for a pictorial of the kits components. NOTE: EFFECTIVE WITH THIS TSB, THROTTLE BODY CLEANING IS NO LONGER COVERED UNDER 5/50 EMISSIONS WARRANTY, UNLESS AS SPECIFIED IN THE FOLLOWING APPLICATION CHARTS. FAILURE TO FOLLOW THE CORRECT PROCEDURE MAY RESULT IN THE CLAIM BEING DISALLOWED. The idle air adjust spacer incorporates sludge tolerant design features that eliminate throttle body sludge related conditions. Once installed, throttle body cleaning is not allowed and periodic adjustment of the throttle body is not required. Procedures, Warranty and Labor CHECKS TO MAKE PRIOR TO SERVICE KIT INSTALLATION Confirm that the following items are not causing the idle quality concern before proceeding with the service kit installation. ^ Contamination within the idle air by-pass solenoid ^ Lack of fuel system control (excessively rich or lean) ^ Ignition timing change ^ Incorrect or malfunctioning EGR system ^ Incorrect or malfunctioning cooling system ^ Vacuum leaks (air intake manifold, vacuum hoses, vacuum reservoirs, power brake booster where applicable) ^ EEC diagnostics have been performed and vehicle malfunction indicated service output codes have been resolved and cleared. If any of the areas listed above are found to be at fault, correct them before proceeding with the service kit installation. Idle Speed Adjustment Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Other Service Bulletins for Idle Speed: > Page 1723 WARNING: BEFORE PROCEEDING WITH THE IDLE SPEED ADJUSTMENT, VERIFY THAT THE FOLLOWING ITEMS ARE TAKEN CARE OF PROPERLY. ^ The transmission is in PARK or Neutral. ^ The parking brake is applied. ^ The wheels are properly blocked. ^ The engine is at operating temperature. ^ The heater, A/C, cooling fan and other accessories are OFF. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Other Service Bulletins for Idle Speed: > Page 1724 Figure 3 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Other Service Bulletins for Idle Speed: > Page 1725 Figure 4 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Other Service Bulletins for Idle Speed: > Page 1726 Figure 5 The EFI throttle body idle speed adjustment procedures for the various model year passenger cars and light trucks are outlined in step-by-step procedures featured in Figures 3, 4 and 5. Select the appropriate procedure for the vehicle involved and adjust the throttle body idle RPM accordingly, after service kit installation. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Other Service Bulletins for Idle Speed: > Page 1727 Figure 6 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Other Service Bulletins for Idle Speed: > Page 1728 Figure 7 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Other Service Bulletins for Idle Speed: > Page 1729 Figure 8 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Other Service Bulletins for Idle Speed: > Page 1730 Figure 9 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Other Service Bulletins for Idle Speed: > Page 1731 Figure 10 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Other Service Bulletins for Idle Speed: > Page 1732 Figure 11 THROTTLE BODY AND IDLE AIR BY-PASS SOLENOID SERVICE PROCEDURE Detailed application charts for throttle body and idle air by-pass solenoid service procedures by engine VIN # /engine displacement/vehicle application and model year are shown in Figures 6 through 11. Refer to these charts to see if the service kit is to be installed and which service cleaning procedure, if any, is to be used. SERVICE CLEANING PROCEDURES The following items should be noted prior to beginning the service cleaning procedure. ^ Confirm that the correct service cleaning procedure is identified in the Application Charts, Figures 6-11, for the vehicle/engine combination being Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Other Service Bulletins for Idle Speed: > Page 1733 serviced. ^ Do not clean throttle bodies identified to accept service kit (F2PZ-9F939-A), IDLE AIR ADJUST SPACER. ^ Use a 1" (25.4 mm) to 1-1/2" (38.1 mm) wire stemmed horse hair or nylon bottle cleaner type brush. ^ Use rubber gloves and eye protection. ^ Do not clean throttle bodies identified with a yellow/black "ATTENTION" label. ^ Do not clean "Black" plastic air by-pass valves. Refer to TSB 89-13-8 for service details. ^ Do not run vehicles with air flow meters when the air duct is removed. ^ Do not use carburetor cleaner as a cleaning solvent. Use Carburetor Tune-up Cleaner (D9AZ-19579-AA). Procedure # 1 THROTTLE BODY AND IDLE AIR BY-PASS VALVE CLEANING CAUTION: DO NOT RUN VEHICLES EQUIPPED WITH AIR FLOW METERS DURING THE CLEANING PROCEDURE. IF THERE IS A YELLOW/BLACK "ATTENTION" LABEL ON THE THROTTLE BODY ADVISING NOT TO CLEAN, OR IF THE VEHICLE IS IDENTIFIED AS ACCEPTING SERVICE KIT (F2PZ-9F939-A), USE PROCEDURE # 2 FOR IDLE AIR BY-PASS VALVE CLEANING ONLY. 1. Plug the actuator into the connector in the Rotunda Cleaner/Tester, Tool 113-00009. 2. Remove the air duct to the throttle body inlet. 3. Disoonnect the idle air by-pass valve signal lead. 4. Attach the actuator harness plug to the idle air by-pass valve. 5. Start the actuator and then start the engine. Do not start engines that have air flow meters. 6. Spray just enough Carburetor Tune-up Cleaner (D9AZ-19579-AA) into the throttle bore to wet the bore and throttle plate. 7. Spray the Carburetor Tune-up Cleaner for about five (5) seconds into the idle air by-pass valve inlet passage while the actuator is operating. 8. Stop the engine and actuator. Let everything soak for fifteen (15) minutes. 9. After a fifteen (15) minute soak, saturate the cleaning brush with solvent and scrub between the throttle body bore and plate while holding the throttle wide open. NOTE: IT IS NECESSARY TO APPLY SOME PRESSURE ON THE BRUSH WHILE SCRUBBING. 10. Repeat saturating the brush and scrubbing for one (1) to two (2) minutes, making sure to reach into the corners where the throttle shaft meets the bore wall. 11. Start the actuator and the start the engine. Do not start engines that have air flow meters. 12. Spray Carburetor Tune-up Cleaner into the throttle bore for up to one (1) minute to wash away residue. Do not spray for longer than six (6) continuous seconds on engines that have air flow meters and are not running. 13. Spray Carburetor Tune-up Cleaner into the idle by-pass valve passage leading to the inlet of the valve for up to one (1) minute. Do not spray for longer than six (6) continuous seconds on engines that have air flow meters and are not running. 14. Stop actuator and stop engine, if running. NOTE: MAKE SURE THE THROTTLE PLATES OPERATE FREELY AND CLOSE PROPERLY. 15. Reinstall the air duct. 16. Start and run the engine for about one (1) minute to dry out the solvent residue. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Other Service Bulletins for Idle Speed: > Page 1734 17. Operate the actuator to make sure the solvent is purged from the idle by-pass valve. 18. Disconnect the actuator from the idle air by-pass valve. 19. Reattach the control signal lead to the air by-pass valve. 20. Check engine for normal operation. It may be necessary to reset the idle speed due to a previous adjustment for an idle concern. (Refer to the respective Powertrain/Emissions Diagnosis Service Manual, Throttle Body Section, for idle speed adjust procedure.) Procedure # 2 Idle Air By-Pass Valve Cleaning Only CAUTION: THIS CLEANING PROCEDURE MAY BE USED WITH SLUDGE TOLERANT THROTTLE BODIES WHICH ARE IDENTIFIED WITH A YELLOW/BLACK "ATTENTION" LABEL AND THOSE USING SERVICE KIT (F2PZ-9F939-A). NO ATTEMPT SHOULD BE MADE TO CLEAN THROTTLE BODY BORE/PLATE AREA BY DIRECT SPRAYING OR SCRUBBING. DO NOT RUN VEHICLES WITH AIR FLOW METERS DURING CLEANING PROCEDURE. 1. Plug the actuator into the connector in the Rotunda Air By-Pass Valve Adapter 113-00009, or equivalent. 2. Remove the air duct to the throttle body inlet. 3. Disconnect the idle air by-pass valve signal lead. 4. Attach the actuator harness plug to the idle air by-pass valve. 5. Start the actuator and then start the engine. NOTE: DO NOT START ENGINES THAT HAVE AIR FLOW METERS. 6. Spray the Carburetor Tune-up Cleaner for about five (5) seconds into the idle air by-pass valve inlet passage while the actuator is operating. CAUTION: AVOID DIRECT SPRAYING ON THROTTLE PLATE/BORE AREA. 7. Stop the engine and actuator. Let everything soak for fifteen (15) minutes. 8. Start the actuator and the start the engine. CAUTION: DO NOT START ENGINES THAT HAVE AIR FLOW METERS. 9. Spray Carburetor Tune-up Cleaner into the throttle bore for up to one (1) minute. CAUTION: DO NOT SPRAY FOR LONGER THAN SIX (6) CONTINUOUS SECONDS ON ENGINES THAT HAVE AIR FLOW METERS AND ARE NOT RUNNING. 10. Stop actuator and stop engine if running. 11. Reinstall the air duct. 12. Start and run the engine for about one (1) minute to dry out the solvent residue. 13. Operate the actuator to make sure the solvent is purged from the idle by-pass valve. 14. Disconnect the actuator from the idle air by-pass valve. 15. Reattach the control signal lead to the air by-pass valve. 16. Check engine for normal operation. NOTE: IT SHOULD NOT BE NECESSARY TO RESET THE IDLE SPEED SINCE ONLY THE IDLE AIR BY-PASS VALVE WAS SERVICED IN THIS PROCEDURE Warranty Coverage Throttle bodies and idle air by-pass valves on all EFI (Port Fuel Injection) engines through the 1992 model year that can be cleaned (as identified in the application charts) are covered under 5/50 Emissions Warranty Coverage. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Other Service Bulletins for Idle Speed: > Page 1735 For those throttle bodies identified as having sludge tolerant designs or using service kit (F2PZ-9F939-A) where cleaning is not allowed per the application charts, the warranty claims for cleaning will not be reimbursed even within the 12/12 warranty coverage period. Cleaning is not allowed. Service kit installation (single time) is covered under 5/50 emission warranty. Labor Standards Operations The labor operations shown in the following Operation/Description/Time columns are identified by procedure number and vehicle line. Specific engines for various vehicles are identified in the sludge cleaning procedure application charts. The throttle body cleaning operations with combinations and the air by-pass valve cleaning combinations will appear in future Labor Manuals under the following operation numbers. ^ 9926 B - Throttle body and idle air by-pass valve cleaning ^ 9926 B2 - Adjust idle speed ^ 9715 A - Air by-pass valve cleaning only ^ 9715 A1 - Adjust idle speed PART NUMBER PART NAME CLASS F2PZ-9F939-A Idle Air By-pass Service Kit B D9AZ-19579-AA Carburstor Tune-Up Cleaner BG OTHER APPLICABLE ARTICLES: 89-13-8 SUPERSEDES: 88-24-5, 88-24-6, 89-16-5, 91-10-9, 91-7-4 Operation Description WARRANTY STATUS: Eligible Under Warranty Coverage As Stated In The Text Of This Article OPERATION DESCRIPTION TIME 912507A Idle Air By-Pass Valve 0.5 Hr. Cleaning - 1983-85 Escort, EXP, LN7, LYNX 1.6L EFI. 912507B Idle Air By-Pass Valve 0.5 Hr. Cleaning - 1986-91 Escort 1.9L EFI, 1986/87 EXP, Lynx 1.9L EFI, 1991 Tracer 1.9L EFI. 912507C Idle Air By Pass Valve 0.5 Hr. Cleaning - 1984-87 Mustang 2.3L T/C, 1986/87 Capri, Cougar 2.3L T/C, 1984-88 T-Bird 2.3L T/C, 1987/92 Mustang 2.3L EFI. 912507D Idle By-Pass Valve Cleaning 0.6 Hr. - 1988-91 Tempo, Topaz 2.3L HSC, 1985-92 Ranger 2.3L EFI. 912507E Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1986/87 Aerostar 2.3L EFI, 1985 Bronco II 2.3L EFI. 912507F Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1986-90 Bronco II 2.9L EFI, 1986-92 Ranger 2.9L EFI. 912507G Idle Air By-Pass Valve 0.6 Hr. Cleaning - 1991/92 Probe 3.0L EFI, 1986-91 Taurus 3.0L EFI, 1987-91 Sable 3.0L EFI. 912507H Idle Air By-Pass Valve 0.7 Hr. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Other Service Bulletins for Idle Speed: > Page 1736 Cleaning - 1986-91 Aerostar 3.0L EFI, 1991 Ranger 3.0L EFI. 912507I Idle Air By-Pass Valve 0.6 Hr. Cleaning - 1988 Continental, Cougar, Taurus, T-Bird, Sable 3.8L EFI. 1988 Cougar, T-Bird 3.8L S/C. 912507J Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1990-92 Aerostar 4.0L EFI, 1990 Bronco II 4.0L EFI, 1991/92 Explorer 4.0L EFI, 1990-92 Ranger 4.0L EFI. 912507K Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1987-92 Bronco 4.9L EFI, 1987-92 F-Series 4.9L EFI, 1987/90 Econoline (Without Rear Heater) 4.9L EFI, 1991/92 Econoline (All) 4.9L EFI. 912507L Idle Air By-Pass Valve 0.6 Hr. Cleaning - 1986-88 Cougar, T-Bird 5.0L EFI, 1986-87 Continental, Mark VII 5.OL EFI, 1986/91 Crn - Victoria, Grn - Marquis 5.0L EFI, 1986-92 Mark VII 5.0L HO, 1982-92 Mustang 5.0L HO. 912507M Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1985-92 Bronco, E-Series, F-Series 5.0L EFI. 912507N Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1988-90 Bronco, F-Series 5.8L. 1991 Econo, F-Series, Bronco 5.8L (Do not Clean Solenoid, Calib; 1-64E-R10, 1-64H-R10, 1-64J-R10, 1-64K-R10, 1-64M-R10, 1-64P-R10, 1-64R-R10, 1-75A-R00, 1-76A-R00, 1-76B-R00, 1-76C-R00. 912507O Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1991/92 F And B Series, 7.0L EFI. 912507P Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1987-92 E-Series, F-Series 7.5L EFI. 912507Q Throttle Body And Idle Air 0.9 Hr. By-Pass Valve Cleaning - 1989/90 Probe 3.0L EFI. 912507R Throttle Body And Idle Air 0.8 Hr. By-Pass Valve Cleaning - 1987-90 Econoline (With Rear Heat) 4.9L EFI. 912507S Throttle Body And Idle Air 0.9 Hr. By-Pass Valve Cleaning - 1988-90 Econoline 5.8L EFI. 912507T Service Kit Install - All Cars 1.0 Hr. And Light Trucks (Except Aerostar And Econoline) - Refer To The Service Procedure Application Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Other Service Bulletins for Idle Speed: > Page 1737 Charts, For Vehicle Application. 912507U Service Kit Install - 1.2 Hr. Aerostar, Econoline - Refer To Service Procedure Application Charts - For Vehicle Application. DEALER CODING BASIC PART NO. CONDITION CODE 9E926 49 OASIS CODES: 602300, 607000, 607400, 607700, 608400, 611500, 618400 Technical Service Bulletin # 91257 Date: 911213 Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up Article No. 91-25-7 12/13/91 ^ HARD COLD START - DURING INITIAL START-UP, IDLE OR DECEL - EFI ENGINES SLUDGE IN THROTTLE BODY AND/OR IDLE AIR BY-PASS VALVE ^ HESITATION/STALLS - DURING INITIAL START-UP, IDLE OR DECEL - EFI ENGINES SLUDGE IN THROTTLE BODY AND/OR IDLE AIR BY-PASS VALVE FORD: 1983-87 EXP 1983-91 ESCORT 1984-90 MUSTANG, THUNDERBIRD 1986-90 TAURUS 1986-91 CROWN VICTORIA 1988-90 TEMPO LINCOLN-MERCURY: 1983-85 LN7 1983-87 LYNX 1984-88 CAPRI 1984-90 COUGAR 1986-90 CONTINENTAL, MARK VII, SABLE 1986-91 GRAND MARQUIS, TOWN CAR 1988-90 TOPAZ 1991 TRACER LIGHT TRUCK: 1985-90 BRONCO II, BRONCO 1985-91 ECONOLINE, F-150-350 SERIES 1985-92 RANGER 1986-91 AEROSTAR 1991 EXPLORER ISSUE: Hard cold starts, hesitation and stalls on initial start-up or during idle or decel may be caused by sludge in the throttle body and/or idle by-pass valve. Sludge deposits or oil film on the throttle body bore and plate or the idle air by-pass valve may cause one or more of the following conditions. ^ Hard Cold Start ^ Stall On Initial Start-Up ^ Stall During Idle ^ Stall During Decel ^ Rough Idle ^ Rolling Idle Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Other Service Bulletins for Idle Speed: > Page 1738 ^ Hesitation During Acceleration ACTION: A new idle air by-pass service kit (F2PZ-9F939-A) is now available for service use to correct sludge contamination concerns of the throttle bore and plate only. It eliminates the need to clean the majority of past model throttle body applications. Cleaning is not required on sludge tolerant throttle body designs released for 1991 and newer model years. Figure 1 Install an idle air by-pass service kit (F2PZ-9F939-A) as applicable to provide a permanent correction for symptoms caused by throttle body sludge deposits. Refer to the instruction sheet included in the kit for installation details. Refer to Figure 1 for a specific application list of EFI (port fuel Injection) engines involved in this TSB article. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Other Service Bulletins for Idle Speed: > Page 1739 The idle air by-pass service kit (F2PZ-9F939-A) includes the following items. ^ One (1) Idle Adjust Spacer ^ Two (2) Gaskets ^ Two (2) Attaching Bolts ^ One (1) "Attention" Sticker ^ One (1) Instruction Sheet Figure 2 Refer to Figure 2 for a pictorial of the kits components. NOTE: EFFECTIVE WITH THIS TSB, THROTTLE BODY CLEANING IS NO LONGER COVERED UNDER 5/50 EMISSIONS WARRANTY, UNLESS AS SPECIFIED IN THE FOLLOWING APPLICATION CHARTS. FAILURE TO FOLLOW THE CORRECT PROCEDURE MAY RESULT IN THE CLAIM BEING DISALLOWED. The idle air adjust spacer incorporates sludge tolerant design features that eliminate throttle body sludge related conditions. Once installed, throttle body cleaning is not allowed and periodic adjustment of the throttle body is not required. Procedures, Warranty and Labor CHECKS TO MAKE PRIOR TO SERVICE KIT INSTALLATION Confirm that the following items are not causing the idle quality concern before proceeding with the service kit installation. ^ Contamination within the idle air by-pass solenoid ^ Lack of fuel system control (excessively rich or lean) ^ Ignition timing change ^ Incorrect or malfunctioning EGR system ^ Incorrect or malfunctioning cooling system ^ Vacuum leaks (air intake manifold, vacuum hoses, vacuum reservoirs, power brake booster where applicable) ^ EEC diagnostics have been performed and vehicle malfunction indicated service output codes have been resolved and cleared. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Other Service Bulletins for Idle Speed: > Page 1740 If any of the areas listed above are found to be at fault, correct them before proceeding with the service kit installation. Idle Speed Adjustment WARNING: BEFORE PROCEEDING WITH THE IDLE SPEED ADJUSTMENT, VERIFY THAT THE FOLLOWING ITEMS ARE TAKEN CARE OF PROPERLY. ^ The transmission is in PARK or Neutral. ^ The parking brake is applied. ^ The wheels are properly blocked. ^ The engine is at operating temperature. ^ The heater, A/C, cooling fan and other accessories are OFF. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Other Service Bulletins for Idle Speed: > Page 1741 Figure 3 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Other Service Bulletins for Idle Speed: > Page 1742 Figure 4 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Other Service Bulletins for Idle Speed: > Page 1743 Figure 5 The EFI throttle body idle speed adjustment procedures for the various model year passenger cars and light trucks are outlined in step-by-step procedures featured in Figures 3, 4 and 5. Select the appropriate procedure for the vehicle involved and adjust the throttle body idle RPM accordingly, after service kit installation. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Other Service Bulletins for Idle Speed: > Page 1744 Figure 6 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Other Service Bulletins for Idle Speed: > Page 1745 Figure 7 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Other Service Bulletins for Idle Speed: > Page 1746 Figure 8 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Other Service Bulletins for Idle Speed: > Page 1747 Figure 9 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Other Service Bulletins for Idle Speed: > Page 1748 Figure 10 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Other Service Bulletins for Idle Speed: > Page 1749 Figure 11 THROTTLE BODY AND IDLE AIR BY-PASS SOLENOID SERVICE PROCEDURE Detailed application charts for throttle body and idle air by-pass solenoid service procedures by engine VIN # /engine displacement/vehicle application and model year are shown in Figures 6 through 11. Refer to these charts to see if the service kit is to be installed and which service cleaning procedure, if any, is to be used. SERVICE CLEANING PROCEDURES The following items should be noted prior to beginning the service cleaning procedure. ^ Confirm that the correct service cleaning procedure is identified in the Application Charts, Figures 6-11, for the vehicle/engine combination being Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Other Service Bulletins for Idle Speed: > Page 1750 serviced. ^ Do not clean throttle bodies identified to accept service kit (F2PZ-9F939-A), IDLE AIR ADJUST SPACER. ^ Use a 1" (25.4 mm) to 1-1/2" (38.1 mm) wire stemmed horse hair or nylon bottle cleaner type brush. ^ Use rubber gloves and eye protection. ^ Do not clean throttle bodies identified with a yellow/black "ATTENTION" label. ^ Do not clean "Black" plastic air by-pass valves. Refer to TSB 89-13-8 for service details. ^ Do not run vehicles with air flow meters when the air duct is removed. ^ Do not use carburetor cleaner as a cleaning solvent. Use Carburetor Tune-up Cleaner (D9AZ-19579-AA). Procedure # 1 THROTTLE BODY AND IDLE AIR BY-PASS VALVE CLEANING CAUTION: DO NOT RUN VEHICLES EQUIPPED WITH AIR FLOW METERS DURING THE CLEANING PROCEDURE. IF THERE IS A YELLOW/BLACK "ATTENTION" LABEL ON THE THROTTLE BODY ADVISING NOT TO CLEAN, OR IF THE VEHICLE IS IDENTIFIED AS ACCEPTING SERVICE KIT (F2PZ-9F939-A), USE PROCEDURE # 2 FOR IDLE AIR BY-PASS VALVE CLEANING ONLY. 1. Plug the actuator into the connector in the Rotunda Cleaner/Tester, Tool 113-00009. 2. Remove the air duct to the throttle body inlet. 3. Disoonnect the idle air by-pass valve signal lead. 4. Attach the actuator harness plug to the idle air by-pass valve. 5. Start the actuator and then start the engine. Do not start engines that have air flow meters. 6. Spray just enough Carburetor Tune-up Cleaner (D9AZ-19579-AA) into the throttle bore to wet the bore and throttle plate. 7. Spray the Carburetor Tune-up Cleaner for about five (5) seconds into the idle air by-pass valve inlet passage while the actuator is operating. 8. Stop the engine and actuator. Let everything soak for fifteen (15) minutes. 9. After a fifteen (15) minute soak, saturate the cleaning brush with solvent and scrub between the throttle body bore and plate while holding the throttle wide open. NOTE: IT IS NECESSARY TO APPLY SOME PRESSURE ON THE BRUSH WHILE SCRUBBING. 10. Repeat saturating the brush and scrubbing for one (1) to two (2) minutes, making sure to reach into the corners where the throttle shaft meets the bore wall. 11. Start the actuator and the start the engine. Do not start engines that have air flow meters. 12. Spray Carburetor Tune-up Cleaner into the throttle bore for up to one (1) minute to wash away residue. Do not spray for longer than six (6) continuous seconds on engines that have air flow meters and are not running. 13. Spray Carburetor Tune-up Cleaner into the idle by-pass valve passage leading to the inlet of the valve for up to one (1) minute. Do not spray for longer than six (6) continuous seconds on engines that have air flow meters and are not running. 14. Stop actuator and stop engine, if running. NOTE: MAKE SURE THE THROTTLE PLATES OPERATE FREELY AND CLOSE PROPERLY. 15. Reinstall the air duct. 16. Start and run the engine for about one (1) minute to dry out the solvent residue. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Other Service Bulletins for Idle Speed: > Page 1751 17. Operate the actuator to make sure the solvent is purged from the idle by-pass valve. 18. Disconnect the actuator from the idle air by-pass valve. 19. Reattach the control signal lead to the air by-pass valve. 20. Check engine for normal operation. It may be necessary to reset the idle speed due to a previous adjustment for an idle concern. (Refer to the respective Powertrain/Emissions Diagnosis Service Manual, Throttle Body Section, for idle speed adjust procedure.) Procedure # 2 Idle Air By-Pass Valve Cleaning Only CAUTION: THIS CLEANING PROCEDURE MAY BE USED WITH SLUDGE TOLERANT THROTTLE BODIES WHICH ARE IDENTIFIED WITH A YELLOW/BLACK "ATTENTION" LABEL AND THOSE USING SERVICE KIT (F2PZ-9F939-A). NO ATTEMPT SHOULD BE MADE TO CLEAN THROTTLE BODY BORE/PLATE AREA BY DIRECT SPRAYING OR SCRUBBING. DO NOT RUN VEHICLES WITH AIR FLOW METERS DURING CLEANING PROCEDURE. 1. Plug the actuator into the connector in the Rotunda Air By-Pass Valve Adapter 113-00009, or equivalent. 2. Remove the air duct to the throttle body inlet. 3. Disconnect the idle air by-pass valve signal lead. 4. Attach the actuator harness plug to the idle air by-pass valve. 5. Start the actuator and then start the engine. NOTE: DO NOT START ENGINES THAT HAVE AIR FLOW METERS. 6. Spray the Carburetor Tune-up Cleaner for about five (5) seconds into the idle air by-pass valve inlet passage while the actuator is operating. CAUTION: AVOID DIRECT SPRAYING ON THROTTLE PLATE/BORE AREA. 7. Stop the engine and actuator. Let everything soak for fifteen (15) minutes. 8. Start the actuator and the start the engine. CAUTION: DO NOT START ENGINES THAT HAVE AIR FLOW METERS. 9. Spray Carburetor Tune-up Cleaner into the throttle bore for up to one (1) minute. CAUTION: DO NOT SPRAY FOR LONGER THAN SIX (6) CONTINUOUS SECONDS ON ENGINES THAT HAVE AIR FLOW METERS AND ARE NOT RUNNING. 10. Stop actuator and stop engine if running. 11. Reinstall the air duct. 12. Start and run the engine for about one (1) minute to dry out the solvent residue. 13. Operate the actuator to make sure the solvent is purged from the idle by-pass valve. 14. Disconnect the actuator from the idle air by-pass valve. 15. Reattach the control signal lead to the air by-pass valve. 16. Check engine for normal operation. NOTE: IT SHOULD NOT BE NECESSARY TO RESET THE IDLE SPEED SINCE ONLY THE IDLE AIR BY-PASS VALVE WAS SERVICED IN THIS PROCEDURE Warranty Coverage Throttle bodies and idle air by-pass valves on all EFI (Port Fuel Injection) engines through the 1992 model year that can be cleaned (as identified in the application charts) are covered under 5/50 Emissions Warranty Coverage. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Other Service Bulletins for Idle Speed: > Page 1752 For those throttle bodies identified as having sludge tolerant designs or using service kit (F2PZ-9F939-A) where cleaning is not allowed per the application charts, the warranty claims for cleaning will not be reimbursed even within the 12/12 warranty coverage period. Cleaning is not allowed. Service kit installation (single time) is covered under 5/50 emission warranty. Labor Standards Operations The labor operations shown in the following Operation/Description/Time columns are identified by procedure number and vehicle line. Specific engines for various vehicles are identified in the sludge cleaning procedure application charts. The throttle body cleaning operations with combinations and the air by-pass valve cleaning combinations will appear in future Labor Manuals under the following operation numbers. ^ 9926 B - Throttle body and idle air by-pass valve cleaning ^ 9926 B2 - Adjust idle speed ^ 9715 A - Air by-pass valve cleaning only ^ 9715 A1 - Adjust idle speed PART NUMBER PART NAME CLASS F2PZ-9F939-A Idle Air By-pass Service Kit B D9AZ-19579-AA Carburstor Tune-Up Cleaner BG OTHER APPLICABLE ARTICLES: 89-13-8 SUPERSEDES: 88-24-5, 88-24-6, 89-16-5, 91-10-9, 91-7-4 Operation Description WARRANTY STATUS: Eligible Under Warranty Coverage As Stated In The Text Of This Article OPERATION DESCRIPTION TIME 912507A Idle Air By-Pass Valve 0.5 Hr. Cleaning - 1983-85 Escort, EXP, LN7, LYNX 1.6L EFI. 912507B Idle Air By-Pass Valve 0.5 Hr. Cleaning - 1986-91 Escort 1.9L EFI, 1986/87 EXP, Lynx 1.9L EFI, 1991 Tracer 1.9L EFI. 912507C Idle Air By Pass Valve 0.5 Hr. Cleaning - 1984-87 Mustang 2.3L T/C, 1986/87 Capri, Cougar 2.3L T/C, 1984-88 T-Bird 2.3L T/C, 1987/92 Mustang 2.3L EFI. 912507D Idle By-Pass Valve Cleaning 0.6 Hr. - 1988-91 Tempo, Topaz 2.3L HSC, 1985-92 Ranger 2.3L EFI. 912507E Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1986/87 Aerostar 2.3L EFI, 1985 Bronco II 2.3L EFI. 912507F Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1986-90 Bronco II 2.9L EFI, 1986-92 Ranger 2.9L EFI. 912507G Idle Air By-Pass Valve 0.6 Hr. Cleaning - 1991/92 Probe 3.0L EFI, 1986-91 Taurus 3.0L EFI, 1987-91 Sable 3.0L EFI. 912507H Idle Air By-Pass Valve 0.7 Hr. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Other Service Bulletins for Idle Speed: > Page 1753 Cleaning - 1986-91 Aerostar 3.0L EFI, 1991 Ranger 3.0L EFI. 912507I Idle Air By-Pass Valve 0.6 Hr. Cleaning - 1988 Continental, Cougar, Taurus, T-Bird, Sable 3.8L EFI. 1988 Cougar, T-Bird 3.8L S/C. 912507J Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1990-92 Aerostar 4.0L EFI, 1990 Bronco II 4.0L EFI, 1991/92 Explorer 4.0L EFI, 1990-92 Ranger 4.0L EFI. 912507K Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1987-92 Bronco 4.9L EFI, 1987-92 F-Series 4.9L EFI, 1987/90 Econoline (Without Rear Heater) 4.9L EFI, 1991/92 Econoline (All) 4.9L EFI. 912507L Idle Air By-Pass Valve 0.6 Hr. Cleaning - 1986-88 Cougar, T-Bird 5.0L EFI, 1986-87 Continental, Mark VII 5.OL EFI, 1986/91 Crn - Victoria, Grn - Marquis 5.0L EFI, 1986-92 Mark VII 5.0L HO, 1982-92 Mustang 5.0L HO. 912507M Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1985-92 Bronco, E-Series, F-Series 5.0L EFI. 912507N Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1988-90 Bronco, F-Series 5.8L. 1991 Econo, F-Series, Bronco 5.8L (Do not Clean Solenoid, Calib; 1-64E-R10, 1-64H-R10, 1-64J-R10, 1-64K-R10, 1-64M-R10, 1-64P-R10, 1-64R-R10, 1-75A-R00, 1-76A-R00, 1-76B-R00, 1-76C-R00. 912507O Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1991/92 F And B Series, 7.0L EFI. 912507P Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1987-92 E-Series, F-Series 7.5L EFI. 912507Q Throttle Body And Idle Air 0.9 Hr. By-Pass Valve Cleaning - 1989/90 Probe 3.0L EFI. 912507R Throttle Body And Idle Air 0.8 Hr. By-Pass Valve Cleaning - 1987-90 Econoline (With Rear Heat) 4.9L EFI. 912507S Throttle Body And Idle Air 0.9 Hr. By-Pass Valve Cleaning - 1988-90 Econoline 5.8L EFI. 912507T Service Kit Install - All Cars 1.0 Hr. And Light Trucks (Except Aerostar And Econoline) - Refer To The Service Procedure Application Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Other Service Bulletins for Idle Speed: > Page 1754 Charts, For Vehicle Application. 912507U Service Kit Install - 1.2 Hr. Aerostar, Econoline - Refer To Service Procedure Application Charts - For Vehicle Application. DEALER CODING BASIC PART NO. CONDITION CODE 9E926 49 OASIS CODES: 602300, 607000, 607400, 607700, 608400, 611500, 618400 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > Page 1755 IDLE SPEED SPECIFICATIONS Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Adjustments > Curb Idle Speed Idle Speed: Adjustments Curb Idle Speed CURB IDLE SPEED ADJUSTMENT - Set parking brake, block wheels and place the transmission in Neutral (manual) or Park (automatic). - Bring engine to normal operating temperature (upper radiator hose hot). - Place A/C Heat selector to "OFF" (if equipped). - Disconnect and plug vacuum hoses at air bypass valve, EGR valve, and purge control valve. - Place the transmission in the specified gear. See: Specifications - Check curb idle rpm. Adjust to specification. See: Specifications - Place the transmission in Neutral (manual) or Park (automatic). Rev the engine momentarily. Place the transmission in specified position, and recheck curb idle rpm. Readjust if required. - If vehicle is equipped with A/C, perform the following additional steps: Connect an external vacuum source providing a minimum of 33.7 kPA (10 in-Hg) to the Vacuum Operated Throttle Modulator (VOTM) kicker. - Place the transmission selector in specified position. See: Specifications - Check/adjust VOTM kicker speed. If adjustment is required, loosen kicker locknut and turn kicker to required speed, tighten locknut. - Remove plugs and reconnect vacuum hoses. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Adjustments > Curb Idle Speed > Page 1758 Idle Speed: Adjustments Fast Idle Speed FAST IDLE SPEED ADJUSTMENT - Set parking brake, block wheels and place the transmission in Park (automatic) or Neutral (manual). - Bring the engine to normal operating temperature. - Disconnect the vacuum hose at the EGR valve, air bypass valve, and purge control valve and plug. - Place the fast idle adjustment mechanism on specified step of fast idle cam. Check/adjust fast idle rpm to specification. See: Specifications - Recheck for repeatability. - Remove plugs from the EGR valve, air bypass valve, and purge control valve vacuum hoses and reconnect. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Element <--> [Air Filter Element] > Component Information > Technical Service Bulletins > Engine Lack of Power/No Start Diagnosis Air Cleaner Element: Technical Service Bulletins Engine - Lack of Power/No Start Diagnosis Article No. 91-12-11 06/12/91 LACK OF POWER 7.5L, 5.8L, 5.0L, 4.9L - CATALYTIC CONVERTER DIAGNOSTIC TIPS LIGHT TRUCK: 1986-91 BRONCO, ECONOLINE, F-150-350 SERIES 1988-91 F SUPER DUTY, F47 ISSUE: Lack of power or a no start condition may be diagnosed as an exhaust restriction caused by a plugged catalytic converter. A plugged catalytic converter (internal deterioration) is usually caused by abnormal engine operation. ACTION: Diagnose the catalytic converter to confirm internal failure. Refer to the Catalyst and Exhaust System Diagnostic Section, in the Engine/Emissions Diagnostic Shop Manual and the following procedures for service details. 1. Lack of proper HEGO operation may cause, or be the result of a rich or lean fuel condition, which could cause additional heat in the catalyst. Perform self test KOEO and KOER, service any codes. NOTE: IF TWO DIGIT CODES 41, 42, 85 OR THREE DIGIT CODES 171, 172, 173, 179, 181, 182, 183 AND 565 ARE RECEIVED, CHECK FOR PROPER HEGO GROUND. If the HEGO ground is good, the following areas may be at fault: ^ Ignition Coil ^ Distributor Cap ^ Distributor Rotor ^ Fouled Spark Plug ^ Spark Plug Wires ^ Air Filter ^ Stuck Open Injector ^ Fuel Contamination Engine OIL ^ Manifold Leaks Intake/ Exhaust ^ Fuel Pressure ^ Poor Power Ground ^ Engine Not At Normal Operating Temperature ^ HEGO Sensor 2. Spark timing that is retarded from specification may increase exhaust gas temperature and shorten catalyst life. Refer to the following procedure for service details. a. Check spark timing. Check base timing with spout disconnected. Set base timing to the specification on the vehicle emission decal. b. Check computed timing with spout connected. NOTE: COMPUTED TIMING IS EQUAL TO BASE TIMING PLUS 20~ BTDC +/- 3~. 3. Misfiring spark plugs may cause an unburned fuel air mixture to pass through the catalyst, which could cause higher than normal catalyst temperatures. Refer to the following procedure for service details. a. Check secondary ignition, hook the vehicle up to an engine analyzer and check for a secondary ignition misfire. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Element <--> [Air Filter Element] > Component Information > Technical Service Bulletins > Engine Lack of Power/No Start Diagnosis > Page 1764 NOTE: SERVICE ANY ITEM THAT IS NOT PERFORMING AT PROPER SPECIFICATIONS BEFORE CONTINUING. 4. Fuel pressure that is too high may cause rich air fuel mixtures to pass through the catalyst which could cause higher than normal catalyst temperatures. Refer to the following procedure for service details. a. Check fuel pressure, install fuel pressure gauge, start and run the engine at idle. Fuel pressures between 28 and 34 PSI are typical (4.9L typically is 15 PSI higher). b. Disconnect the vacuum line going to the fuel pressure regulator. Fuel pressure typically jumps to 40 PSI +/- 3 PSI (4.9L typically is 15 PSI higher). Visually inspect vacuum line for raw fuel. NOTE: FUEL PRESSURES ABOVE THESE VALUES SHOULD BE CORRECTED. HOWEVER, THIS MAY NOT BE THE CAUSE OF THE CONCERN. SERVICE AS NECESSARY. 5. Throttle plates in the throttle body not returning to the proper closed position may cause excessive catalyst temperatures during downhill grades. Refer to the following procedure for service details. a. Visually inspect the throttle body and linkage for: ^ Binding or sticking throttle linkage. ^ Tight speed control linkage or cable. ^ Vacuum line interference. ^ Electrical harness interference. NOTE: AFTERMARKET GOVERNORS, THROTTLE LINKAGE AND CABLES ASSOCIATED WITH POWER TAKE-OFF UNITS, MAY ALSO INTERFERE WITH PROPER THROTTLE RETURN. SERVICE AS NECESSARY. 6. It is extremely important that all systems related to the engine and emission systems operate properly. a. Visually inspect the engine compartment to make sure all vacuum hoses and spark plug wires are properly routed and securely connected. b. Inspect all wiring harnesses and connectors for insulation damage, burned, overheated, loose or broken conditions. c. Verify proper operation of the thermactor system. Thermactor systems that fail to dump thermactor air to the atmosphere properly or at the correct time can cause high catalyst temperatures. d. Visually inspect thermactor system for damaged or kinked hoses and perform a function test on following components: air control valve, check valve, silencer, filter and the air bypass solenoid. e. Verify proper operation of the engine cooling system thermostat. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under Basic Warranty Coverage, Emissions Warranty Coverage OPERATION DESCRIPTION TIME 911211A Diagnostics - Perform 0.5 Hrs. KOEO And KOER Self Tests 911211B Timing - Check Or Adjust 0.5 Hrs. Spark Timing, Check Computed Timing And Check Secondary Ignition System With Engine Analyzer. 911211C Check - Fuel Pressure And 0.2 Hrs. Inspect Vacuum Line For Raw Fuel. 911211D Inspect - Throttle Body And 0.1 Hrs. Linkage. 911211E Inspect - Vacuum Hoses, 0.1 Hrs. Electrical Harnesses, Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Element <--> [Air Filter Element] > Component Information > Technical Service Bulletins > Engine Lack of Power/No Start Diagnosis > Page 1765 Connectors And Spark Plug Wires For Routing Damage. 911211F Thermactor System - 0.3 Hrs. Inspect For Proper Operation And Damaged Component. Includes Function Check Of Air Control Valve, Thermactor Air Bypass Solenoid, Check Valves, Silencer And Filter. 911211G Thermostat - Check For 0.2 Hrs. Proper Operation. DEALER CODING BASIC PART NO. CONDITION CODE 5E212 25 OASIS CODES: 403000, 603300, 614000 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Service and Repair Fuel Filter: Service and Repair REMOVAL - Remove the air cleaner. - Hold the fuel filter inlet hex nut with a backup wrench and unscrew the fuel line tube nut from the fuel filter inlet. WARNING: Use care to prevent combustion from fuel spillage. - Unscrew the fuel inlet fitting. - Remove the gasket, filter and spring. - Discard the gasket and filter. INSTALLATION - Install the spring, new filter and gasket. - Hand start the fuel inlet fitting into the carburetor then, tighten to 30-35 Nm (22-26 lb-ft). Apply oil, ESE-M2C39-E or equivalent to the fuel tube nut threads and tube flare. - Hand start the fuel line tube nut into the fuel inlet fitting (approximately two threads). - Use a backup wrench on the fuel inlet fitting while tightening the fuel line tube nut to 20-24 Nm (15-18 lb-ft). - Start the engine and check for fuel leak. - Install the air cleaner. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications Firing Order: Specifications Location On Distributor FIRING ORDER: 1-3-7-2-6-5-4-8 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Timing > Ignition Timing Connector > Component Information > Description and Operation Ignition Timing Connector: Description and Operation Fig. 20 Ignition Timing Vacuum Switch Below vacuum setting, this switch, Fig. 20, used on some vehicles, is open and signals the ignition module to retard spark timing. The switch is closed above the vacuum setting and the ignition module is in the non-retard spark timing mode. Calibration resistors inside the switch control the amount of retard. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Timing > Ignition Timing Connector > Component Information > Description and Operation > Page 1776 Ignition Timing Connector: Testing and Inspection Ignition Timing Vacuum Switch Ignition Timing Vacuum Switch Test Chart 1. Disconnect switch from ignition module. 2. Connect suitable ohmmeter across switch terminals and compare resistance measured to ``less than'' values in the Ignition Timing vacuum Switch Test chart. 3. Apply vacuum to switch, using an outside vacuum source. Compare resistance now measured across switch terminals to ``greater than'' values in the Ignition Timing vacuum Switch Test chart. 4. Replace switch if resistance is not within specifications. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Timing > Number One Cylinder > Component Information > Locations Number One Cylinder: Locations Cylinder Numbering And Distributor Location Location On Distributor Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Timing > Timing Marks and Indicators > System Information > Diagrams Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Engine - Lack of Power/No Start Diagnosis Ignition Cable: Technical Service Bulletins Engine - Lack of Power/No Start Diagnosis Article No. 91-12-11 06/12/91 LACK OF POWER 7.5L, 5.8L, 5.0L, 4.9L - CATALYTIC CONVERTER DIAGNOSTIC TIPS LIGHT TRUCK: 1986-91 BRONCO, ECONOLINE, F-150-350 SERIES 1988-91 F SUPER DUTY, F47 ISSUE: Lack of power or a no start condition may be diagnosed as an exhaust restriction caused by a plugged catalytic converter. A plugged catalytic converter (internal deterioration) is usually caused by abnormal engine operation. ACTION: Diagnose the catalytic converter to confirm internal failure. Refer to the Catalyst and Exhaust System Diagnostic Section, in the Engine/Emissions Diagnostic Shop Manual and the following procedures for service details. 1. Lack of proper HEGO operation may cause, or be the result of a rich or lean fuel condition, which could cause additional heat in the catalyst. Perform self test KOEO and KOER, service any codes. NOTE: IF TWO DIGIT CODES 41, 42, 85 OR THREE DIGIT CODES 171, 172, 173, 179, 181, 182, 183 AND 565 ARE RECEIVED, CHECK FOR PROPER HEGO GROUND. If the HEGO ground is good, the following areas may be at fault: ^ Ignition Coil ^ Distributor Cap ^ Distributor Rotor ^ Fouled Spark Plug ^ Spark Plug Wires ^ Air Filter ^ Stuck Open Injector ^ Fuel Contamination Engine OIL ^ Manifold Leaks Intake/ Exhaust ^ Fuel Pressure ^ Poor Power Ground ^ Engine Not At Normal Operating Temperature ^ HEGO Sensor 2. Spark timing that is retarded from specification may increase exhaust gas temperature and shorten catalyst life. Refer to the following procedure for service details. a. Check spark timing. Check base timing with spout disconnected. Set base timing to the specification on the vehicle emission decal. b. Check computed timing with spout connected. NOTE: COMPUTED TIMING IS EQUAL TO BASE TIMING PLUS 20~ BTDC +/- 3~. 3. Misfiring spark plugs may cause an unburned fuel air mixture to pass through the catalyst, which could cause higher than normal catalyst temperatures. Refer to the following procedure for service details. a. Check secondary ignition, hook the vehicle up to an engine analyzer and check for a secondary ignition misfire. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Engine - Lack of Power/No Start Diagnosis > Page 1787 NOTE: SERVICE ANY ITEM THAT IS NOT PERFORMING AT PROPER SPECIFICATIONS BEFORE CONTINUING. 4. Fuel pressure that is too high may cause rich air fuel mixtures to pass through the catalyst which could cause higher than normal catalyst temperatures. Refer to the following procedure for service details. a. Check fuel pressure, install fuel pressure gauge, start and run the engine at idle. Fuel pressures between 28 and 34 PSI are typical (4.9L typically is 15 PSI higher). b. Disconnect the vacuum line going to the fuel pressure regulator. Fuel pressure typically jumps to 40 PSI +/- 3 PSI (4.9L typically is 15 PSI higher). Visually inspect vacuum line for raw fuel. NOTE: FUEL PRESSURES ABOVE THESE VALUES SHOULD BE CORRECTED. HOWEVER, THIS MAY NOT BE THE CAUSE OF THE CONCERN. SERVICE AS NECESSARY. 5. Throttle plates in the throttle body not returning to the proper closed position may cause excessive catalyst temperatures during downhill grades. Refer to the following procedure for service details. a. Visually inspect the throttle body and linkage for: ^ Binding or sticking throttle linkage. ^ Tight speed control linkage or cable. ^ Vacuum line interference. ^ Electrical harness interference. NOTE: AFTERMARKET GOVERNORS, THROTTLE LINKAGE AND CABLES ASSOCIATED WITH POWER TAKE-OFF UNITS, MAY ALSO INTERFERE WITH PROPER THROTTLE RETURN. SERVICE AS NECESSARY. 6. It is extremely important that all systems related to the engine and emission systems operate properly. a. Visually inspect the engine compartment to make sure all vacuum hoses and spark plug wires are properly routed and securely connected. b. Inspect all wiring harnesses and connectors for insulation damage, burned, overheated, loose or broken conditions. c. Verify proper operation of the thermactor system. Thermactor systems that fail to dump thermactor air to the atmosphere properly or at the correct time can cause high catalyst temperatures. d. Visually inspect thermactor system for damaged or kinked hoses and perform a function test on following components: air control valve, check valve, silencer, filter and the air bypass solenoid. e. Verify proper operation of the engine cooling system thermostat. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under Basic Warranty Coverage, Emissions Warranty Coverage OPERATION DESCRIPTION TIME 911211A Diagnostics - Perform 0.5 Hrs. KOEO And KOER Self Tests 911211B Timing - Check Or Adjust 0.5 Hrs. Spark Timing, Check Computed Timing And Check Secondary Ignition System With Engine Analyzer. 911211C Check - Fuel Pressure And 0.2 Hrs. Inspect Vacuum Line For Raw Fuel. 911211D Inspect - Throttle Body And 0.1 Hrs. Linkage. 911211E Inspect - Vacuum Hoses, 0.1 Hrs. Electrical Harnesses, Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Engine - Lack of Power/No Start Diagnosis > Page 1788 Connectors And Spark Plug Wires For Routing Damage. 911211F Thermactor System - 0.3 Hrs. Inspect For Proper Operation And Damaged Component. Includes Function Check Of Air Control Valve, Thermactor Air Bypass Solenoid, Check Valves, Silencer And Filter. 911211G Thermostat - Check For 0.2 Hrs. Proper Operation. DEALER CODING BASIC PART NO. CONDITION CODE 5E212 25 OASIS CODES: 403000, 603300, 614000 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Engine - Lack of Power/No Start Diagnosis > Page 1789 Ignition Cable: Technical Service Bulletins Ignition System - Diagnostics Manual Correction Article No. 89-5A-4 EEC IV - TFI IV - IGNITION SYSTEM - REVISED TIMING PROCEDURES AND DIAGNOSTICS SHOP MANUAL CORRECTION FORD: 1984-86 LTD 1984-88 EXP 1984-88 ESCORT THUNDERBIRD, MUSTANG, TEMPO, AND CROWN VICTORIA LINCOLN-MERCURY: 1984-86 CAPRI, MARQUIS 1984-87 LYNX 1984-88 COUGAR, TOPAZ, GRAND MARQUIS, CONTINENTAL, MARK VII, AND LINCOLN TOWN CAR LIGHT TRUCK: 1984-88 RANGER, BRONCO II, ECONOLINE, BRONCO, AND F-SERIES 1986-88 AEROSTAR ISSUE: The Ignition Coil and Secondary Wire Test Steps on pages 13-51 and 13-65 of the 1989 Engine Emissions Diagnosis Shop Manual, Volume H, have been revised. The new service information directs technicians to use a substitute coil instead of a resistance test. ACTION: Refer to this TSB for revised ignition coil and secondary wire test information. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" OASIS CODES: 680000 1989 Ignition Systems, Timing Procedures and Diagnostics 13-51 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Engine - Lack of Power/No Start Diagnosis > Page 1790 Ignition Coil and Secondary Wire TFI-IV And TFI With CCD Part 2 Test 7 1989 13-52 Ignition Systems, Timing Procedures and Diagnostics Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Engine - Lack of Power/No Start Diagnosis > Page 1791 EEC-IV - TFI-IV TFI-IV And TFI-IV With CCD Part 2 Test 8 1989 Ignition Systems, Timing Procedures and Diagnostics 13-65 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Engine - Lack of Power/No Start Diagnosis > Page 1792 Ignition Coil And Secondary Wire TFI-IV Closed Bowl Distributor Part 2 Test 8 1989 13-66 Ignition Systems, Timing Procedures and Diagnostics Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Engine - Lack of Power/No Start Diagnosis > Page 1793 EEC-IV - Wiring TFI-IV Closed Bowl Distributor Part 2 Test 9 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Page 1794 Ignition Cable: Testing and Inspection Spark Plug Wire Resistance *** UPDATED BY TSB #85-9-33 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Distributor, Ignition > Distributor Advance Unit > Component Information > Specifications DISTRIBUTOR TIMING ADVANCE Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Distributor, Ignition > Distributor Advance Unit > Component Information > Description and Operation > Vacuum Spark Advance Mechanism Distributor Advance Unit: Description and Operation Vacuum Spark Advance Mechanism The vacuum spark control mechanism can provide spark advance if a single diaphragm assembly is used or spark advance and retard if a dual diaphragm assembly is used. The diaphragm assembly used depends on the engine calibration. Single Diaphragm Assembly SINGLE DIAPHRAGM ASSEMBLY The single diaphragm assembly, Fig. 11, also changes the armature to stator relationship to give spark advance. The stator assembly position is changed by means of vacuum being applied to the diaphragm assembly. Vacuum applied to the diaphragm assembly causes the diaphragm and attached diaphragm rod to move, compressing the advance spring, which controls the rate of advance. The movement of the diaphragm rod, which is attached to the stator assembly, makes the the stator assembly move with respect to the armature. This changes the initial armature to stator relationship set during initial timing, causing spark advance. The stator assembly is mounted on the lower plate assembly which with the diaphragm assembly, is attached to the distributor base. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Distributor, Ignition > Distributor Advance Unit > Component Information > Description and Operation > Vacuum Spark Advance Mechanism > Page 1801 Dual Diaphragm Assembly DUAL DIAPHRAGM ASSEMBLY The dual diaphragm assembly, Fig. 12, obtains spark advance in the same manner as the single diaphragm assembly. In this case vacuum applied to the vacuum advance port causes the advance diaphragm and attached rod to move, otherwise the action is the same. Spark retard is done by applying vacuum to the vacuum retard port. This causes the retard diaphragm to move, compressing the retard spring, which controls the rate of spark retard. Compressing the retard spring allows the diaphragm rod stop to move due to the force applied by the advance spring pushing against it by means of the diaphragm rod. The result is the diaphragm rod moves causing the attached stator assembly to change position with respect to the armature. In this instance the direction of the stator assembly movement is opposite that occurring during vacuum advance, resulting in spark retard. NOTE: Any vacuum applied to the advance port overrides any spark retard caused by vacuum being applied to the retard port. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Distributor, Ignition > Distributor Advance Unit > Component Information > Description and Operation > Vacuum Spark Advance Mechanism > Page 1802 Distributor Advance Unit: Description and Operation Centrifugal Spark Advance Mechanism Distributor - Exploded view The centrifugal advance mechanism varies the relationship of the armature to the stator assembly. The armature is mounted to the sleeve and plate assembly which rotates in relation to the distributor shaft. The rotation is a result of the centrifugal weights moving in response to engine RPM. The movement of the weights change the initial relationship of the armature to the stator assembly by rotating the sleeve and plate assembly ahead of its static position on the distributor shaft Fig. 1. This produces spark advance. The rate of movement of the weights is controlled by calibrated springs. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Distributor, Ignition > Distributor Advance Unit > Component Information > Description and Operation > Page 1803 Distributor Advance Unit: Service and Repair 1. Remove distributor cap and rotor. 2. Disconnect vacuum lines, then remove snap ring that secures vacuum advance link to pickup assembly. 3. Remove vacuum advance attaching screws, then tilt unit downward to disconnect link. 4. Carefully remove unit from distributor. 5. Reverse procedure to install. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Distributor, Ignition > Distributor Cap > Component Information > Technical Service Bulletins > Engine - Lack of Power/No Start Diagnosis Distributor Cap: Technical Service Bulletins Engine - Lack of Power/No Start Diagnosis Article No. 91-12-11 06/12/91 LACK OF POWER 7.5L, 5.8L, 5.0L, 4.9L - CATALYTIC CONVERTER DIAGNOSTIC TIPS LIGHT TRUCK: 1986-91 BRONCO, ECONOLINE, F-150-350 SERIES 1988-91 F SUPER DUTY, F47 ISSUE: Lack of power or a no start condition may be diagnosed as an exhaust restriction caused by a plugged catalytic converter. A plugged catalytic converter (internal deterioration) is usually caused by abnormal engine operation. ACTION: Diagnose the catalytic converter to confirm internal failure. Refer to the Catalyst and Exhaust System Diagnostic Section, in the Engine/Emissions Diagnostic Shop Manual and the following procedures for service details. 1. Lack of proper HEGO operation may cause, or be the result of a rich or lean fuel condition, which could cause additional heat in the catalyst. Perform self test KOEO and KOER, service any codes. NOTE: IF TWO DIGIT CODES 41, 42, 85 OR THREE DIGIT CODES 171, 172, 173, 179, 181, 182, 183 AND 565 ARE RECEIVED, CHECK FOR PROPER HEGO GROUND. If the HEGO ground is good, the following areas may be at fault: ^ Ignition Coil ^ Distributor Cap ^ Distributor Rotor ^ Fouled Spark Plug ^ Spark Plug Wires ^ Air Filter ^ Stuck Open Injector ^ Fuel Contamination Engine OIL ^ Manifold Leaks Intake/ Exhaust ^ Fuel Pressure ^ Poor Power Ground ^ Engine Not At Normal Operating Temperature ^ HEGO Sensor 2. Spark timing that is retarded from specification may increase exhaust gas temperature and shorten catalyst life. Refer to the following procedure for service details. a. Check spark timing. Check base timing with spout disconnected. Set base timing to the specification on the vehicle emission decal. b. Check computed timing with spout connected. NOTE: COMPUTED TIMING IS EQUAL TO BASE TIMING PLUS 20~ BTDC +/- 3~. 3. Misfiring spark plugs may cause an unburned fuel air mixture to pass through the catalyst, which could cause higher than normal catalyst temperatures. Refer to the following procedure for service details. a. Check secondary ignition, hook the vehicle up to an engine analyzer and check for a secondary ignition misfire. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Distributor, Ignition > Distributor Cap > Component Information > Technical Service Bulletins > Engine - Lack of Power/No Start Diagnosis > Page 1808 NOTE: SERVICE ANY ITEM THAT IS NOT PERFORMING AT PROPER SPECIFICATIONS BEFORE CONTINUING. 4. Fuel pressure that is too high may cause rich air fuel mixtures to pass through the catalyst which could cause higher than normal catalyst temperatures. Refer to the following procedure for service details. a. Check fuel pressure, install fuel pressure gauge, start and run the engine at idle. Fuel pressures between 28 and 34 PSI are typical (4.9L typically is 15 PSI higher). b. Disconnect the vacuum line going to the fuel pressure regulator. Fuel pressure typically jumps to 40 PSI +/- 3 PSI (4.9L typically is 15 PSI higher). Visually inspect vacuum line for raw fuel. NOTE: FUEL PRESSURES ABOVE THESE VALUES SHOULD BE CORRECTED. HOWEVER, THIS MAY NOT BE THE CAUSE OF THE CONCERN. SERVICE AS NECESSARY. 5. Throttle plates in the throttle body not returning to the proper closed position may cause excessive catalyst temperatures during downhill grades. Refer to the following procedure for service details. a. Visually inspect the throttle body and linkage for: ^ Binding or sticking throttle linkage. ^ Tight speed control linkage or cable. ^ Vacuum line interference. ^ Electrical harness interference. NOTE: AFTERMARKET GOVERNORS, THROTTLE LINKAGE AND CABLES ASSOCIATED WITH POWER TAKE-OFF UNITS, MAY ALSO INTERFERE WITH PROPER THROTTLE RETURN. SERVICE AS NECESSARY. 6. It is extremely important that all systems related to the engine and emission systems operate properly. a. Visually inspect the engine compartment to make sure all vacuum hoses and spark plug wires are properly routed and securely connected. b. Inspect all wiring harnesses and connectors for insulation damage, burned, overheated, loose or broken conditions. c. Verify proper operation of the thermactor system. Thermactor systems that fail to dump thermactor air to the atmosphere properly or at the correct time can cause high catalyst temperatures. d. Visually inspect thermactor system for damaged or kinked hoses and perform a function test on following components: air control valve, check valve, silencer, filter and the air bypass solenoid. e. Verify proper operation of the engine cooling system thermostat. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under Basic Warranty Coverage, Emissions Warranty Coverage OPERATION DESCRIPTION TIME 911211A Diagnostics - Perform 0.5 Hrs. KOEO And KOER Self Tests 911211B Timing - Check Or Adjust 0.5 Hrs. Spark Timing, Check Computed Timing And Check Secondary Ignition System With Engine Analyzer. 911211C Check - Fuel Pressure And 0.2 Hrs. Inspect Vacuum Line For Raw Fuel. 911211D Inspect - Throttle Body And 0.1 Hrs. Linkage. 911211E Inspect - Vacuum Hoses, 0.1 Hrs. Electrical Harnesses, Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Distributor, Ignition > Distributor Cap > Component Information > Technical Service Bulletins > Engine - Lack of Power/No Start Diagnosis > Page 1809 Connectors And Spark Plug Wires For Routing Damage. 911211F Thermactor System - 0.3 Hrs. Inspect For Proper Operation And Damaged Component. Includes Function Check Of Air Control Valve, Thermactor Air Bypass Solenoid, Check Valves, Silencer And Filter. 911211G Thermostat - Check For 0.2 Hrs. Proper Operation. DEALER CODING BASIC PART NO. CONDITION CODE 5E212 25 OASIS CODES: 403000, 603300, 614000 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Distributor, Ignition > Ignition Rotor > Component Information > Technical Service Bulletins > Customer Interest: > 85218 > Oct > 85 > Distributor Rotor - Engine Bucking/Surging Ignition Rotor: Customer Interest Distributor Rotor - Engine Bucking/Surging Article No. 85-21-8 ENGINE MISS - DISTRIBUTOR WITH BLADE ROTOR - SILICONE GREASE ENGINE SURGE - DISTRIBUTOR WITH BLADE ROTOR - SILICONE GREASE RADIO NOISE - DISTRIBUTOR WITH BLADE ROTOR - SILICONE GREASE FORD 1986 ESCORT, EXP, TEMPO, MUSTANG, THUNDERBIRD, TAURUS, LTD, CROWN VICTORIA LINCOLN-MERCURY 1986 LYNX, TOPAZ, CAPRI, COUGAR, SABLE, MARQUIS, CONTINENTAL, MARK VII, LINCOLN LIGHT TRUCK 1986 E/F SERIES, BRONCO, RANGER, BRONCO II, AEROSTAR CALIBRATION: All with EEC IV 1986 vehicles are equipped with a new "blade" design distributor rotor. This design replaces the multi-point rotor used in recent model years. This new rotor requires the use of silicone grease on the blade. Electrical interference can result from a blade rotor that does not have silicone grease. The electrical interference affects the distributor stator assembly and can cause engine "missing", "bucking", or "surging". These drive concerns are usually intermittent and tend to occur during crank and heavy or wide-open throttle. It is important to remember not to remove the silicone grease for radio noise concerns, on 1986 vehicles with EEC IV; removing the grease can cause driveability concerns. A future TSB article will address the radio noise issue. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Distributor, Ignition > Ignition Rotor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Rotor: > 911211 > Jun > 91 > Engine - Lack of Power/No Start Diagnosis Ignition Rotor: All Technical Service Bulletins Engine - Lack of Power/No Start Diagnosis Article No. 91-12-11 06/12/91 LACK OF POWER 7.5L, 5.8L, 5.0L, 4.9L - CATALYTIC CONVERTER DIAGNOSTIC TIPS LIGHT TRUCK: 1986-91 BRONCO, ECONOLINE, F-150-350 SERIES 1988-91 F SUPER DUTY, F47 ISSUE: Lack of power or a no start condition may be diagnosed as an exhaust restriction caused by a plugged catalytic converter. A plugged catalytic converter (internal deterioration) is usually caused by abnormal engine operation. ACTION: Diagnose the catalytic converter to confirm internal failure. Refer to the Catalyst and Exhaust System Diagnostic Section, in the Engine/Emissions Diagnostic Shop Manual and the following procedures for service details. 1. Lack of proper HEGO operation may cause, or be the result of a rich or lean fuel condition, which could cause additional heat in the catalyst. Perform self test KOEO and KOER, service any codes. NOTE: IF TWO DIGIT CODES 41, 42, 85 OR THREE DIGIT CODES 171, 172, 173, 179, 181, 182, 183 AND 565 ARE RECEIVED, CHECK FOR PROPER HEGO GROUND. If the HEGO ground is good, the following areas may be at fault: ^ Ignition Coil ^ Distributor Cap ^ Distributor Rotor ^ Fouled Spark Plug ^ Spark Plug Wires ^ Air Filter ^ Stuck Open Injector ^ Fuel Contamination Engine OIL ^ Manifold Leaks Intake/ Exhaust ^ Fuel Pressure ^ Poor Power Ground ^ Engine Not At Normal Operating Temperature ^ HEGO Sensor 2. Spark timing that is retarded from specification may increase exhaust gas temperature and shorten catalyst life. Refer to the following procedure for service details. a. Check spark timing. Check base timing with spout disconnected. Set base timing to the specification on the vehicle emission decal. b. Check computed timing with spout connected. NOTE: COMPUTED TIMING IS EQUAL TO BASE TIMING PLUS 20~ BTDC +/- 3~. 3. Misfiring spark plugs may cause an unburned fuel air mixture to pass through the catalyst, which could cause higher than normal catalyst temperatures. Refer to the following procedure for service details. a. Check secondary ignition, hook the vehicle up to an engine analyzer and check for a secondary ignition misfire. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Distributor, Ignition > Ignition Rotor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Rotor: > 911211 > Jun > 91 > Engine - Lack of Power/No Start Diagnosis > Page 1823 NOTE: SERVICE ANY ITEM THAT IS NOT PERFORMING AT PROPER SPECIFICATIONS BEFORE CONTINUING. 4. Fuel pressure that is too high may cause rich air fuel mixtures to pass through the catalyst which could cause higher than normal catalyst temperatures. Refer to the following procedure for service details. a. Check fuel pressure, install fuel pressure gauge, start and run the engine at idle. Fuel pressures between 28 and 34 PSI are typical (4.9L typically is 15 PSI higher). b. Disconnect the vacuum line going to the fuel pressure regulator. Fuel pressure typically jumps to 40 PSI +/- 3 PSI (4.9L typically is 15 PSI higher). Visually inspect vacuum line for raw fuel. NOTE: FUEL PRESSURES ABOVE THESE VALUES SHOULD BE CORRECTED. HOWEVER, THIS MAY NOT BE THE CAUSE OF THE CONCERN. SERVICE AS NECESSARY. 5. Throttle plates in the throttle body not returning to the proper closed position may cause excessive catalyst temperatures during downhill grades. Refer to the following procedure for service details. a. Visually inspect the throttle body and linkage for: ^ Binding or sticking throttle linkage. ^ Tight speed control linkage or cable. ^ Vacuum line interference. ^ Electrical harness interference. NOTE: AFTERMARKET GOVERNORS, THROTTLE LINKAGE AND CABLES ASSOCIATED WITH POWER TAKE-OFF UNITS, MAY ALSO INTERFERE WITH PROPER THROTTLE RETURN. SERVICE AS NECESSARY. 6. It is extremely important that all systems related to the engine and emission systems operate properly. a. Visually inspect the engine compartment to make sure all vacuum hoses and spark plug wires are properly routed and securely connected. b. Inspect all wiring harnesses and connectors for insulation damage, burned, overheated, loose or broken conditions. c. Verify proper operation of the thermactor system. Thermactor systems that fail to dump thermactor air to the atmosphere properly or at the correct time can cause high catalyst temperatures. d. Visually inspect thermactor system for damaged or kinked hoses and perform a function test on following components: air control valve, check valve, silencer, filter and the air bypass solenoid. e. Verify proper operation of the engine cooling system thermostat. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under Basic Warranty Coverage, Emissions Warranty Coverage OPERATION DESCRIPTION TIME 911211A Diagnostics - Perform 0.5 Hrs. KOEO And KOER Self Tests 911211B Timing - Check Or Adjust 0.5 Hrs. Spark Timing, Check Computed Timing And Check Secondary Ignition System With Engine Analyzer. 911211C Check - Fuel Pressure And 0.2 Hrs. Inspect Vacuum Line For Raw Fuel. 911211D Inspect - Throttle Body And 0.1 Hrs. Linkage. 911211E Inspect - Vacuum Hoses, 0.1 Hrs. Electrical Harnesses, Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Distributor, Ignition > Ignition Rotor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Rotor: > 911211 > Jun > 91 > Engine - Lack of Power/No Start Diagnosis > Page 1824 Connectors And Spark Plug Wires For Routing Damage. 911211F Thermactor System - 0.3 Hrs. Inspect For Proper Operation And Damaged Component. Includes Function Check Of Air Control Valve, Thermactor Air Bypass Solenoid, Check Valves, Silencer And Filter. 911211G Thermostat - Check For 0.2 Hrs. Proper Operation. DEALER CODING BASIC PART NO. CONDITION CODE 5E212 25 OASIS CODES: 403000, 603300, 614000 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Distributor, Ignition > Ignition Rotor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Rotor: > 85218 > Oct > 85 > Distributor Rotor - Engine Bucking/Surging Ignition Rotor: All Technical Service Bulletins Distributor Rotor - Engine Bucking/Surging Article No. 85-21-8 ENGINE MISS - DISTRIBUTOR WITH BLADE ROTOR - SILICONE GREASE ENGINE SURGE - DISTRIBUTOR WITH BLADE ROTOR - SILICONE GREASE RADIO NOISE - DISTRIBUTOR WITH BLADE ROTOR - SILICONE GREASE FORD 1986 ESCORT, EXP, TEMPO, MUSTANG, THUNDERBIRD, TAURUS, LTD, CROWN VICTORIA LINCOLN-MERCURY 1986 LYNX, TOPAZ, CAPRI, COUGAR, SABLE, MARQUIS, CONTINENTAL, MARK VII, LINCOLN LIGHT TRUCK 1986 E/F SERIES, BRONCO, RANGER, BRONCO II, AEROSTAR CALIBRATION: All with EEC IV 1986 vehicles are equipped with a new "blade" design distributor rotor. This design replaces the multi-point rotor used in recent model years. This new rotor requires the use of silicone grease on the blade. Electrical interference can result from a blade rotor that does not have silicone grease. The electrical interference affects the distributor stator assembly and can cause engine "missing", "bucking", or "surging". These drive concerns are usually intermittent and tend to occur during crank and heavy or wide-open throttle. It is important to remember not to remove the silicone grease for radio noise concerns, on 1986 vehicles with EEC IV; removing the grease can cause driveability concerns. A future TSB article will address the radio noise issue. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Distributor, Ignition > Ignition Rotor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Rotor: > 911211 > Jun > 91 > Engine - Lack of Power/No Start Diagnosis Ignition Rotor: All Technical Service Bulletins Engine - Lack of Power/No Start Diagnosis Article No. 91-12-11 06/12/91 LACK OF POWER 7.5L, 5.8L, 5.0L, 4.9L - CATALYTIC CONVERTER DIAGNOSTIC TIPS LIGHT TRUCK: 1986-91 BRONCO, ECONOLINE, F-150-350 SERIES 1988-91 F SUPER DUTY, F47 ISSUE: Lack of power or a no start condition may be diagnosed as an exhaust restriction caused by a plugged catalytic converter. A plugged catalytic converter (internal deterioration) is usually caused by abnormal engine operation. ACTION: Diagnose the catalytic converter to confirm internal failure. Refer to the Catalyst and Exhaust System Diagnostic Section, in the Engine/Emissions Diagnostic Shop Manual and the following procedures for service details. 1. Lack of proper HEGO operation may cause, or be the result of a rich or lean fuel condition, which could cause additional heat in the catalyst. Perform self test KOEO and KOER, service any codes. NOTE: IF TWO DIGIT CODES 41, 42, 85 OR THREE DIGIT CODES 171, 172, 173, 179, 181, 182, 183 AND 565 ARE RECEIVED, CHECK FOR PROPER HEGO GROUND. If the HEGO ground is good, the following areas may be at fault: ^ Ignition Coil ^ Distributor Cap ^ Distributor Rotor ^ Fouled Spark Plug ^ Spark Plug Wires ^ Air Filter ^ Stuck Open Injector ^ Fuel Contamination Engine OIL ^ Manifold Leaks Intake/ Exhaust ^ Fuel Pressure ^ Poor Power Ground ^ Engine Not At Normal Operating Temperature ^ HEGO Sensor 2. Spark timing that is retarded from specification may increase exhaust gas temperature and shorten catalyst life. Refer to the following procedure for service details. a. Check spark timing. Check base timing with spout disconnected. Set base timing to the specification on the vehicle emission decal. b. Check computed timing with spout connected. NOTE: COMPUTED TIMING IS EQUAL TO BASE TIMING PLUS 20~ BTDC +/- 3~. 3. Misfiring spark plugs may cause an unburned fuel air mixture to pass through the catalyst, which could cause higher than normal catalyst temperatures. Refer to the following procedure for service details. a. Check secondary ignition, hook the vehicle up to an engine analyzer and check for a secondary ignition misfire. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Distributor, Ignition > Ignition Rotor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Rotor: > 911211 > Jun > 91 > Engine - Lack of Power/No Start Diagnosis > Page 1834 NOTE: SERVICE ANY ITEM THAT IS NOT PERFORMING AT PROPER SPECIFICATIONS BEFORE CONTINUING. 4. Fuel pressure that is too high may cause rich air fuel mixtures to pass through the catalyst which could cause higher than normal catalyst temperatures. Refer to the following procedure for service details. a. Check fuel pressure, install fuel pressure gauge, start and run the engine at idle. Fuel pressures between 28 and 34 PSI are typical (4.9L typically is 15 PSI higher). b. Disconnect the vacuum line going to the fuel pressure regulator. Fuel pressure typically jumps to 40 PSI +/- 3 PSI (4.9L typically is 15 PSI higher). Visually inspect vacuum line for raw fuel. NOTE: FUEL PRESSURES ABOVE THESE VALUES SHOULD BE CORRECTED. HOWEVER, THIS MAY NOT BE THE CAUSE OF THE CONCERN. SERVICE AS NECESSARY. 5. Throttle plates in the throttle body not returning to the proper closed position may cause excessive catalyst temperatures during downhill grades. Refer to the following procedure for service details. a. Visually inspect the throttle body and linkage for: ^ Binding or sticking throttle linkage. ^ Tight speed control linkage or cable. ^ Vacuum line interference. ^ Electrical harness interference. NOTE: AFTERMARKET GOVERNORS, THROTTLE LINKAGE AND CABLES ASSOCIATED WITH POWER TAKE-OFF UNITS, MAY ALSO INTERFERE WITH PROPER THROTTLE RETURN. SERVICE AS NECESSARY. 6. It is extremely important that all systems related to the engine and emission systems operate properly. a. Visually inspect the engine compartment to make sure all vacuum hoses and spark plug wires are properly routed and securely connected. b. Inspect all wiring harnesses and connectors for insulation damage, burned, overheated, loose or broken conditions. c. Verify proper operation of the thermactor system. Thermactor systems that fail to dump thermactor air to the atmosphere properly or at the correct time can cause high catalyst temperatures. d. Visually inspect thermactor system for damaged or kinked hoses and perform a function test on following components: air control valve, check valve, silencer, filter and the air bypass solenoid. e. Verify proper operation of the engine cooling system thermostat. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under Basic Warranty Coverage, Emissions Warranty Coverage OPERATION DESCRIPTION TIME 911211A Diagnostics - Perform 0.5 Hrs. KOEO And KOER Self Tests 911211B Timing - Check Or Adjust 0.5 Hrs. Spark Timing, Check Computed Timing And Check Secondary Ignition System With Engine Analyzer. 911211C Check - Fuel Pressure And 0.2 Hrs. Inspect Vacuum Line For Raw Fuel. 911211D Inspect - Throttle Body And 0.1 Hrs. Linkage. 911211E Inspect - Vacuum Hoses, 0.1 Hrs. Electrical Harnesses, Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Distributor, Ignition > Ignition Rotor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Rotor: > 911211 > Jun > 91 > Engine - Lack of Power/No Start Diagnosis > Page 1835 Connectors And Spark Plug Wires For Routing Damage. 911211F Thermactor System - 0.3 Hrs. Inspect For Proper Operation And Damaged Component. Includes Function Check Of Air Control Valve, Thermactor Air Bypass Solenoid, Check Valves, Silencer And Filter. 911211G Thermostat - Check For 0.2 Hrs. Proper Operation. DEALER CODING BASIC PART NO. CONDITION CODE 5E212 25 OASIS CODES: 403000, 603300, 614000 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Distributor, Ignition > Distributor Plate W/ Pick-up Sensor > Component Information > Service and Repair Distributor Plate W/ Pick-up Sensor: Service and Repair 1. Remove distributor cap and rotor. 2. Remove vacuum advance unit and magnetic pickup assembly. 3. Remove attaching screws and lift base plate from distributor. 4. Reverse procedure to install. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Engine - Lack of Power/No Start Diagnosis Spark Plug: Technical Service Bulletins Engine - Lack of Power/No Start Diagnosis Article No. 91-12-11 06/12/91 LACK OF POWER 7.5L, 5.8L, 5.0L, 4.9L - CATALYTIC CONVERTER DIAGNOSTIC TIPS LIGHT TRUCK: 1986-91 BRONCO, ECONOLINE, F-150-350 SERIES 1988-91 F SUPER DUTY, F47 ISSUE: Lack of power or a no start condition may be diagnosed as an exhaust restriction caused by a plugged catalytic converter. A plugged catalytic converter (internal deterioration) is usually caused by abnormal engine operation. ACTION: Diagnose the catalytic converter to confirm internal failure. Refer to the Catalyst and Exhaust System Diagnostic Section, in the Engine/Emissions Diagnostic Shop Manual and the following procedures for service details. 1. Lack of proper HEGO operation may cause, or be the result of a rich or lean fuel condition, which could cause additional heat in the catalyst. Perform self test KOEO and KOER, service any codes. NOTE: IF TWO DIGIT CODES 41, 42, 85 OR THREE DIGIT CODES 171, 172, 173, 179, 181, 182, 183 AND 565 ARE RECEIVED, CHECK FOR PROPER HEGO GROUND. If the HEGO ground is good, the following areas may be at fault: ^ Ignition Coil ^ Distributor Cap ^ Distributor Rotor ^ Fouled Spark Plug ^ Spark Plug Wires ^ Air Filter ^ Stuck Open Injector ^ Fuel Contamination Engine OIL ^ Manifold Leaks Intake/ Exhaust ^ Fuel Pressure ^ Poor Power Ground ^ Engine Not At Normal Operating Temperature ^ HEGO Sensor 2. Spark timing that is retarded from specification may increase exhaust gas temperature and shorten catalyst life. Refer to the following procedure for service details. a. Check spark timing. Check base timing with spout disconnected. Set base timing to the specification on the vehicle emission decal. b. Check computed timing with spout connected. NOTE: COMPUTED TIMING IS EQUAL TO BASE TIMING PLUS 20~ BTDC +/- 3~. 3. Misfiring spark plugs may cause an unburned fuel air mixture to pass through the catalyst, which could cause higher than normal catalyst temperatures. Refer to the following procedure for service details. a. Check secondary ignition, hook the vehicle up to an engine analyzer and check for a secondary ignition misfire. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Engine - Lack of Power/No Start Diagnosis > Page 1843 NOTE: SERVICE ANY ITEM THAT IS NOT PERFORMING AT PROPER SPECIFICATIONS BEFORE CONTINUING. 4. Fuel pressure that is too high may cause rich air fuel mixtures to pass through the catalyst which could cause higher than normal catalyst temperatures. Refer to the following procedure for service details. a. Check fuel pressure, install fuel pressure gauge, start and run the engine at idle. Fuel pressures between 28 and 34 PSI are typical (4.9L typically is 15 PSI higher). b. Disconnect the vacuum line going to the fuel pressure regulator. Fuel pressure typically jumps to 40 PSI +/- 3 PSI (4.9L typically is 15 PSI higher). Visually inspect vacuum line for raw fuel. NOTE: FUEL PRESSURES ABOVE THESE VALUES SHOULD BE CORRECTED. HOWEVER, THIS MAY NOT BE THE CAUSE OF THE CONCERN. SERVICE AS NECESSARY. 5. Throttle plates in the throttle body not returning to the proper closed position may cause excessive catalyst temperatures during downhill grades. Refer to the following procedure for service details. a. Visually inspect the throttle body and linkage for: ^ Binding or sticking throttle linkage. ^ Tight speed control linkage or cable. ^ Vacuum line interference. ^ Electrical harness interference. NOTE: AFTERMARKET GOVERNORS, THROTTLE LINKAGE AND CABLES ASSOCIATED WITH POWER TAKE-OFF UNITS, MAY ALSO INTERFERE WITH PROPER THROTTLE RETURN. SERVICE AS NECESSARY. 6. It is extremely important that all systems related to the engine and emission systems operate properly. a. Visually inspect the engine compartment to make sure all vacuum hoses and spark plug wires are properly routed and securely connected. b. Inspect all wiring harnesses and connectors for insulation damage, burned, overheated, loose or broken conditions. c. Verify proper operation of the thermactor system. Thermactor systems that fail to dump thermactor air to the atmosphere properly or at the correct time can cause high catalyst temperatures. d. Visually inspect thermactor system for damaged or kinked hoses and perform a function test on following components: air control valve, check valve, silencer, filter and the air bypass solenoid. e. Verify proper operation of the engine cooling system thermostat. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under Basic Warranty Coverage, Emissions Warranty Coverage OPERATION DESCRIPTION TIME 911211A Diagnostics - Perform 0.5 Hrs. KOEO And KOER Self Tests 911211B Timing - Check Or Adjust 0.5 Hrs. Spark Timing, Check Computed Timing And Check Secondary Ignition System With Engine Analyzer. 911211C Check - Fuel Pressure And 0.2 Hrs. Inspect Vacuum Line For Raw Fuel. 911211D Inspect - Throttle Body And 0.1 Hrs. Linkage. 911211E Inspect - Vacuum Hoses, 0.1 Hrs. Electrical Harnesses, Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Engine - Lack of Power/No Start Diagnosis > Page 1844 Connectors And Spark Plug Wires For Routing Damage. 911211F Thermactor System - 0.3 Hrs. Inspect For Proper Operation And Damaged Component. Includes Function Check Of Air Control Valve, Thermactor Air Bypass Solenoid, Check Valves, Silencer And Filter. 911211G Thermostat - Check For 0.2 Hrs. Proper Operation. DEALER CODING BASIC PART NO. CONDITION CODE 5E212 25 OASIS CODES: 403000, 603300, 614000 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Page 1845 Spark Plug: Specifications SPARK PLUGS Gap ...................................................................................................................................................... ............................................................ 0.044 in Torque ...................................................................... ................................................................................................................. 9-20 Nm (7-15 ft-lbs) Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Page 1846 Spark Plug: Service and Repair REMOVAL - Remove the wire from each spark plug by grasping the molded boot with tool T74P-6666-A or equivalent. Twist the boot until it loosens and then pull it off the spark plug. Do not pull on the wire, as the connection may become damaged. - Any wire damaged must be replaced. Each original spark plug wire is numbered for the cylinder to which it is designated. If wires are not numbered, each wire should be numbered as to the plug from which it was removed. - Clean the area around each spark plug port with compressed air. - Using the proper size spark plug socket remove the spark plugs. INSTALLATION Check the gap on each new spark plug and set to specification. See: Specifications - Install each spark plug and tighten to 9-20 Nm (7-15 ft-lbs). Cylinder Numbering And Distributor Location Location On Distributor - Coat the inside of each spark plug boot with silicone dielectric compound. Connect each spark plug wire to the plug from which it was removed. Be sure each wire is fully depressed on each plug and molded boot is firmly in place. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Compression Check > System Information > System Diagnosis Compression Check: Testing and Inspection COMPRESSION TEST 1. Ensure oil in crankcase is of the correct viscosity and at proper level and battery is properly charged. Operate vehicle until engine is at normal operating temperature. Turn OFF ignition switch, then remove all spark plugs. 2. Set throttle plates (and choke plates, if equipped) in wide-open position. 3. Install a compression gauge such as Rotunda Compression Tester 059-00009 or equivalent in No. 1 cylinder. 4. Install an auxiliary starter switch in starting circuit. With ignition switch in the OFF position, and using auxiliary starter switch, crank engine at least five compression strokes and record highest reading. Note the approximate number of compression strokes required to obtain the highest reading. 5. Repeat test on each cylinder cranking the engine approximately the same number of compression strokes. TEST CONCLUSION 1. The indicated compression pressures are considered within specification if the lowest reading cylinder is within 75 percent of the highest. 2. If one or more cylinders read low, squirt approximately one tablespoon of heavy SAE 50 weight or equivalent engine oil on top of the pistons in the low reading cylinders. Repeat compression pressure check on these cylinders. a. If compression improves considerably, piston rings are at fault. b. If compression does not improve, valves are sticking or seating poorly. c. If two adjacent cylinders indicate low compression pressures and squirting oil on pistons does not increase compression, cause may be a cylinder head gasket leak between cylinders. Engine oil and/or coolant in cylinders could result from this problem. Compression Pressure Limit Chart NOTE: Refer to the compression pressure limit chart for pressure specifications. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications Valve Clearance: Specifications ENGINE YEAR CLEARANCE V6-232 82-83 .088-.189 V8-255 81-82 .123-.173 6-300 80-87 .125-.175 V8-302 80-87 .096-.165 V8-351M 80-81 .125 V8-351W 80-87 .123-.173 V8-400 80-82 .175 V8-460 80-87 .100-.150 On engines with hydraulic lifters, clearance specified is at valve stem tip with lifter collapsed. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications > Page 1853 Valve Clearance: Locations FRONT TO REAR 6-300 E-I-E-I-E-I-E-I-E-I-E-I V6-232 Right I-E-I-E-I-E V6-232 Left E-I-E-I-E-I V8-255, 302 Left Bank E-I-E-I-E-I-E-I V8-255, 302 Right Bank I-E-I-E-I-E-I-E V8-351, 400 Right Bank I-E-I-E-I-E-I-E V8-351, 400 Left Bank E-I-E-I-E-I-E-I V8-460 Left Bank E-I-E-I-E-I-E-I V8-460 Right Bank I-E-I-E-I-E-I-E Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications > Page 1854 Valve Clearance: Adjustments Fig. 2 Positioning crankshaft for valve clearance check Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications > Page 1855 Fig. 3 Checking collapsed tappet clearance Valves, Adjust To provide a means to compensate for dimensional changes in the valve train and provide for valve adjustment, .060 inch shorter or longer pushrods are available. If the valve clearance is less than the minimum, the .060 inch shorter pushrod should be used. If the clearance is more than the maximum, the longer pushrod should be used. To check the valve clearance, proceed as follows: 1. Mark crankshaft pulley at three locations, with No. 1 location at TDC timing mark (end of compression stroke), location No. 2 one full turn (360°) clockwise from TDC and No. 3 location one quarter turn clockwise (90°) from position No. 2, Fig. 2. 2. Turn crankshaft to number 1 location, then compress valve lifter using tool T71P-6513-A or equivalent, Fig. 3, and check the clearance on the following valves: a. On V8-302 and 460 engines, check intake valve Nos. 1 , 7 and 8; exhaust valve Nos. 1, 4 and 5. b. On V8-351, check intake valve Nos. 1, 4 and No. 8; exhaust valve Nos. 1, 3 and 7. 3. Turn crankshaft to number 2 location, then compress valve lifter using tool T71P-6513-A or equivalent, Fig. 3, and check the clearance on the following valves: a. On V8-301 and 460 engines check intake valve Nos. 4 and 5; exhaust valve Nos. 2 and 6. b. On V8-351 engines, check intake valve Nos. 3 and 7; exhaust valve Nos. 2 and 6. 4. Turn crankshaft to number 3 location, then compress valve lifter using tool T71P-6513-A or equivalent and check the clearance on the following valves: a. V8-302 and 460 engines check intake valve Nos. 2, 3 and 6; exhaust valve Nos. 3, 7 and 8. b. On V8-351 engines, check intake valve Nos. 2, 5 and 6; exhaust valve Nos. 4, 5 and 8. Valve Arrangement Front to Rear V8-302 Left Bank.................................................................................................................................. ...........................................................E-I-E-I-E-I-E-I V8-302 Right Bank............................................. ..............................................................................................................................................I-E-I-E-IE-I-E V8-351 Right Bank...................................................................................................................... .....................................................................I-E-I-E-I-E-I-E V8-351 Left Bank...................................... .......................................................................................................................................................E-IE-I-E-I-E-I V8-460 Left Bank................................................................................................................. ............................................................................E-I-E-I-E-I-E-I V8-460 Right Bank............................ .............................................................................................................................................................. .I-E-I-E-I-E-I-E Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Service and Repair Water Pump: Service and Repair ]All water pumps have a sealed bearing integral with the water pump shaft. The bearing requires no lubrication. A bleed hole in the pump housing allows water that may leak past the seal to be thrown out by the slinger. This is not a lubrication hole. If the pump is damaged and requires repair, replace it with a new pump or a rebuilt one. F-100-350 & Bronco 1. Drain cooling system. 2. Remove fan shroud attaching bolts and position shroud over fan. 3. Disconnect lower radiator hose, heater hose and bypass hose from water pump. 4. Remove drive belts, fan, spacer, water pump pulley and fan shroud. 5. Loosen alternator pivot bolt and alternator adjusting arm-to-water pump attaching bolt. 6. Remove water pump attaching bolts and the water pump. 7. Reverse procedure to install. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Recycled Engine Coolant - Service Tips Coolant: Technical Service Bulletins Recycled Engine Coolant - Service Tips Article No. 95-18-2 09/11/95 ^ COOLANT - USE OF RECYCLED ENGINE, COOLANT - SERVICE TIP ^ COOLING SYSTEM - USE OF RECYCLED ENGINE, COOLANT - SERVICE TIP FORD: 1980 and after CROWN VICTORIA, MUSTANG, THUNDERBIRD 1981 and after ESCORT 1982-88 EXP 1984-94 TEMPO 1986 and after TAURUS 1988-93 FESTIVA 1989 and after PROBE 1994 and after ASPIRE 1995 and after CONTOUR LINCOLN-MERCURY: 1980 and after CONTINENTAL, COUGAR, GRAND MARQUIS, TOWN CAR 1981-86 CAPRI 1981-87 LYNX 1984-92 MARK VII 1984-94 TOPAZ 1986 and after SABLE 1987-89 TRACER 1991-94 CAPRI 1991 and after TRACER 1993 and after MARK VIII 1995 and after MYSTIQUE MERKUR: 1985-89 XR4TI 1988-89 SCORPIO LIGHT TRUCK: 1980 and after F-150-350 SERIES 1981 and after ECONOLINE 1982 and after BRONCO 1983 and after RANGER 1984-90 BRONCO II 1986 and after AEROSTAR 1988 and after F SUPER DUTY 1991 and after EXPLORER 1993 and after VILLAGER 1995 and after WINDSTAR This TSB is being republished in its entirety to include warranty information when using recycled coolant ISSUE: Ford Motor Company authorizes the use of recycled engine coolant that, when properly processed and reinhibited, meets Ford specification ESE-M97B44-A. At this time, the Rotunda Coolant Recycler (181-00003) process is the only approved coolant recycling method available through Ford that is capable of producing recycled engine coolant that meets Ford specification ESE-M97B44-A. ACTION: Refer to the following Service Procedure for coolant processing and reinhibiting using Rotunda Coolant Recycler (181-00003). NOTE: WHILE TESTING SHOWS THAT RECYCLED ENGINE COOLANT CAN PROVIDE ACCEPTABLE PERFORMANCE, THE COOLANT PRODUCED FROM ROTUNDA EQUIPMENT IS INTENDED FOR USE WITHIN DEALERSHIPS ON WARRANTY AND CUSTOMER PAY REPAIRS ONLY AND NOT INTENDED FOR RETAIL SALE. THERE ARE REGULATORY, PACKAGING AND LABELING CONCERNS Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Recycled Engine Coolant - Service Tips > Page 1864 ASSOCIATED WITH THE RETAIL SALE OF CHEMICAL PRODUCTS. CAUTION: THE REINHIBITOR CHEMICALS PROVIDED WITH THIS EQUIPMENT ARE NOT APPROPRIATE FOR USE ON MEDIUM/HEAVY TRUCK APPLICATIONS. WARNING: ROTUNDA PREMIUM COOLANT REINHIBITORS # 1 AND # 2 HAVE BEEN SPECIFICALLY FORMULATED TO WORK WITH ROTUNDA COOLANT RECYCLER (181-00003). USE OF ANY OTHER CHEMICAL ADDITIVES WITH THIS SYSTEM WILL VOID ALL WARRANTIES FOR THE EQUIPMENT AND FOR THE FINAL COOLANT PRODUCT. SERVICE PROCEDURE DIRECTIONS FOR PROCESSING USED ENGINE COOLANT WITH ROTUNDA COOLANT RECYCLER 1. Close the drain valve on the unit. 2. Open the fill valve. 3. Pour used engine coolant into the funnel on the side of the unit. NOTE: MAXIMUM CAPACITY 15 25 GALLONS (95 L). 4. Insert the outlet hoses of the recycler into clean, properly labeled containers. One (1) container is for the outlet process water and the other container is for distilled ethylene glycol. 5. Push the "ON" switch on the front to start the operation. The unit will process 1 gallon (3.8 L) per hour of operation and will automatically shut off when cycle is complete. 6. Add reinhibitor following the directions in this article. 7. Open the drain valve to drain the residue from the distillation vessel. Dispose of residue in accordance with all local. state and federal regulations. ADDING REINHIBITOR CHEMICALS 1. Process the coolant according to the directions listed in this article 2. Thoroughly mix 4 fl oz (118 ml) of Reinhibitor # 1 to each gallon of distilled ethylene glycol. 3. Thoroughly mix 4 fl oz (118 ml) of Reinhibitor # 2 to each gallon of distilled ethylene glycol. 4. Mix well. 5. Check the pH level of the coolant. The pH level must be between 9 and 11. 6. Add enough water to the concentrated coolant to produce a 50/50 mixture of coolant and water. NOTE: THE CONCENTRATED COOLANT MUST BE MIXED WITH WATER TO MEET THE NECESSARY ENGINE FREEZE PROTECTION. 7. Check the coolant freeze point of the 50% coolant solution. Freeze point should be -34°F (-37°C). Consult the Rotunda Coolant Recycler Manual for more detailed operating instructions. Call 1-800-ROTUNDA, 8 AM to 8 PM EST, for inquiries regarding the Rotunda Coolant Recycler and to order the Reinhibitor (187-R0001). PART NUMBER PART NAME Rotunda # 187-R0001 Rotunda Premium Coolant Reinhibitor WARRANTY CLAIMS: Dealer can claim recycled engine coolant by Ford approved process via a warranty repair on an 1863 claim as follows: Part Number: RECCOOL (not a valid part number, but it is recognized on an 1863 claim). Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Recycled Engine Coolant - Service Tips > Page 1865 Quantity: Indicate the number of QUARTS of recycled coolant used. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 95-16-6 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 402000 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Recycled Engine Coolant - Service Tips > Page 1866 Coolant: Technical Service Bulletins Engine Coolant - Recycled Coolant Not Authorized Article No. 90-4-10 COOLING SYSTEM - USE OF RECYCLED ENGINE COOLANT - SERVICE TIP FORD: 1984-90 CROWN VICTORIA, ESCORT, MUSTANG, TEMPO, THUNDERBIRD 1986-90 TAURUS 1988-90 FESTIVA 1989-90 PROBE LINCOLN-MERCURY: 1984-86 CAPRI 1984-87 LYNX 1984-90 CONTINENTAL, COUGAR, GRAND MARQUIS, MARK VII, TOPAZ, TOWN CAR 1986-90 SABLE 1987-90 TRACER MERKUR: 1985-90 XR4TI 1988-89 SCORPIO LIGHT TRUCK: 1984-90 BRONCO II, BRONCO, ECONOLINE, F-150, F-250, F-350, RANGER 1986-90 AEROSTAR MEDIUM/HEAVY TRUCK: 1984-90 C SERIES, F & B SERIES, L SERIES 1986-90 CARGO SERIES ISSUE: Ford Motor Company does not authorize the use of recycled engine coolant nor do they sanction the use of any machines or devices that recycle engine coolant. Recycled engine coolant is not equivalent to the factory fill OEM coolant, the Ford premium cooling system fluid (E2FZ-19549-AA) or the Ford heavy duty low silicate cooling fluid (E6HZ-19549-A). The quality of engine coolant degenerates with use. Recycling used engine coolant is very difficult to do without exposing the used coolant to additional foreign substances. Merely adding an additive to the coolant will not restore it. ACTION: Use new engine coolant that meets Ford Motor coolant specifications for the engine being serviced. Properly dispose of the used coolant. WARNING: THE DISPOSAL OF ALL USED ENGINE COOLANT MUST ALWAYS BE DONE IN ACCORDANCE WITH ALL APPLICABLE FEDERAL, STATE AND LOCAL LAWS AND REGULATIONS. PART NUMBER PART NAME CLASS E2FZ-19549-AA Coolant System Fluid - Ford V Premium E6HZ-19549-A Coolant System Fluid - Ford V Heavy Duty Low Silicate (For use in diesel powered med/hvy trucks) OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 4300 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Specifications > Capacity Specifications Coolant: Capacity Specifications Coolant Capacity Manual Transmission Less A/C .............................................................................................................................................. ............................................................... 15 qts A/C ............................................................................ ......................................................................................................................................... 16 qts A/C And Super Cooling .............................................................................................................................. ....................................................... 17 qts Automatic Transmission Less A/C and Super Cooling ............................................................................................................... ............................................................... 16 qts Super Cooling With A/C ............................................ ........................................................................................................................................ 17 qts All Other Models With A/C ................................................................................................................... ................................................................... 15 qts Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Specifications > Capacity Specifications > Page 1869 Coolant: Fluid Type Specifications COOLING SYSTEM FLUID, PREMIUM Ford Part No. U.S.A (Except Oregon) ............................................................................................................................................................ E2FZ-19549-AA or -B Canada ............................................................................................................ .............................................................................................. CXC-8-B Oregon .................................. ............................................................................................................................................................. F5FZ-19549-CC Ford Specification ................................................................................................................................ ................................................... ESE-M97B44-A COOLING SYSTEM FLUSH Ford Part No. ....................................................................................................................................... ................................................... F1AZ-19A503-A Ford Specification ................................................. ..................................................................................................................................... ESR-M14P7-A Coolant Mixture with Water ................................................................................................................. ...................................................................... 50% Warning: Do not mix coolant types. Check the owners manual or refer to your local dealer for the correct coolant type. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Level Indicator Lamp > Component Information > Description and Operation Coolant Level Indicator Lamp: Description and Operation This lamp will be illuminated when engine coolant level in the radiator drops below a pre-determined level. To turn lamp off, check cooling system, then add coolant to bring system to proper level. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Temperature Sensor / Switch > Component Information > Specifications Radiator Cooling Fan Temperature Sensor / Switch: Specifications Switch Torque Switch Torque Cooling Fan Switch 8-18 ft.lb Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Blade > Component Information > Testing and Inspection > Inspection Fan Blade: Testing and Inspection Inspection WARNING: Do not operate engine until fan has first been inspected for cracks and/or separations. If a fan blade is found to be bent or damaged in any way, do not attempt to repair or reuse damaged part. Proper balance is essential in fan assembly operation. Balance cannot be assured once a fan assembly has been found to be bent or damaged and failure may occur during operation, creating an extremely dangerous condition. Always replace damaged fan assembly. Place fan on flat surface with leading edge facing down. If there is a clearance between fan blade touching surface and opposite blade of more than .090 inch (2 mm), replace fan. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Blade > Component Information > Testing and Inspection > Inspection > Page 1881 Fan Blade: Testing and Inspection Looseness Lateral movement can be observed at the fan blade tip under various temperature conditions because of the type bearing used. This movement should not exceed 1/4 inch (6.5 mm) as measured at the fan tip. If this lateral movement does not exceed specifications, there is no cause for replacement. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch > Component Information > Testing and Inspection > Fan Clutch Fluid Leak Fan Clutch: Testing and Inspection Fan Clutch Fluid Leak Small fluid leaks do not generally affect the operation of the unit. These leaks generally occur around the area of the bearing assembly, but if the leaks appear to be excessive, engine overheating may occur. Check for clutch and fan free-wheeling by attempting to rotate fan and clutch assembly by hand five times. If no drag is felt, replace clutch. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch > Component Information > Testing and Inspection > Fan Clutch Fluid Leak > Page 1886 Fan Clutch: Testing and Inspection Fan Clutch Noise Fan clutch noise can sometimes be noticed when clutch is engaged for maximum cooling. Clutch noise is also noticeable within the first few minutes after starting engine while clutch is redistributing the silicone fluid back to its normal, disengaged operating condition after settling for long periods of time (over night). However, continuous fan noise or an excessive roar indicates the clutch assembly is locked-up due to internal failure. This condition can be checked by attempting to manually rotate fan. If fan cannot be rotated manually or there is a rough, abrasive feel as fan is rotated, the clutch should be replaced. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch > Component Information > Testing and Inspection > Fan Clutch Fluid Leak > Page 1887 Fan Clutch: Testing and Inspection Fan Clutch Operational Test Do not operate the engine until the fan has been first checked for possible cracks and separations. Run engine at a fast idle speed (1000 RPM) until normal operating temperature is reached. This process can be done more quickly by blocking off the front of the radiator with cardboard. Regardless of temperatures, unit must be operated for at least five minutes immediately before being tested. Stop engine and using a glove or a cloth to protect the hand, immediately check the effort required to turn the fan. If considerable effort is required, it can be assumed that coupling is operating satisfactorily. If very little effort is required to turn the fan, it is an indication that the coupling is not operating properly and should be replaced. Bi-Metallic Coiled Spring Removal The clutch fan may be tested while vehicle is being driven. To check, disconnect the bimetal spring, Fig. 2, and rotate 90° counterclockwise. This disables the temperature-controlled, free-wheeling feature and the clutch performs like a conventional fan. If this cures the overheating condition, replace the clutch fan. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications TEMPERATURE SENSORS Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 1892 Coolant Temperature Sensor/Switch (For Computer): Locations RH Side Of V8-351/5. Front Of Engine, Near Distributor Applicable to: 8L Engine With EEC-IV Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 1893 Coolant Temperature Sensor/Switch (For Computer): Description and Operation The Engine Coolant Temperature (ECT) Sensor, detects the temperature of engine coolant and supplies the Information to Electronic Control Assembly (ECA). The ECT sensor is threaded into the heater outlet fitting or cooling passage on the engine. For engine control applications, the ECT signal is used to modify ignition timing, EGR flow, and air to fuel ratio as a function of engine coolant temperature. On electronic instrument cluster applications, the ECT output is used to control a coolant temperature indicator. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 1894 Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection Ford provides trouble code/symptom driven diagnostics for this component. For complete diagnosis and pinpoint testing, refer to Computers and Control Systems, Testing and Inspection. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Radiator Cooling Fan Temperature Sensor / Switch > Component Information > Specifications Radiator Cooling Fan Temperature Sensor / Switch: Specifications Switch Torque Switch Torque Cooling Fan Switch 8-18 ft.lb Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Locations Temperature Sensor (Gauge): Locations LH Side Of V8-351/5. On Intake Manifold, Near Distributor Applicable to: 8L Engine Less EEC-IV Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Service and Repair Heater Core: Service and Repair Fig. 13 Heater core replacement. F-100---350 & Bronco less air conditioning F-100---350 & BRONCO Less Air Conditioning 1. Disconnect battery ground cable. 2. Disconnect cable from temperature blend door and the mounting bracket from top of heater assembly. 3. Disconnect blower motor and resistor electrical connectors. 4. Disconnect and plug hoses from heater core. 5. Working under instrument panel, remove 2 nuts on 1980---81 models, or 3 nuts on 1982---87 models, attaching left side of heater assembly and right side of plenum to dash. 6. On 1980---81 models, remove screw attaching top center of heater assembly to dash. 7. On all models, remove 2 screws attaching right side of heater assembly to dash, then lift heater assembly out of vehicle. 8. Remove heater housing plate attaching screws, nut and bolt and the plate. 9. On 1980---82 models, remove 3 heater core frame attaching screws and the frame. 10. On all models, slide heater core and seal out of heater assembly, Fig. 13. 11. Reverse procedure to install. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Service and Repair > Page 1904 Fig. 14 Heater core replacement. F-100---350 & Bronco w/air conditioning W/Air Conditioning 1. Disconnect battery ground cable. 2. Disconnect and plug hoses from heater core. 3. Remove glove compartment liner. 4. Remove 8 heater core cover attaching screws and the cover. 5. Remove heater core from plenum, Fig. 14. 6. Reverse procedure to install. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System > Coolant Level Indicator Lamp > Component Information > Description and Operation Coolant Level Indicator Lamp: Description and Operation This lamp will be illuminated when engine coolant level in the radiator drops below a pre-determined level. To turn lamp off, check cooling system, then add coolant to bring system to proper level. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System > Temperature Gauge > Component Information > Testing and Inspection > Dash Gauge Test Temperature Gauge: Testing and Inspection Dash Gauge Test Gauge failures are often caused by defective wiring or grounds. The first step in locating trouble should be a thorough inspection of all wiring, terminals and printed circuits. If wiring is secured by clamps, check to see whether the insulation has been severed, thereby grounding the wire. In the case of a fuel gauge installation, rust may cause failure by corrosion at the ground connection of the tank unit. The Constant Voltage Regulator (CVR) type indicator is a bimetal-resistance type system consisting of an Instrument Voltage Regulator (IVR), an indicator gauge, and a variable resistance sending unit. Current to the system is applied to the gauge terminals by the IVR, which maintains an average-pulsating value of 5 volts. The indicator gauge consists of a pointer which is attached to a wire-wound bimetal strip. Current passing through the coil heats the bimetal strip, causing the pointer to move. As more current passes through the coil, heat increases, moving the pointer farther. The circuit is completed through a sending unit which contains a variable resistor. When resistance is high, less current is allowed to pass through the gauge, and the pointer moves very little. As resistance decreases due to changing conditions in system being monitored, more current passes through gauge coil, causing pointer to move farther. Do not apply battery voltage to system or ground output terminals of IVR, as damage to system components or wiring circuits may result. DASH GAUGE TEST 1. Disconnect battery ground cable and remove gauge from vehicle. 2. Connect ohmmeter between gauge terminals and read coil winding resistance. 3. An upward movement of ohmmeter needle from 10 ohms to 14 ohms is normal, as test current of ohmmeter causes a temperature rise in gauge coil windings. 4. If ohmmeter reads below 10 ohms or above 14 ohms, gauge is defective. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System > Temperature Gauge > Component Information > Testing and Inspection > Dash Gauge Test > Page 1913 Temperature Gauge: Testing and Inspection Electrical Temperature Gauges This temperature indicating system consists of a sending unit, located on the cylinder head, electrical temperature gauge and an instrument voltage regulator. As engine temperature increases or decreases, the resistance of the sending unit changes, in turn controlling current flow to the gauge. When engine temperature is low, the resistance of the sending unit is high, restricting current flow to the gauge, in turn indicating low engine temperature. As engine temperature increases, the resistance of the ending unit decreases, permitting an increased current flow to the gauge, resulting in an increased temperature reading. TROUBLESHOOTING A special tester is required to diagnose this type gauge. Follow instructions included with the tester. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System > Temperature Warning Lamp/Indicator, Engine Cooling > Component Information > Testing and Inspection Temperature Warning Lamp/Indicator: Testing and Inspection A bimetal temperature switch located in the cylinder head control the operation of a temperature indicator light with a red lens. If the engine cooling system is not functioning properly and coolant temperature exceeds a predetermined value, the warning light will illuminate. TROUBLESHOOTING If the red light is not lit when the engine is being cranked, check for a burned out bulb, an open in the light circuit, or a defective ignition switch. If the red light is lit when the engine is running, check the wiring between light and switch for a ground, defective temperature switch, or overheated cooling system. As a test circuit to check whether the red bulb is functioning properly, a wire which is connected to the ground terminal of the ignition switch is tapped into its circuit. When the ignition is in the ``Start'' (engine cranking) position, the ground terminal is grounded inside the switch and the red bulb will be lit. When the engine is started and the ignition switch is in the ``On'' position, the test circuit is opened and the bulb is then controlled by the temperature switch. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cap > Component Information > Specifications Radiator Cap: Specifications Release Pressure 13 psi Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications TEMPERATURE SENSORS Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 1925 Coolant Temperature Sensor/Switch (For Computer): Locations RH Side Of V8-351/5. Front Of Engine, Near Distributor Applicable to: 8L Engine With EEC-IV Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 1926 Coolant Temperature Sensor/Switch (For Computer): Description and Operation The Engine Coolant Temperature (ECT) Sensor, detects the temperature of engine coolant and supplies the Information to Electronic Control Assembly (ECA). The ECT sensor is threaded into the heater outlet fitting or cooling passage on the engine. For engine control applications, the ECT signal is used to modify ignition timing, EGR flow, and air to fuel ratio as a function of engine coolant temperature. On electronic instrument cluster applications, the ECT output is used to control a coolant temperature indicator. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 1927 Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection Ford provides trouble code/symptom driven diagnostics for this component. For complete diagnosis and pinpoint testing, refer to Computers and Control Systems, Testing and Inspection. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Radiator Cooling Fan Temperature Sensor / Switch > Component Information > Specifications Radiator Cooling Fan Temperature Sensor / Switch: Specifications Switch Torque Switch Torque Cooling Fan Switch 8-18 ft.lb Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Locations Temperature Sensor (Gauge): Locations LH Side Of V8-351/5. On Intake Manifold, Near Distributor Applicable to: 8L Engine Less EEC-IV Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Gauge > Component Information > Testing and Inspection > Dash Gauge Test Temperature Gauge: Testing and Inspection Dash Gauge Test Gauge failures are often caused by defective wiring or grounds. The first step in locating trouble should be a thorough inspection of all wiring, terminals and printed circuits. If wiring is secured by clamps, check to see whether the insulation has been severed, thereby grounding the wire. In the case of a fuel gauge installation, rust may cause failure by corrosion at the ground connection of the tank unit. The Constant Voltage Regulator (CVR) type indicator is a bimetal-resistance type system consisting of an Instrument Voltage Regulator (IVR), an indicator gauge, and a variable resistance sending unit. Current to the system is applied to the gauge terminals by the IVR, which maintains an average-pulsating value of 5 volts. The indicator gauge consists of a pointer which is attached to a wire-wound bimetal strip. Current passing through the coil heats the bimetal strip, causing the pointer to move. As more current passes through the coil, heat increases, moving the pointer farther. The circuit is completed through a sending unit which contains a variable resistor. When resistance is high, less current is allowed to pass through the gauge, and the pointer moves very little. As resistance decreases due to changing conditions in system being monitored, more current passes through gauge coil, causing pointer to move farther. Do not apply battery voltage to system or ground output terminals of IVR, as damage to system components or wiring circuits may result. DASH GAUGE TEST 1. Disconnect battery ground cable and remove gauge from vehicle. 2. Connect ohmmeter between gauge terminals and read coil winding resistance. 3. An upward movement of ohmmeter needle from 10 ohms to 14 ohms is normal, as test current of ohmmeter causes a temperature rise in gauge coil windings. 4. If ohmmeter reads below 10 ohms or above 14 ohms, gauge is defective. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Gauge > Component Information > Testing and Inspection > Dash Gauge Test > Page 1938 Temperature Gauge: Testing and Inspection Electrical Temperature Gauges This temperature indicating system consists of a sending unit, located on the cylinder head, electrical temperature gauge and an instrument voltage regulator. As engine temperature increases or decreases, the resistance of the sending unit changes, in turn controlling current flow to the gauge. When engine temperature is low, the resistance of the sending unit is high, restricting current flow to the gauge, in turn indicating low engine temperature. As engine temperature increases, the resistance of the ending unit decreases, permitting an increased current flow to the gauge, resulting in an increased temperature reading. TROUBLESHOOTING A special tester is required to diagnose this type gauge. Follow instructions included with the tester. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Warning Lamp/Indicator, Engine Cooling > Component Information > Testing and Inspection Temperature Warning Lamp/Indicator: Testing and Inspection A bimetal temperature switch located in the cylinder head control the operation of a temperature indicator light with a red lens. If the engine cooling system is not functioning properly and coolant temperature exceeds a predetermined value, the warning light will illuminate. TROUBLESHOOTING If the red light is not lit when the engine is being cranked, check for a burned out bulb, an open in the light circuit, or a defective ignition switch. If the red light is lit when the engine is running, check the wiring between light and switch for a ground, defective temperature switch, or overheated cooling system. As a test circuit to check whether the red bulb is functioning properly, a wire which is connected to the ground terminal of the ignition switch is tapped into its circuit. When the ignition is in the ``Start'' (engine cranking) position, the ground terminal is grounded inside the switch and the red bulb will be lit. When the engine is started and the ignition switch is in the ``On'' position, the test circuit is opened and the bulb is then controlled by the temperature switch. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Technical Service Bulletins > Cooling System - New System Diagnostics Thermostat: Technical Service Bulletins Cooling System - New System Diagnostics Article No. 93-24-8 11/24/93 ^ HESITATION - ROUGH IDLE - ENGINE COOLANT DOES NOT REACH NORMAL OPERATING TEMPERATURE - MEDIUM TRUCKS WITH 7.0L ENGINES ^ HESITATION/STALL DURING ACCELERATION OR DECELERATION ^ IDLE - ROUGH - ENGINE COOLANT DOES NOT REACH NORMAL OPERATING TEMPERATURE ^ HEATER/DEFROSTER - POOR HEATER OUTPUT - THERMOSTAT STUCK OPEN ^ COOLING SYSTEM - NEW DIAGNOSTICS FOR ENGINES THAT DO NOT REACH NORMAL OPERATING TEMPERATURE FORD: 1983-94 ESCORT 1984-87 EXP 1984-94 CROWN VICTORIA, MUSTANG, TEMPO, THUNDERBIRD 1986-94 TAURUS LINCOLN-MERCURY: 1984-86 CAPRI 1984-87 LYNX 1984-92 MARK VII 1984-94 CONTINENTAL, COUGAR, GRAND MARQUIS, TOPAZ, TOWN CAR 1986-94 SABLE 1988-89 TRACER 1991-94 CAPRI, TRACER MERKUR: 1985-89 XR4TI 1988-89 SCORPIO LIGHT TRUCK: 1984-94 BRONCO, ECONOLINE, F-150-350 SERIES, RANGER 1985-90 BRONCO II 1986-94 AEROSTAR 1988-94 F SUPER DUTY 1991-94 EXPLORER This TSB article is being republished in its entirety to include 1994 model year vehicles. ISSUE: Engine performance concerns such as hesitation or stall, rough idle, and/or poor fuel economy may be caused by the thermostat stuck in an open position or opening at a temperature lower than specified. ACTION: Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Technical Service Bulletins > Cooling System - New System Diagnostics > Page 1946 Use the following "Cooling System Diagnosis" procedure to diagnose a cooling system that may not be reaching normal operating temperature. Follow the "Thermostat Diagnosis" procedure to determine if the thermostat may be at fault. Check the thermostat without removing it from the vehicle by using Rotunda Service Coolant Temperature Monitor Harness 007-00064. A new cooling system diagnosis procedure has been developed for engines that do not reach normal operating temperature. A new thermostat diagnosis procedure also has been developed, using a new service coolant temperature monitor harness. NOTE: THIS PROCEDURE WILL DIAGNOSE ONLY COOLING SYSTEMS THAT MAY NOT BE REACHING NORMAL OPERATING TEMPERATURE. IT WILL NOT DIAGNOSE A THERMOSTAT THAT CAUSES AN ENGINE OVERHEAT CONDITION. NOTE: THE ESCORT/TRACER SPECIFIC APPLICATION FOR THIS ARTICLE IS AS FOLLOWS: ^ 1983-1990 Escort 1.9L and 1.6L ^ 1991-1994 Escort 1.9L ^ 1991-1994 Tracer 1.9L Only THERMOSTAT DIAGNOSIS NOTE: DISCONNECTING THE POWERTRAIN CONTROL MODULE (PCM) TO ATTACH A BREAKOUT BOX OR AN EEC IV MONITOR WILL ERASE THE ADAPTIVE LEARNING FROM MEMORY AND MAY "HIDE" A DRIVE CONCERN TEMPORARILY UNTIL THE ADAPTIVE LEARNING IS RE-LEARNED. NOTE: THIS PROCEDURE IS MOST ACCURATE IF PERFORMED INDOORS AT LESS THAN 100~F (38~C) AMBIENT TEMPERATURE. THIS TEST MAY BE PERFORMED WITH OR WITHOUT THE HOOD OPEN AND WITH THE ENGINE WARM OR COLD. CAUTION: ALWAYS VENT THE EXHAUST TO THE OUTSIDE WHEN PERFORMING THIS TEST. 1. Check the coolant level in the radiator and coolant recovery reservoir. 2. With the key in the "off" position, proceed as follows: a. Remove the engine coolant temperature (ECT) sensor harness connector. b. Attach Rotunda Service Coolant Temperature Monitor Harness 007-00064 as a jumper between the PCM and the ECT. c. Attach Rotunda 73 Digital Multimeter 105-00051 or equivalent to the thermostat monitor harness. Voltage values (0-5vdc) may now be Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Technical Service Bulletins > Cooling System - New System Diagnostics > Page 1947 monitored while the sensor retains its connection to the wiring harness. NOTE: A ROTUNDA NEW GENERATION STAR TESTER (NGS) 007-00500 OR THE ROTUNDA SERVICE BAY DIAGNOSTIC SYSTEM (SBDS) 001-00001 MAY BE USED TO MONITOR THE ECT ON VEHICLES EQUIPPED WITH DATA COMMUNICATIONS LINK (DCL). THE SBDS SEQUENCE TO USE FOR THE SCREEN IS "TOOLBOX - ELECTRONIC ENGINE CONTROL AND DCL - ITEM". 3. Vehicles equipped with electric engine cooling fan(s) must have a fan running during this test (high or low speed may be used). Two methods may be used to turn the fan(s) on: a. Disconnect the A/C compressor clutch power supply and turn the climate control to A/C "ON". Or b. Disconnect the power supply to the cooling fan and supply 12 volts direct to the fan connector from the battery. NOTE: A GROUND MAY BE REQUIRED FOR SOME APPLICATIONS. 4. Place transmission in "park" or "neutral". NOTE: RUNNING THIS TEST WITH THE VEHICLE IN GEAR OR WITH THE A/C COMPRESSOR CLUTCH ENGAGED (RUNNING) WILL CAUSE IMPROPER DIAGNOSIS 5. Start the engine and allow to idle throughout this test: a. Allow engine to run for 2 minutes, then record ECT voltage. b. From now on, record ECT voltage every 60 seconds. c. When the ECT voltage trend changes direction or changes only slightly (0.03 volts or less) from the previous reading, record this as the thermostat opening voltage. d. Use the "Voltage and Corresponding Temperature Chart" shown to obtain actual coolant temperatures. 6. If the opening voltage is GREATER than 0.75 volts (less than 18~ F/ 82~ C), or 0.85 volts (170~ F/ 77~ C) for 2.3L HSC engine only, replace the thermostat. Refer to the dealer Master Parts Catalog for correct thermostat usage. 7. If the thermostat opening voltage is LESS than 0.75 volts (greater than 180~ F/ 82~ C), or 0.85 volts (170~ F/ 77~ C) for 2.3L HSC engine only, the thermostat is good and should NOT be replaced. The "Cooling System Diagnosis Chart" should be referenced for further instructions. NOTE: The 10~ F opening temperature difference for the 2.3L HSC engine is due to the ECT sensor location. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 93-14-4 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 208000, 208100, 402000, 608000, 608400, 609000, 609400, 611000, 611500, 622000, 690000 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Service and Repair Water Pump: Service and Repair ]All water pumps have a sealed bearing integral with the water pump shaft. The bearing requires no lubrication. A bleed hole in the pump housing allows water that may leak past the seal to be thrown out by the slinger. This is not a lubrication hole. If the pump is damaged and requires repair, replace it with a new pump or a rebuilt one. F-100-350 & Bronco 1. Drain cooling system. 2. Remove fan shroud attaching bolts and position shroud over fan. 3. Disconnect lower radiator hose, heater hose and bypass hose from water pump. 4. Remove drive belts, fan, spacer, water pump pulley and fan shroud. 5. Loosen alternator pivot bolt and alternator adjusting arm-to-water pump attaching bolt. 6. Remove water pump attaching bolts and the water pump. 7. Reverse procedure to install. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Engine - Lack of Power/No Start Diagnosis Catalytic Converter: Technical Service Bulletins Engine - Lack of Power/No Start Diagnosis Article No. 91-12-11 06/12/91 LACK OF POWER 7.5L, 5.8L, 5.0L, 4.9L - CATALYTIC CONVERTER DIAGNOSTIC TIPS LIGHT TRUCK: 1986-91 BRONCO, ECONOLINE, F-150-350 SERIES 1988-91 F SUPER DUTY, F47 ISSUE: Lack of power or a no start condition may be diagnosed as an exhaust restriction caused by a plugged catalytic converter. A plugged catalytic converter (internal deterioration) is usually caused by abnormal engine operation. ACTION: Diagnose the catalytic converter to confirm internal failure. Refer to the Catalyst and Exhaust System Diagnostic Section, in the Engine/Emissions Diagnostic Shop Manual and the following procedures for service details. 1. Lack of proper HEGO operation may cause, or be the result of a rich or lean fuel condition, which could cause additional heat in the catalyst. Perform self test KOEO and KOER, service any codes. NOTE: IF TWO DIGIT CODES 41, 42, 85 OR THREE DIGIT CODES 171, 172, 173, 179, 181, 182, 183 AND 565 ARE RECEIVED, CHECK FOR PROPER HEGO GROUND. If the HEGO ground is good, the following areas may be at fault: ^ Ignition Coil ^ Distributor Cap ^ Distributor Rotor ^ Fouled Spark Plug ^ Spark Plug Wires ^ Air Filter ^ Stuck Open Injector ^ Fuel Contamination Engine OIL ^ Manifold Leaks Intake/ Exhaust ^ Fuel Pressure ^ Poor Power Ground ^ Engine Not At Normal Operating Temperature ^ HEGO Sensor 2. Spark timing that is retarded from specification may increase exhaust gas temperature and shorten catalyst life. Refer to the following procedure for service details. a. Check spark timing. Check base timing with spout disconnected. Set base timing to the specification on the vehicle emission decal. b. Check computed timing with spout connected. NOTE: COMPUTED TIMING IS EQUAL TO BASE TIMING PLUS 20~ BTDC +/- 3~. 3. Misfiring spark plugs may cause an unburned fuel air mixture to pass through the catalyst, which could cause higher than normal catalyst temperatures. Refer to the following procedure for service details. a. Check secondary ignition, hook the vehicle up to an engine analyzer and check for a secondary ignition misfire. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Engine - Lack of Power/No Start Diagnosis > Page 1956 NOTE: SERVICE ANY ITEM THAT IS NOT PERFORMING AT PROPER SPECIFICATIONS BEFORE CONTINUING. 4. Fuel pressure that is too high may cause rich air fuel mixtures to pass through the catalyst which could cause higher than normal catalyst temperatures. Refer to the following procedure for service details. a. Check fuel pressure, install fuel pressure gauge, start and run the engine at idle. Fuel pressures between 28 and 34 PSI are typical (4.9L typically is 15 PSI higher). b. Disconnect the vacuum line going to the fuel pressure regulator. Fuel pressure typically jumps to 40 PSI +/- 3 PSI (4.9L typically is 15 PSI higher). Visually inspect vacuum line for raw fuel. NOTE: FUEL PRESSURES ABOVE THESE VALUES SHOULD BE CORRECTED. HOWEVER, THIS MAY NOT BE THE CAUSE OF THE CONCERN. SERVICE AS NECESSARY. 5. Throttle plates in the throttle body not returning to the proper closed position may cause excessive catalyst temperatures during downhill grades. Refer to the following procedure for service details. a. Visually inspect the throttle body and linkage for: ^ Binding or sticking throttle linkage. ^ Tight speed control linkage or cable. ^ Vacuum line interference. ^ Electrical harness interference. NOTE: AFTERMARKET GOVERNORS, THROTTLE LINKAGE AND CABLES ASSOCIATED WITH POWER TAKE-OFF UNITS, MAY ALSO INTERFERE WITH PROPER THROTTLE RETURN. SERVICE AS NECESSARY. 6. It is extremely important that all systems related to the engine and emission systems operate properly. a. Visually inspect the engine compartment to make sure all vacuum hoses and spark plug wires are properly routed and securely connected. b. Inspect all wiring harnesses and connectors for insulation damage, burned, overheated, loose or broken conditions. c. Verify proper operation of the thermactor system. Thermactor systems that fail to dump thermactor air to the atmosphere properly or at the correct time can cause high catalyst temperatures. d. Visually inspect thermactor system for damaged or kinked hoses and perform a function test on following components: air control valve, check valve, silencer, filter and the air bypass solenoid. e. Verify proper operation of the engine cooling system thermostat. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under Basic Warranty Coverage, Emissions Warranty Coverage OPERATION DESCRIPTION TIME 911211A Diagnostics - Perform 0.5 Hrs. KOEO And KOER Self Tests 911211B Timing - Check Or Adjust 0.5 Hrs. Spark Timing, Check Computed Timing And Check Secondary Ignition System With Engine Analyzer. 911211C Check - Fuel Pressure And 0.2 Hrs. Inspect Vacuum Line For Raw Fuel. 911211D Inspect - Throttle Body And 0.1 Hrs. Linkage. 911211E Inspect - Vacuum Hoses, 0.1 Hrs. Electrical Harnesses, Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Engine - Lack of Power/No Start Diagnosis > Page 1957 Connectors And Spark Plug Wires For Routing Damage. 911211F Thermactor System - 0.3 Hrs. Inspect For Proper Operation And Damaged Component. Includes Function Check Of Air Control Valve, Thermactor Air Bypass Solenoid, Check Valves, Silencer And Filter. 911211G Thermostat - Check For 0.2 Hrs. Proper Operation. DEALER CODING BASIC PART NO. CONDITION CODE 5E212 25 OASIS CODES: 403000, 603300, 614000 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Description and Operation > Dual Catalytic Converter Catalytic Converter: Description and Operation Dual Catalytic Converter Fig. 17 Dual catalytic converter This converter consists of two catalytic converters in one shell, with a mixing chamber in between the two, Fig. 17. Each converter is composed of a ceramic ``honey comb'' coated with a rhodium/platinum catalyst designed to control oxides of nitrogen (NOx), unburned hydrocarbons (HC) and carbon monoxide (CO), and is therefore called a ``three way catalyst'' (TWC). The rear converter is coated with platinum catalyst and is called a ``conventional'' oxidation catalyst'' (COC) converter. The platinum catalyst is also called a ``two way catalyst'' since it only acts on two of the major pollutants, HC and CO. The TWC converter acts on the exhaust gases from the engine. As the gases flow from the TWC to the COC converter, they mix with air from the thermactor pump injected into the mixing chamber or ``mid-bed''. This air is required for proper oxidation of HC and CO in the COC converter. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Description and Operation > Dual Catalytic Converter > Page 1960 Catalytic Converter: Description and Operation General Description Fig. 4 Single type catalytic converter with single substrate catalyst Fig. 5 Single type catalytic converter with dual substrate catalyst Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Description and Operation > Dual Catalytic Converter > Page 1961 Fig. 6 Dual type catalytic converter The catalytic converter used on some vehicles, serves two purposes: it permits a faster chemical reaction to take place and although it enters into the chemical reaction, it remains unchanged, ready to repeat the process. The catalytic converter combines hydrocarbons (HC) and carbon monoxide (CO) with oxygen to form water (H2O) and carbon dioxide (CO2). The catalyst is structured in the form of a honeycomb monolithic composition, Figs. 4,5 and 6 . The catalyst consists of a porous substrate of an inert material, coated with platinum and other noble metals (the catalytically active materials.) This device, located in the exhaust system between the exhaust manifold and muffler, requires the use of heat shields, in some cases, due to its high operating temperatures. The heat shields are necessary to protect chassis components, passenger compartment and other areas from heat related damage. A small diameter fuel tank filler tube neck is incorporated to prevent the larger service station pump nozzle, used for leaded fuels, being inserted into the filler tube, thereby preventing system contamination. Since the use of leaded fuels contaminates the catalysts, deteriorating its effectiveness, the use of unleaded fuels is mandatory in vehicles equipped with catalytic converters. The catalytic converter can tolerate small amounts of leaded fuels without permanently reducing the catalyst effectiveness. There are basically three types of catalysts, the conventional oxidation catalyst (COC) containing Platinum (Pt) and Palladium (Pd) which are effective for catalyzing the oxidation reactions of hydrocarbons (HC) and carbon monoxide (CO) emissions. A three-way catalyst (TWC) containing Platinum (Pt) and Rhodium (RH), is not only effective for catalyzing the oxidation reactions of HC and CO emissions, but it also catalyzes the reduction of nitrogen oxides (NOx). A light off catalyst (LOC) is a single bed converter. It is arranged in series with the main catalytic converter assembly of COC and/or TWC as the aft member(s). This converter is designed to perform the very specialized function of exhaust emission control during engine warm-up when the main converter(s) is not yet at the temperature required for maximum efficiency. The LOC is designed to operate effectively in the high environmental conditions that exist near the manifold flange. The LOC is designed with a minimum heat sink effect and, provides minimum delay in warm-up of the main catalytic converter(s). The oxidation catalyst requires the use of a secondary air source which is provided by the pulse air or thermactor air injection systems. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Description and Operation > Page 1962 Catalytic Converter: Testing and Inspection Blocked or restricted exhaust system usually results in lack of power or popping through the intake system. Verify that this condition is not caused by ignition timing problems, then proceed with diagnosis. Catalyst and Exhaust Systems Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Description and Operation > Page 1963 Catalyst and Exhaust Systems Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Technical Service Bulletins > Engine - Lack of Power/No Start Diagnosis Exhaust Manifold: Technical Service Bulletins Engine - Lack of Power/No Start Diagnosis Article No. 91-12-11 06/12/91 LACK OF POWER 7.5L, 5.8L, 5.0L, 4.9L - CATALYTIC CONVERTER DIAGNOSTIC TIPS LIGHT TRUCK: 1986-91 BRONCO, ECONOLINE, F-150-350 SERIES 1988-91 F SUPER DUTY, F47 ISSUE: Lack of power or a no start condition may be diagnosed as an exhaust restriction caused by a plugged catalytic converter. A plugged catalytic converter (internal deterioration) is usually caused by abnormal engine operation. ACTION: Diagnose the catalytic converter to confirm internal failure. Refer to the Catalyst and Exhaust System Diagnostic Section, in the Engine/Emissions Diagnostic Shop Manual and the following procedures for service details. 1. Lack of proper HEGO operation may cause, or be the result of a rich or lean fuel condition, which could cause additional heat in the catalyst. Perform self test KOEO and KOER, service any codes. NOTE: IF TWO DIGIT CODES 41, 42, 85 OR THREE DIGIT CODES 171, 172, 173, 179, 181, 182, 183 AND 565 ARE RECEIVED, CHECK FOR PROPER HEGO GROUND. If the HEGO ground is good, the following areas may be at fault: ^ Ignition Coil ^ Distributor Cap ^ Distributor Rotor ^ Fouled Spark Plug ^ Spark Plug Wires ^ Air Filter ^ Stuck Open Injector ^ Fuel Contamination Engine OIL ^ Manifold Leaks Intake/ Exhaust ^ Fuel Pressure ^ Poor Power Ground ^ Engine Not At Normal Operating Temperature ^ HEGO Sensor 2. Spark timing that is retarded from specification may increase exhaust gas temperature and shorten catalyst life. Refer to the following procedure for service details. a. Check spark timing. Check base timing with spout disconnected. Set base timing to the specification on the vehicle emission decal. b. Check computed timing with spout connected. NOTE: COMPUTED TIMING IS EQUAL TO BASE TIMING PLUS 20~ BTDC +/- 3~. 3. Misfiring spark plugs may cause an unburned fuel air mixture to pass through the catalyst, which could cause higher than normal catalyst temperatures. Refer to the following procedure for service details. a. Check secondary ignition, hook the vehicle up to an engine analyzer and check for a secondary ignition misfire. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Technical Service Bulletins > Engine - Lack of Power/No Start Diagnosis > Page 1968 NOTE: SERVICE ANY ITEM THAT IS NOT PERFORMING AT PROPER SPECIFICATIONS BEFORE CONTINUING. 4. Fuel pressure that is too high may cause rich air fuel mixtures to pass through the catalyst which could cause higher than normal catalyst temperatures. Refer to the following procedure for service details. a. Check fuel pressure, install fuel pressure gauge, start and run the engine at idle. Fuel pressures between 28 and 34 PSI are typical (4.9L typically is 15 PSI higher). b. Disconnect the vacuum line going to the fuel pressure regulator. Fuel pressure typically jumps to 40 PSI +/- 3 PSI (4.9L typically is 15 PSI higher). Visually inspect vacuum line for raw fuel. NOTE: FUEL PRESSURES ABOVE THESE VALUES SHOULD BE CORRECTED. HOWEVER, THIS MAY NOT BE THE CAUSE OF THE CONCERN. SERVICE AS NECESSARY. 5. Throttle plates in the throttle body not returning to the proper closed position may cause excessive catalyst temperatures during downhill grades. Refer to the following procedure for service details. a. Visually inspect the throttle body and linkage for: ^ Binding or sticking throttle linkage. ^ Tight speed control linkage or cable. ^ Vacuum line interference. ^ Electrical harness interference. NOTE: AFTERMARKET GOVERNORS, THROTTLE LINKAGE AND CABLES ASSOCIATED WITH POWER TAKE-OFF UNITS, MAY ALSO INTERFERE WITH PROPER THROTTLE RETURN. SERVICE AS NECESSARY. 6. It is extremely important that all systems related to the engine and emission systems operate properly. a. Visually inspect the engine compartment to make sure all vacuum hoses and spark plug wires are properly routed and securely connected. b. Inspect all wiring harnesses and connectors for insulation damage, burned, overheated, loose or broken conditions. c. Verify proper operation of the thermactor system. Thermactor systems that fail to dump thermactor air to the atmosphere properly or at the correct time can cause high catalyst temperatures. d. Visually inspect thermactor system for damaged or kinked hoses and perform a function test on following components: air control valve, check valve, silencer, filter and the air bypass solenoid. e. Verify proper operation of the engine cooling system thermostat. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under Basic Warranty Coverage, Emissions Warranty Coverage OPERATION DESCRIPTION TIME 911211A Diagnostics - Perform 0.5 Hrs. KOEO And KOER Self Tests 911211B Timing - Check Or Adjust 0.5 Hrs. Spark Timing, Check Computed Timing And Check Secondary Ignition System With Engine Analyzer. 911211C Check - Fuel Pressure And 0.2 Hrs. Inspect Vacuum Line For Raw Fuel. 911211D Inspect - Throttle Body And 0.1 Hrs. Linkage. 911211E Inspect - Vacuum Hoses, 0.1 Hrs. Electrical Harnesses, Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Technical Service Bulletins > Engine - Lack of Power/No Start Diagnosis > Page 1969 Connectors And Spark Plug Wires For Routing Damage. 911211F Thermactor System - 0.3 Hrs. Inspect For Proper Operation And Damaged Component. Includes Function Check Of Air Control Valve, Thermactor Air Bypass Solenoid, Check Valves, Silencer And Filter. 911211G Thermostat - Check For 0.2 Hrs. Proper Operation. DEALER CODING BASIC PART NO. CONDITION CODE 5E212 25 OASIS CODES: 403000, 603300, 614000 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Technical Service Bulletins > Page 1970 Exhaust Manifold: Service and Repair V8-255, 302 & 351W 1. Disconnect battery ground cable. 2. Remove air cleaner and intake duct assembly including crankcase ventilation hose. 3. Remove bolts attaching air cleaner inlet duct, if equipped. 4. Disconnect exhaust pipes at manifolds. 5. Remove exhaust manifold heat shields with attaching bolts and flat washers, if equipped. 6. Remove oil dipstick tube assembly, speed control bracket and exhaust heat control valve from left side exhaust manifold, if equipped, then remove exhaust manifold. 7. Reverse procedure to install, torquing attaching bolts to specifications from centermost bolts outward. V8-351M & 400 1. Disconnect battery ground cable. 2. When removing right side manifold, remove air cleaner, intake duct and heat shield. 3. When removing left side manifold, remove oil filter. 4. On 1980-82 models, remove oil dipstick and tube assembly and speed control bracket from left side exhaust manifold, if equipped. 5. On vehicles equipped with column selector and automatic transmission, disconnect selector lever cross shaft. 6. On all models, disconnect exhaust pipe at manifold and remove spark plug heat shields. 7. Remove exhaust manifold attaching bolts and the exhaust manifold. 8. Reverse procedure to install, torquing attaching bolts to specifications from center most bolts outward. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Electronic Throttle Control Module > Component Information > Locations Electronic Throttle Control Module: Locations Under LH Side Of I/P Under LH Side Of I/P Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Electronic Throttle Control Module > Component Information > Locations > Page 1977 Electronic Throttle Control Module: Testing and Inspection Ford provides trouble code/symptom driven diagnostics for this component. For complete diagnosis and pinpoint testing, refer to Computers and Control Systems, Testing and Inspection. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Body/Frame - Arc Welding Precautions Engine Control Module: Technical Service Bulletins Body/Frame - Arc Welding Precautions Article No. 90-11-6 EEC IV-ELECTRONIC CONTROL MODULES AND PROCESSORS-POSSIBLE DAMAGE FROM ARC WELDING FORD: 1985-90 CROWN VICTORIA, ESCORT, MUSTANG, TEMPO, THUNDERBIRD 1986-90 TAURUS LINCOLN-MERCURY: 1985-86 CAPRI 1985-90 CONTINENTAL, COUGAR, GRAND MARQUIS, MARK VII, TOPAZ, TOWN CAR 1986-90 SABLE MERKUR: 1985-89 XR4Ti 1988-90 SCORPIO LIGHT TRUCK: 1985-90 BRONCO II, BRONCO, ECONOLINE, F-150, F-250, F-350, RANGER 1986-90 AEROSTAR 1989-90 F SUPER DUTY 1991 EXPLORER ISSUE: Electronic control modules, including EEC processors, may be damaged if the negative battery ground cable is not disconnected before arc welding is done to the vehicle, This occurs because the arc welding process can produce high electrical currents in the body of a vehicle when the negative battery ground cable is left connected. ACTION: If arc welding procedures are to be performed, be sure to disconnect the battery ground cable, CAUTION: DISCONNECT THE NEGATIVE BATTERY GROUND CABLE BEFORE USING ANY ELECTRIC WELDING EQUIPMENT OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 2800, 680000 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 1982 Right Hand Instrument Panel Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions Engine Control Module: Diagram Information and Instructions Symbol Identification Wire Color Code Identification Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1985 NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Page 1986 Engine Control Module: Description and Operation The center of the EEC IV system is a microprocessor called the Electronic Control Assembly (ECA). The ECA, receives data from a number of sensors and other electronic components (switches, relays, etc.). The ECA contains a specific calibration for optimizing emissions, fuel economy, and driveability. Based on information received and programmed into its memory, the ECA generates output signals to control various relays, solenoids, and other actuators. The ECA in the EEC IV system is a microprocessor like the one in the other EEC systems. One significant difference is that this ECA has the calibration module located inside the ECA assembly, unlike the EEC III system. The ECA is found in different locations, depending on the model. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Page 1987 Engine Control Module: Testing and Inspection Ford provides trouble code/symptom driven diagnostics for this component. For complete diagnosis and pinpoint testing, refer to Computers and Control Systems, Testing and Inspection. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Component Locations Main Relay (Computer/Fuel System): Component Locations Fuel Pump Relay Engine Compartment Components. LH Side Of Engine Compartment, On Relay Bracket. Fuel pump relay is next to the EEC Relay. Applicable to: 4.9L/6-300 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Component Locations > Page 1992 Engine Compartment Components. LH Side Of Engine Compartment, On Relay Bracket. Fuel pump relay is next to the EEC Relay. Applicable to: 5.0L/V8-302 & 5.8L/V8-350 Engine Compartment Components. LH Side Of Engine Compartment, On Relay Bracket. Fuel pump relay is next to the EEC Relay. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Component Locations > Page 1993 Applicable to: 7.5L/V8-460 EEC Power Relay Under Dash Panel Next To, Or On ECA Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Component Locations > Page 1994 Right Hand Instrument Panel Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 1995 Main Relay (Computer/Fuel System): Description and Operation There are two types of relays: the power relay and the time delay power relay. The time delay relay has a delay of 5 to 10 seconds and is used with an actuator assembly throttle control. Both relay types consist of a movable contact in the normally open position. All power relays (except time delay) have the same design with a different bracket attachment. Function EEC power relays are in parallel with the ignition switch and provide power to the EEC module. Power relays also provide reverse battery protection and increased load handling to improve ignition switch reliability. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 1996 Main Relay (Computer/Fuel System): Testing and Inspection Ford provides trouble code/symptom driven diagnostics for this component. For complete diagnosis and pinpoint testing, refer to Computers and Control Systems, Testing and Inspection. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Emission Control Systems > EGR Control Module > Component Information > Locations EGR Control Module: Locations Back View Of I/P On I/P, To Left Of Steering Column Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Technical Service Bulletins > Customer Interest for Fuel Pump Relay: > 90183 > Aug > 90 > Fuel Pump - Buzzing/Humming After Engine Shut Down Fuel Pump Relay: Customer Interest Fuel Pump - Buzzing/Humming After Engine Shut Down ^ NO START - 1.9L, 2.3L, 3.0L, 3.8L, 4.9L, 5.0L, 5.8L, 7.5L - LOW STATE OF BATTERY CHARGE ^ BATTERY - DISCHARGED - 1.9L, 2.3L, 3.0L, 3.8L, 4.9L, 5.0L, 5.8L, 7.5L ^ FUEL PUMP - NOISY - 1.9L, 2.3L, 3.0L, 3.8L, 4.9L, 5.0L, 5.8L, 7.5L ^ NOISE - "BUZZING" OR "HUMMING" FROM FUEL PUMP AFTER ENGINE IS TURNED OFF Article No. 90-18-3 FORD: 1983-90 CROWN VICTORIA, ESCORT, EXP, MUSTANG, TEMPO, THUNDERBIRD 1986 LTD 1986-90 TAURUS LINCOLN-MERCURY: 1983-87 LYNX 1983-90 CONTINENTAL, COUGAR, GRAND MARQUIS, MARK VII, TOPAZ, TOWN CAR 1985-86 CAPRI, MARQUIS 1986-90 SABLE LIGHT TRUCK: 1983-90 BRONCO II, BRONCO, ECONOLINE, F-150, F-250, F-350, RANGER 1988-90 F SUPER DUTY ISSUE: A "buzzing" or "humming" noise from the fuel pump may occur after the engine has been shut off. There may also be a no start condition or a discharged battery. These conditions are caused by a sticking fuel pump relay. ACTION: Install a new fuel pump relay. Refer to the following procedure for service details. 1. Check the fuel pump relay circuit for proper operation. Refer to the appropriate EVTM for troubleshooting details. 2. Install a new fuel pump relay, if the old one is defective. 3. Check the vehicle for proper operation. PART NUMBER PART NAME F19Z-9345-A Fuel Pump Relay Assy. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION DESCRIPTION TIME 901803A 1985-86 LTD/Marquis 0.6 Hr. (includes pinpoint test) 901803A 1990 Town Car (includes 0.4 Hr. pinpoint test) 901803A All Other Cars (includes 0.5 Hr. pinpoint test) 901803A All Trucks (includes pinpoint 0.5 Hr. test) DEALER CODING BASIC PART NO. CONDITION CODE 9345 09 OASIS CODES: 404000, 603300, 203000, 203100, 702000 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Pump Relay: > 90183 > Aug > 90 > Fuel Pump - Buzzing/Humming After Engine Shut Down Fuel Pump Relay: All Technical Service Bulletins Fuel Pump - Buzzing/Humming After Engine Shut Down ^ NO START - 1.9L, 2.3L, 3.0L, 3.8L, 4.9L, 5.0L, 5.8L, 7.5L - LOW STATE OF BATTERY CHARGE ^ BATTERY - DISCHARGED - 1.9L, 2.3L, 3.0L, 3.8L, 4.9L, 5.0L, 5.8L, 7.5L ^ FUEL PUMP - NOISY - 1.9L, 2.3L, 3.0L, 3.8L, 4.9L, 5.0L, 5.8L, 7.5L ^ NOISE - "BUZZING" OR "HUMMING" FROM FUEL PUMP AFTER ENGINE IS TURNED OFF Article No. 90-18-3 FORD: 1983-90 CROWN VICTORIA, ESCORT, EXP, MUSTANG, TEMPO, THUNDERBIRD 1986 LTD 1986-90 TAURUS LINCOLN-MERCURY: 1983-87 LYNX 1983-90 CONTINENTAL, COUGAR, GRAND MARQUIS, MARK VII, TOPAZ, TOWN CAR 1985-86 CAPRI, MARQUIS 1986-90 SABLE LIGHT TRUCK: 1983-90 BRONCO II, BRONCO, ECONOLINE, F-150, F-250, F-350, RANGER 1988-90 F SUPER DUTY ISSUE: A "buzzing" or "humming" noise from the fuel pump may occur after the engine has been shut off. There may also be a no start condition or a discharged battery. These conditions are caused by a sticking fuel pump relay. ACTION: Install a new fuel pump relay. Refer to the following procedure for service details. 1. Check the fuel pump relay circuit for proper operation. Refer to the appropriate EVTM for troubleshooting details. 2. Install a new fuel pump relay, if the old one is defective. 3. Check the vehicle for proper operation. PART NUMBER PART NAME F19Z-9345-A Fuel Pump Relay Assy. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION DESCRIPTION TIME 901803A 1985-86 LTD/Marquis 0.6 Hr. (includes pinpoint test) 901803A 1990 Town Car (includes 0.4 Hr. pinpoint test) 901803A All Other Cars (includes 0.5 Hr. pinpoint test) 901803A All Trucks (includes pinpoint 0.5 Hr. test) DEALER CODING BASIC PART NO. CONDITION CODE 9345 09 OASIS CODES: 404000, 603300, 203000, 203100, 702000 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Technical Service Bulletins > Page 2015 Fuel Pump Relay: Locations The EEC Power Relay is mounted to the Electronic Control Assembly in the rear center of the instrument panel. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions Fuel Pump Relay: Diagram Information and Instructions Symbol Identification Wire Color Code Identification Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2018 NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Shut-off Solenoid Relay > Component Information > Locations Fuel Shut-off Solenoid Relay: Locations LH Side Of Dash Panel In Engine Compartment, On LH Side Of Dash Panel Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Component Locations Main Relay (Computer/Fuel System): Component Locations Fuel Pump Relay Engine Compartment Components. LH Side Of Engine Compartment, On Relay Bracket. Fuel pump relay is next to the EEC Relay. Applicable to: 4.9L/6-300 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Component Locations > Page 2026 Engine Compartment Components. LH Side Of Engine Compartment, On Relay Bracket. Fuel pump relay is next to the EEC Relay. Applicable to: 5.0L/V8-302 & 5.8L/V8-350 Engine Compartment Components. LH Side Of Engine Compartment, On Relay Bracket. Fuel pump relay is next to the EEC Relay. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Component Locations > Page 2027 Applicable to: 7.5L/V8-460 EEC Power Relay Under Dash Panel Next To, Or On ECA Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Component Locations > Page 2028 Right Hand Instrument Panel Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 2029 Main Relay (Computer/Fuel System): Description and Operation There are two types of relays: the power relay and the time delay power relay. The time delay relay has a delay of 5 to 10 seconds and is used with an actuator assembly throttle control. Both relay types consist of a movable contact in the normally open position. All power relays (except time delay) have the same design with a different bracket attachment. Function EEC power relays are in parallel with the ignition switch and provide power to the EEC module. Power relays also provide reverse battery protection and increased load handling to improve ignition switch reliability. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 2030 Main Relay (Computer/Fuel System): Testing and Inspection Ford provides trouble code/symptom driven diagnostics for this component. For complete diagnosis and pinpoint testing, refer to Computers and Control Systems, Testing and Inspection. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 87720 > Apr > 87 > Tape Player - Ignition Noise Through Speakers Ignition Control Module: Customer Interest Tape Player - Ignition Noise Through Speakers RADIO - IGNITION NOISE THROUGH FACTORY Article No. TAPE PLAYER - 4.9L - WITH TSB MODIFICATION87-3-20 87-7-20 LIGHT TRUCK: 1984-86 F SERIES, BRONCO ISSUE: Ignition noise through the radio speakers when operating the radio in the tape player mode may result if a new multispark ignition module was installed to correct a rough idle condition per TSB 87-3-20. ACTION: To correct this, modify the multi-spark ignition module wire harness as outlined in the following service procedure. 1. Shorten the heavy gauge BLACK wire on the module to 14 inches (357 mm). Crimp on a new solderless lug and hook up wire directly to negative terminal of battery. 2. Perform TSB 86-24-26 to eliminate the radio noise. OTHER APPLICABLE ARTICLES: 86-24-26, 87-3-20 WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual OPERATION: SP870720A TIME: 0.3 Hr. DLR. CODING: Basic Part No. 12A199 Code: 85 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 87610 > Mar > 87 > Engine - Stalling and/or A No Start Condition Ignition Control Module: Customer Interest Engine - Stalling and/or A No Start Condition ^ STALL - THICK FILM IGNITION (TFI) MODULE - Article No. EEC IV VEHICLES 87-6-10 ^ STALL/NO START - THICK FILM IGNITION (TFI) MODULE - EEC IV VEHICLES FORD 1984-87 ALL LINCOLN-MERCURY 1984-87 ALL MERKUR 1985-87 XR4Ti LIGHT TRUCK 1984-87 ALL ISSUE: Stalling and/or a no-start condition on vehicles with EEC IV and certain TFI modules may be caused by moisture or salt splash entering at the upper right hand mounting hole of the TFI module housing. This condition will result in a service code 14. ACTION: To correct this, use the following diagnostic and service procedure to seal the hole and prevent further concerns. NOTE: The distributor does not have to be removed to perform this repair. 1. Check to see if the TFI-IV module part number suffix is A2A and the date code is 6K08 or prior, (mounting hole was sealed after 6K08). If the suffix is not A2A, use normal diagnostic procedures and do not perform Steps 2 and 3. 2. Thoroughly clean and dry upper right hand mounting hole of the TFI module with a clean paper towel. 3. Fill the cleaned hole with silicone grease (D7AZ-19A331-A). 4. Clear service code 14 from memory. PART NUMBER PART NAME CLASS D7AZ-19A331-A Silicone Grease AM OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual OPERATION: SP870610A TIME: 1.0 Hr. DLR. CODING: Basic Part No. 12A297 - Code: 09 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 86220 > Jan > 86 > Ignition System - Weak/No Spark Ignition Control Module: Customer Interest Ignition System - Weak/No Spark Article No. 86-2-20 IGNITION SYSTEM - TFI - WEAK OR NO SPARK - DIAGNOSTIC TIP FORD 1982-86 ESCORT, EXP; 1983-86 THUNDERBIRD, LTD, CROWN VICTORIA, MUSTANG; 1984-86 TEMPO; 1986 TAURUS LINCOLN-MERCURY 1982-83 LN7; 1982-86 LYNX; 1983-86 COUGAR, MERCURY, GRAND MARQUIS, CONTINENTAL, MARK VII, LINCOLN; 1984-86 TOPAZ; 1986 SABLE LIGHT TRUCK 1983-86 EAND F-SERIES, RANGER, BRONCO; 1984-86 BRONCO II; 1986 AEROSTAR CALIBRATIONS: All with TFI Systems If the TFI module fails and causes a short to ground, the primary winding of the ignition coil can be damaged. The TFI diagnostic procedure published in the Shop Manual will not identify this condition. When servicing a weak or no spark condition, perform the following: 1. Check for spark using the procedures found in the Manual Information, Computerized Engine, Quick Test Section, Test 1. 2. If there is no spark, test the coil primary resistance using Rotunda digital volt-ohmmeter 007-00001, as shown. 3. If the coil primary resistance is O.K., continue with the diagnostic procedure in Test 1. 4. If the coil primary resistance is not O.K., replace the coil and recheck for weak or no spark. If the spark is now O.K., the problem is resolved. 5. If the spark is still NOT O.K., continue with normal diagnostic procedure in Test 1. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Wiring Harness TFI-IV Part 2 Test 5 TEST EQUIPMENT: VOM, STRAIGHT PIN TEST PROCEDURE 1. Separate wiring harness connector from ignition module. Inspect for dirt, corrosion, and damage. NOTE: PUSH connector tabs to separate. 2. Disconnect wire at S terminal of starter relay. 3. Attach negative (-) VOM, Rotunda Number 007-00001, lead to distributor base. 4. Measure battery voltage. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 86220 > Jan > 86 > Ignition System - Weak/No Spark > Page 2048 5. Following table below, measure connector terminal voltage by attaching VOM to small straight pin inserted into connector terminal and turning ignition switch to position shown. CAUTION: Do not allow straight pin to contact electrical ground. CONNECTOR IGNITION SWITCH TERMINAL WIRE/CIRCUIT TEST POSITION #2 TO IGNITION RUN COIL (-) TERMINAL #3 RUN CIRCUIT RUN AND START #4 START CIRCUIT START 6. Turn ignition switch to Off position. 7. Remove straight pin. 8. Reconnect wire to S terminal of starter relay. TEST RESULT TEST RESOLUTION 90 percent of ^ Test result OK. battery ^ Go to Part 2, Test 6. voltage minimum Less than 90 ^ Inspect for faults in wiring percent of harness and connectors. battery ^ Refer to vehicle wiring voltage diagram for appropriate circuit. ^ Damaged or worn ignition switch, Refer to Shop Manual, Group 33. Primary Circuit Continuity TFI-IV Part 2 Test 8 TEST EQUIPMENT: VOM, STRAIGHT PIN TEST PROCEDURE 1. Separate wiring harness connector from ignition module. Inspect for dirt, corrosion, and damage. NOTE: PUSH connector tabs to separate. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 86220 > Jan > 86 > Ignition System - Weak/No Spark > Page 2049 2. Attach negative (-) VOM, Rotunda Number 007-00001, lead to distributor base. 3. Measure battery voltage. 4. Attach VOM to small straight pin inserted into connector terminal No. 2. CAUTION: Do not allow straight pin to contact electrical ground. 5. Turn ignition switch to Run position and measure terminal No. 2 voltage. 6. Turn ignition switch to Off position. 7. Remove straight pin. TEST RESULT TEST RESOLUTION 90 percent of ^ Go to Part 2, Test 5. battery voltage minimum Less than 90 ^ Go to Part 2, Test 9. percent of battery voltage Ignition Coil Primary Resistance TFI-IV Part 2 Test 3 TEST EQUIPMENT: VOM TEST PROCEDURE 1. Turn ignition switch to Off. 2. Disconnect ignition coil connector. Inspect for dirt, corrosion, and damage. 3. Measure resistance from positive (+) to negative (-) terminal of ignition coil, using Rotunda digital volt-ohmmeter 007-00001. TEST RESULT TEST RESOLUTION 0.3 to 1.0 ^ Test result OK. ohm ^ Go to Test 4. Less than ^ Replace ignition coil. 0.3 ohm or greater than 1.0 ohm Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure Technical Service Bulletin # 872110 Date: 871021 TFI Module/PIP Sensor - New Diagnostic Procedure EEC IV - TFI MODULE AND PIP SENSOR - Article No. NEW DIAGNOSTIC PROCEDURE 87-21-10 FORD: 1983-88 ESCORT/EXP, MUSTANG, THUNDERBIRD, FORD 1984-88 TEMPO 1986-88 TAURUS LINCOLN-MERCURY: 1983 MARK VI 1983-86 CAPRI 1983-87 LYNX 1983-88 COUGAR, MERCURY, CONTINENTAL, LINCOLN TOWN CAR 1984-88 TOPAZ, MARK VII 1986-88 SABLE MERKUR: 1985-88 XR4Ti 1988 SCORPIO LIGHT TRUCK: 1983-88 ALL LIGHT TRUCK LINES ISSUE: A new diagnostic procedure for testing the TFI module and PIP sensor has been developed. This new procedure allows the technician to take a direct path when testing the TFI module and PIP sensor with the use of the new TFI IV diagnostic tester (Rotunda No. 105-00003). ACTION: If service is required, use the diagnostic procedures on pages 29 through 60 of this TSB. Insert these pages in the Engine/Emission Diagnosis Manual, Volume H, Section 15. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Preliminary Checkout, Equipment & Notes CHECKOUT ^ Visually inspect the engine compartment to ensure all vacuum hoses and spark plug wires are properly routed and securely connected. ^ Examine all wiring harnesses and connectors for insulation damage, burned, overheated, loose or broken conditions. ^ Check that the TFI module is securely fastened to the distributor base. ^ Be certain the battery is fully charged. ^ All accessories should be off during diagnosis. EQUIPMENT Obtain the following test equipment or an equivalent: ^ Spark Tester, Special Service Tool D81P-6666-A. See note. ^ Volt/Ohm Meter Rotunda 014-00407. ^ 12 Volt Test Light. ^ Small straight pin. ^ Remote Starter Switch. ^ TFI Ignition Tester, Rotunda 105-00002. NOTES ^ A spark plug with a broken side electrode is not sufficient to check for spark and may lead to incorrect results. ^ When instructed to inspect a wiring harness, both a visual inspection and a continuity test should be performed. ^ When making measurements on a wiring harness or connector, it is good practice to wiggle the wires while measuring. ^ References to pin-in-line connector apply to a shorting bar type connector used to set base timing. ^ This procedure is intended to identify faulty components or wiring while the fault is present. If the complaint is of an intermittent condition, refer to Intermittent Diagnosis. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 2055 Functional Schematic TFI-IV The TFI-IV system electrical schematic is shown below. For detailed information, refer to the vehicle wiring diagram. Ignition Coil Secondary Voltage (Crank Mode) TFI-IV Part 2 Test 1 & 2 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 2056 Ignition Coil Secondary Voltage (Run Mode) TFI-IV Part 2 Test 2 Wiring Harness Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 2057 TFI-IV Part 2 Test 3 Stator - TFI Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 2058 TFI-IV Part 2 Test 4 & 5 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 2059 Stator - TFI-IV TFI-IV Part 2 Test 5 TFI Module TFI-IV Part 2 Test 6 Ignition Coils - Secondary & Primary Resistance Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 2060 Ignition Coil Primary Resistance TFI-IV Part 2 Test 7 & 8 Ignition Coil Secondary Resistance TFI-IV Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 2061 Part 2 Test 8 EEC-IV - TFI-IV TFI-IV Part 2 Test 9 Ignition Coil Supply Voltage Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 2062 TFI-IV Part 2 Test 10 Wiring Harness Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 2063 TFI-IV Part 2 Test 11 Preliminary Checkout, Equipment & Notes CHECKOUT ^ Visually inspect the engine compartment to ensure all vacuum hoses and spark plug wires are properly routed and securely connected. ^ Examine all wiring harnesses and connectors for insulation damage, burned, overheated, loose, or broken conditions. ^ Be certain the battery is fully charged. ^ All accessories should be off during diagnosis. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 2064 EQUIPMENT Obtain the following test equipment or an equivalent: ^ Spark Tester, Special Service Tool D81P-6666-A. See note. ^ Volt/Ohm Meter Rotunda 014-00407. ^ 12 Volt Test Light. ^ Small straight pin. ^ Remote Starter Switch. ^ TFI Ignition Tester, Rotunda 105-00003. NOTES ^ A spark plug with a broken side electrode is not sufficient to check for spark and may lead to incorrect results. ^ When instructed to inspect a wiring harness, both a visual inspection and a continuity test should be performed. ^ When making measurements on a wiring harness or connector, it is good practice to wiggle the wires while measuring. ^ References to pin-in-line connector apply to shorting bar type connector used to set base timing. ^ This procedure is intended to identify faulty components or wiring while the fault is present. If the complaint is of an intermittent condition refer to Intermittent Diagnosis. Functional Schematic TFI-IV Closed Bowl Distributor The TFI-IV Closed Bowl Distributor system electrical schematic is shown below. For detailed information, refer to the vehicle wiring diagram. Ignition Coil Secondary Voltage - Crank Mode Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 2065 TFI-IV Closed Bowl Distributor Part 2 Test 1 & 2 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 2066 Ignition Coil Secondary Voltage - Run Mode TFI-IV Closed Bowl Distributor Part 2 Test 2 Wiring Harness Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 2067 TFI-IV Closed Bowl Distributor Part 2 Test 3 Stator Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 2068 TFI-IV Closed Bowl Distributor Part 2 Test 4, 5 & 6 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 2069 Stator TFI-IV Closed Bowl Distributor Part 2 Test 5 Stator TFI-IV Closed Bowl Distributor Part 2 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 2070 Test 6 TFI Module TFI-IV Closed Bowl Distributor Part 2 Test 7 Ignition Coil, Primary & Secondary Ignition Coil Primary Resistance TFI-IV Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 2071 Closed Bowl Distributor Part 2 Test 8 Ignition Coil Secondary Resistance TFI-IV Closed Bowl Distributor Part 2 Test 9 EEC IV - Wiring Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 2072 TFI-IV Closed Bowl Distributor Part 2 Test 10 Wiring Harness Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 2073 TFI IV Closed Bowl Distributor Part 2 Test 11 Ignition Coil, TFI & Stator Voltage Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 2074 Ignition Coil Supply Voltage TFI IV Closed Bowl Distributor Part 2 Test 12 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 2075 TFI Supply Voltage TFI-IV Closed Bowl Distributor Part 2 Test 13 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 2076 Stator Supply Voltage TFI IV Closed Bowl Distributor Part 2 Test 14 Wiring Harness Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 2077 TFI IV Closed Bowl Distributor Part 2 Test 15 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 87720 > Apr > 87 > Tape Player - Ignition Noise Through Speakers Ignition Control Module: All Technical Service Bulletins Tape Player - Ignition Noise Through Speakers RADIO - IGNITION NOISE THROUGH FACTORY Article No. TAPE PLAYER - 4.9L - WITH TSB MODIFICATION87-3-20 87-7-20 LIGHT TRUCK: 1984-86 F SERIES, BRONCO ISSUE: Ignition noise through the radio speakers when operating the radio in the tape player mode may result if a new multispark ignition module was installed to correct a rough idle condition per TSB 87-3-20. ACTION: To correct this, modify the multi-spark ignition module wire harness as outlined in the following service procedure. 1. Shorten the heavy gauge BLACK wire on the module to 14 inches (357 mm). Crimp on a new solderless lug and hook up wire directly to negative terminal of battery. 2. Perform TSB 86-24-26 to eliminate the radio noise. OTHER APPLICABLE ARTICLES: 86-24-26, 87-3-20 WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual OPERATION: SP870720A TIME: 0.3 Hr. DLR. CODING: Basic Part No. 12A199 Code: 85 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 87610 > Mar > 87 > Engine - Stalling and/or A No Start Condition Ignition Control Module: All Technical Service Bulletins Engine - Stalling and/or A No Start Condition ^ STALL - THICK FILM IGNITION (TFI) MODULE - Article No. EEC IV VEHICLES 87-6-10 ^ STALL/NO START - THICK FILM IGNITION (TFI) MODULE - EEC IV VEHICLES FORD 1984-87 ALL LINCOLN-MERCURY 1984-87 ALL MERKUR 1985-87 XR4Ti LIGHT TRUCK 1984-87 ALL ISSUE: Stalling and/or a no-start condition on vehicles with EEC IV and certain TFI modules may be caused by moisture or salt splash entering at the upper right hand mounting hole of the TFI module housing. This condition will result in a service code 14. ACTION: To correct this, use the following diagnostic and service procedure to seal the hole and prevent further concerns. NOTE: The distributor does not have to be removed to perform this repair. 1. Check to see if the TFI-IV module part number suffix is A2A and the date code is 6K08 or prior, (mounting hole was sealed after 6K08). If the suffix is not A2A, use normal diagnostic procedures and do not perform Steps 2 and 3. 2. Thoroughly clean and dry upper right hand mounting hole of the TFI module with a clean paper towel. 3. Fill the cleaned hole with silicone grease (D7AZ-19A331-A). 4. Clear service code 14 from memory. PART NUMBER PART NAME CLASS D7AZ-19A331-A Silicone Grease AM OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual OPERATION: SP870610A TIME: 1.0 Hr. DLR. CODING: Basic Part No. 12A297 - Code: 09 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 86219 > Jan > 86 > Ignition System Resistance - Manual Revision Ignition Control Module: All Technical Service Bulletins Ignition System Resistance - Manual Revision Article No. 86-2-19 IGNITION SYSTEM - RESISTANCE TESTS - SHOP MANUAL REVISION EMISSION DIAGNOSIS MANUAL FORD 1982-86 ESCORT, EXP; 1983-86 LTD, THUNDERBIRD, CROWN VICTORIA, MUSTANG; 1984-86 TEMPO; 1986 TAURUS LINCOLN-MERCURY 1982-83 LN7; 1982-86 LYNX; 1983-86 MARQUIS, COUGAR, MERCURY, CONTINENTAL, MARK VII, LINCOLN; 1984-86 TOPAZ; 1986 SABLE LIGHT TRUCK 1983-86 EAND F-SERIES, BRONCO, RANGER; 1984-86 BRONCO II; 1986 AEROSTAR If your voltmeter has a high impedance, it will not draw enough current to show a voltage drop when testing TFI power circuits for resistive connections. To assure an accurate test, attach a test light between the circuit being tested and ground as shown. The light will draw current through the connection and allow measurement of the voltage drop so a resistive connection can be identified. IMPORTANT Do not use a test light while monitoring the PIP or SPOUT signal. The test light draws more current than the signal circuit can supply. The test light should be used only on power circuits. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 86220 > Jan > 86 > Ignition System - Weak/No Spark Ignition Control Module: All Technical Service Bulletins Ignition System - Weak/No Spark Article No. 86-2-20 IGNITION SYSTEM - TFI - WEAK OR NO SPARK - DIAGNOSTIC TIP FORD 1982-86 ESCORT, EXP; 1983-86 THUNDERBIRD, LTD, CROWN VICTORIA, MUSTANG; 1984-86 TEMPO; 1986 TAURUS LINCOLN-MERCURY 1982-83 LN7; 1982-86 LYNX; 1983-86 COUGAR, MERCURY, GRAND MARQUIS, CONTINENTAL, MARK VII, LINCOLN; 1984-86 TOPAZ; 1986 SABLE LIGHT TRUCK 1983-86 EAND F-SERIES, RANGER, BRONCO; 1984-86 BRONCO II; 1986 AEROSTAR CALIBRATIONS: All with TFI Systems If the TFI module fails and causes a short to ground, the primary winding of the ignition coil can be damaged. The TFI diagnostic procedure published in the Shop Manual will not identify this condition. When servicing a weak or no spark condition, perform the following: 1. Check for spark using the procedures found in the Manual Information, Computerized Engine, Quick Test Section, Test 1. 2. If there is no spark, test the coil primary resistance using Rotunda digital volt-ohmmeter 007-00001, as shown. 3. If the coil primary resistance is O.K., continue with the diagnostic procedure in Test 1. 4. If the coil primary resistance is not O.K., replace the coil and recheck for weak or no spark. If the spark is now O.K., the problem is resolved. 5. If the spark is still NOT O.K., continue with normal diagnostic procedure in Test 1. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Wiring Harness TFI-IV Part 2 Test 5 TEST EQUIPMENT: VOM, STRAIGHT PIN TEST PROCEDURE 1. Separate wiring harness connector from ignition module. Inspect for dirt, corrosion, and damage. NOTE: PUSH connector tabs to separate. 2. Disconnect wire at S terminal of starter relay. 3. Attach negative (-) VOM, Rotunda Number 007-00001, lead to distributor base. 4. Measure battery voltage. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 86220 > Jan > 86 > Ignition System - Weak/No Spark > Page 2094 5. Following table below, measure connector terminal voltage by attaching VOM to small straight pin inserted into connector terminal and turning ignition switch to position shown. CAUTION: Do not allow straight pin to contact electrical ground. CONNECTOR IGNITION SWITCH TERMINAL WIRE/CIRCUIT TEST POSITION #2 TO IGNITION RUN COIL (-) TERMINAL #3 RUN CIRCUIT RUN AND START #4 START CIRCUIT START 6. Turn ignition switch to Off position. 7. Remove straight pin. 8. Reconnect wire to S terminal of starter relay. TEST RESULT TEST RESOLUTION 90 percent of ^ Test result OK. battery ^ Go to Part 2, Test 6. voltage minimum Less than 90 ^ Inspect for faults in wiring percent of harness and connectors. battery ^ Refer to vehicle wiring voltage diagram for appropriate circuit. ^ Damaged or worn ignition switch, Refer to Shop Manual, Group 33. Primary Circuit Continuity TFI-IV Part 2 Test 8 TEST EQUIPMENT: VOM, STRAIGHT PIN TEST PROCEDURE 1. Separate wiring harness connector from ignition module. Inspect for dirt, corrosion, and damage. NOTE: PUSH connector tabs to separate. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 86220 > Jan > 86 > Ignition System - Weak/No Spark > Page 2095 2. Attach negative (-) VOM, Rotunda Number 007-00001, lead to distributor base. 3. Measure battery voltage. 4. Attach VOM to small straight pin inserted into connector terminal No. 2. CAUTION: Do not allow straight pin to contact electrical ground. 5. Turn ignition switch to Run position and measure terminal No. 2 voltage. 6. Turn ignition switch to Off position. 7. Remove straight pin. TEST RESULT TEST RESOLUTION 90 percent of ^ Go to Part 2, Test 5. battery voltage minimum Less than 90 ^ Go to Part 2, Test 9. percent of battery voltage Ignition Coil Primary Resistance TFI-IV Part 2 Test 3 TEST EQUIPMENT: VOM TEST PROCEDURE 1. Turn ignition switch to Off. 2. Disconnect ignition coil connector. Inspect for dirt, corrosion, and damage. 3. Measure resistance from positive (+) to negative (-) terminal of ignition coil, using Rotunda digital volt-ohmmeter 007-00001. TEST RESULT TEST RESOLUTION 0.3 to 1.0 ^ Test result OK. ohm ^ Go to Test 4. Less than ^ Replace ignition coil. 0.3 ohm or greater than 1.0 ohm Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure Technical Service Bulletin # 872110 Date: 871021 TFI Module/PIP Sensor - New Diagnostic Procedure EEC IV - TFI MODULE AND PIP SENSOR - Article No. NEW DIAGNOSTIC PROCEDURE 87-21-10 FORD: 1983-88 ESCORT/EXP, MUSTANG, THUNDERBIRD, FORD 1984-88 TEMPO 1986-88 TAURUS LINCOLN-MERCURY: 1983 MARK VI 1983-86 CAPRI 1983-87 LYNX 1983-88 COUGAR, MERCURY, CONTINENTAL, LINCOLN TOWN CAR 1984-88 TOPAZ, MARK VII 1986-88 SABLE MERKUR: 1985-88 XR4Ti 1988 SCORPIO LIGHT TRUCK: 1983-88 ALL LIGHT TRUCK LINES ISSUE: A new diagnostic procedure for testing the TFI module and PIP sensor has been developed. This new procedure allows the technician to take a direct path when testing the TFI module and PIP sensor with the use of the new TFI IV diagnostic tester (Rotunda No. 105-00003). ACTION: If service is required, use the diagnostic procedures on pages 29 through 60 of this TSB. Insert these pages in the Engine/Emission Diagnosis Manual, Volume H, Section 15. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Preliminary Checkout, Equipment & Notes CHECKOUT ^ Visually inspect the engine compartment to ensure all vacuum hoses and spark plug wires are properly routed and securely connected. ^ Examine all wiring harnesses and connectors for insulation damage, burned, overheated, loose or broken conditions. ^ Check that the TFI module is securely fastened to the distributor base. ^ Be certain the battery is fully charged. ^ All accessories should be off during diagnosis. EQUIPMENT Obtain the following test equipment or an equivalent: ^ Spark Tester, Special Service Tool D81P-6666-A. See note. ^ Volt/Ohm Meter Rotunda 014-00407. ^ 12 Volt Test Light. ^ Small straight pin. ^ Remote Starter Switch. ^ TFI Ignition Tester, Rotunda 105-00002. NOTES ^ A spark plug with a broken side electrode is not sufficient to check for spark and may lead to incorrect results. ^ When instructed to inspect a wiring harness, both a visual inspection and a continuity test should be performed. ^ When making measurements on a wiring harness or connector, it is good practice to wiggle the wires while measuring. ^ References to pin-in-line connector apply to a shorting bar type connector used to set base timing. ^ This procedure is intended to identify faulty components or wiring while the fault is present. If the complaint is of an intermittent condition, refer to Intermittent Diagnosis. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 2101 Functional Schematic TFI-IV The TFI-IV system electrical schematic is shown below. For detailed information, refer to the vehicle wiring diagram. Ignition Coil Secondary Voltage (Crank Mode) TFI-IV Part 2 Test 1 & 2 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 2102 Ignition Coil Secondary Voltage (Run Mode) TFI-IV Part 2 Test 2 Wiring Harness Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 2103 TFI-IV Part 2 Test 3 Stator - TFI Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 2104 TFI-IV Part 2 Test 4 & 5 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 2105 Stator - TFI-IV TFI-IV Part 2 Test 5 TFI Module TFI-IV Part 2 Test 6 Ignition Coils - Secondary & Primary Resistance Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 2106 Ignition Coil Primary Resistance TFI-IV Part 2 Test 7 & 8 Ignition Coil Secondary Resistance TFI-IV Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 2107 Part 2 Test 8 EEC-IV - TFI-IV TFI-IV Part 2 Test 9 Ignition Coil Supply Voltage Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 2108 TFI-IV Part 2 Test 10 Wiring Harness Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 2109 TFI-IV Part 2 Test 11 Preliminary Checkout, Equipment & Notes CHECKOUT ^ Visually inspect the engine compartment to ensure all vacuum hoses and spark plug wires are properly routed and securely connected. ^ Examine all wiring harnesses and connectors for insulation damage, burned, overheated, loose, or broken conditions. ^ Be certain the battery is fully charged. ^ All accessories should be off during diagnosis. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 2110 EQUIPMENT Obtain the following test equipment or an equivalent: ^ Spark Tester, Special Service Tool D81P-6666-A. See note. ^ Volt/Ohm Meter Rotunda 014-00407. ^ 12 Volt Test Light. ^ Small straight pin. ^ Remote Starter Switch. ^ TFI Ignition Tester, Rotunda 105-00003. NOTES ^ A spark plug with a broken side electrode is not sufficient to check for spark and may lead to incorrect results. ^ When instructed to inspect a wiring harness, both a visual inspection and a continuity test should be performed. ^ When making measurements on a wiring harness or connector, it is good practice to wiggle the wires while measuring. ^ References to pin-in-line connector apply to shorting bar type connector used to set base timing. ^ This procedure is intended to identify faulty components or wiring while the fault is present. If the complaint is of an intermittent condition refer to Intermittent Diagnosis. Functional Schematic TFI-IV Closed Bowl Distributor The TFI-IV Closed Bowl Distributor system electrical schematic is shown below. For detailed information, refer to the vehicle wiring diagram. Ignition Coil Secondary Voltage - Crank Mode Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 2111 TFI-IV Closed Bowl Distributor Part 2 Test 1 & 2 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 2112 Ignition Coil Secondary Voltage - Run Mode TFI-IV Closed Bowl Distributor Part 2 Test 2 Wiring Harness Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 2113 TFI-IV Closed Bowl Distributor Part 2 Test 3 Stator Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 2114 TFI-IV Closed Bowl Distributor Part 2 Test 4, 5 & 6 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 2115 Stator TFI-IV Closed Bowl Distributor Part 2 Test 5 Stator TFI-IV Closed Bowl Distributor Part 2 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 2116 Test 6 TFI Module TFI-IV Closed Bowl Distributor Part 2 Test 7 Ignition Coil, Primary & Secondary Ignition Coil Primary Resistance TFI-IV Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 2117 Closed Bowl Distributor Part 2 Test 8 Ignition Coil Secondary Resistance TFI-IV Closed Bowl Distributor Part 2 Test 9 EEC IV - Wiring Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 2118 TFI-IV Closed Bowl Distributor Part 2 Test 10 Wiring Harness Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 2119 TFI IV Closed Bowl Distributor Part 2 Test 11 Ignition Coil, TFI & Stator Voltage Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 2120 Ignition Coil Supply Voltage TFI IV Closed Bowl Distributor Part 2 Test 12 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 2121 TFI Supply Voltage TFI-IV Closed Bowl Distributor Part 2 Test 13 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 2122 Stator Supply Voltage TFI IV Closed Bowl Distributor Part 2 Test 14 Wiring Harness Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 2123 TFI IV Closed Bowl Distributor Part 2 Test 15 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 86219 > Jan > 86 > Ignition System Resistance - Manual Revision Ignition Control Module: All Technical Service Bulletins Ignition System Resistance - Manual Revision Article No. 86-2-19 IGNITION SYSTEM - RESISTANCE TESTS - SHOP MANUAL REVISION EMISSION DIAGNOSIS MANUAL FORD 1982-86 ESCORT, EXP; 1983-86 LTD, THUNDERBIRD, CROWN VICTORIA, MUSTANG; 1984-86 TEMPO; 1986 TAURUS LINCOLN-MERCURY 1982-83 LN7; 1982-86 LYNX; 1983-86 MARQUIS, COUGAR, MERCURY, CONTINENTAL, MARK VII, LINCOLN; 1984-86 TOPAZ; 1986 SABLE LIGHT TRUCK 1983-86 EAND F-SERIES, BRONCO, RANGER; 1984-86 BRONCO II; 1986 AEROSTAR If your voltmeter has a high impedance, it will not draw enough current to show a voltage drop when testing TFI power circuits for resistive connections. To assure an accurate test, attach a test light between the circuit being tested and ground as shown. The light will draw current through the connection and allow measurement of the voltage drop so a resistive connection can be identified. IMPORTANT Do not use a test light while monitoring the PIP or SPOUT signal. The test light draws more current than the signal circuit can supply. The test light should be used only on power circuits. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > Page 2128 Ignition Control Module: Locations LH Inner Fender Well Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > Page 2129 Ignition Control Module: Description and Operation Typical Ignition System The Ignition Module shuts off the primary circuit each time it receives a pulse from the magnetic pick-up Fig. 9. A timing circuit in the ignition module turns the primary current back on after a short period of time. High voltage is created each time the magnetic field is built up and collapsed. The red ignition module wire provides operating voltage for the module's electronic components in the Run mode. The white module wire and start bypass provide increased voltage for the module and coil during Start mode. Ignition Modules Dura Spark II systems with UIM (Universal Ignition Module) Fig. 10 can respond to another control signal from either an Ignition Barometric Pressure Switch, Ignition Timing Vacuum Switch, or the Microprocessor Control Unit (MCU), depending on the engine calibration. Responding to this second signal, the UIM provides additional spark timing control for certain operating conditions by shutting off the ignition coil current flow at a different time than with just the distributor pick-up signal. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > Page 2130 Module Identification Chart For proper ignition module identification refer to Fig. 1. The modules are not interchangeable, Dura Spark II has 6 wire connector while Dura Spark III has a 5 wire connector. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > Page 2131 Ignition Control Module: Service and Repair Open Bowl Distributor 1. Remove distributor cap and adapter. Position cap and wires aside. 2. Disconnect TFI wiring. 3. Remove distributor from engine using tool T82L-12270-A or equivalent to remove security-type hold-down bolt, if equipped. 4. Place distributor on workbench and remove 2 TFI module screws, Fig. 2. 5. Pull right side of module down distributor mounting flange and then back up to disengage module terminals from connector in distributor base. Module may then be pulled toward flange and away from distributor. Do not attempt to lift module from mounting surface before moving entire TFI module toward distributor flange, as pins at distributor/module connector will break otherwise. 6. Coat metal base plate of TFI ignition module with 1/32 inch thick layer of silicone grease D7AZ-19A331-A, or equivalent. 7. Place TFI module on distributor base mounting flange. Carefully position TFI module assembly toward distributor bowl and securely engage 3 distributor connector pins. 8. Install 2 TFI module mounting screws and torque to 9---35 inch lbs. 9. Install distributor on engine. 10. Install distributor cap and adapter. 11. Connect TFI wiring. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > Page 2132 12. Check and, if necessary adjust engine timing according to decal. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Barometric Pressure Switch > Component Information > Description and Operation Barometric Pressure Switch: Description and Operation The Ignition Barometric Pressure Switch, is used to control spark timing and/or other electrical devices in response to changes in barometric pressure (i.e., altitude). When controlling spark timing, the ignition module (12A244) is made to vary the spark timing by an amount determined by calibration resistors in the switch assembly. In normal operation, spark timing is increased for vehicle operation above the switching point (increasing altitude) and retarded for vehicle operation below the switching point (decreasing altitude). When controlling other electrical devices, only On/Off control is provided; with On (switch closed) above the switching point and Off (switch open) below the switching point. Some switch assemblies control both spark timing and another device (dual switch assembly) and other switch assemblies control only one or the other (single switch assembly). Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Barometric Pressure Switch > Component Information > Testing and Inspection > Component Testing Barometric Pressure Switch: Testing and Inspection Component Testing ^ Dual switch assembly shown. ^ Attaching brackets vary according to installation requirements. ^ Connectors may vary. Either resistance value is correct if altitude is between 3,000 and 4,600 feet. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Barometric Pressure Switch > Component Information > Testing and Inspection > Component Testing > Page 2140 Barometric Pressure Switch: Testing and Inspection Computer Related Diagnostic Information Ford provides trouble code/symptom driven diagnostics for this component. For complete diagnosis and pinpoint testing, refer to Computers and Control Systems, Testing and Inspection. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Camshaft Position Sensor: Diagram Information and Instructions Symbol Identification Wire Color Code Identification Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2145 NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications TEMPERATURE SENSORS Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 2149 Coolant Temperature Sensor/Switch (For Computer): Locations RH Side Of V8-351/5. Front Of Engine, Near Distributor Applicable to: 8L Engine With EEC-IV Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 2150 Coolant Temperature Sensor/Switch (For Computer): Description and Operation The Engine Coolant Temperature (ECT) Sensor, detects the temperature of engine coolant and supplies the Information to Electronic Control Assembly (ECA). The ECT sensor is threaded into the heater outlet fitting or cooling passage on the engine. For engine control applications, the ECT signal is used to modify ignition timing, EGR flow, and air to fuel ratio as a function of engine coolant temperature. On electronic instrument cluster applications, the ECT output is used to control a coolant temperature indicator. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 2151 Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection Ford provides trouble code/symptom driven diagnostics for this component. For complete diagnosis and pinpoint testing, refer to Computers and Control Systems, Testing and Inspection. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Crankshaft Position Sensor: Diagram Information and Instructions Symbol Identification Wire Color Code Identification Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2156 NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision Technical Service Bulletin # 8918A9 Date: 890915 EVP Sensor - Manual Revision ENGINE EMISSIONS DIAGNOSTIC MANUALS, VOLUME H - 1985 THROUGH 1989 - EGR VALVE POSITION SENSOR (EVP) DIAGNOSTIC PROCEDURES REVISED Article No. 89-18A-9 FORD: 1985-89 CROWN VICTORIA, ESCORT 1985-88 EXP 1985-86 LTD 1985-89 MUSTANG, TEMPO, THUNDERBIRD 1986-89 TAURUS 1988-89 FESTIVA 1989 PROBE LINCOLN-MERCURY: 1985-86 CAPRI 1985-89 CONTINENTAL, COUGAR, GRAND MARQUIS 1985-87 LYNX 1985-89 MARK VII 1985-86 MARQUIS 1985-89 TOPAZ, TOWN CAR 1986-89 SABLE 1987-89 TRACER MERKUR: 1986-89 XR4TI 1988-89 SCORPIO LIGHT TRUCK: 1985-89 BRONCO, BRONCO II, ECONOLINE, F-150, F-250, F-350, RANGER 1986-89 AEROSTAR ISSUE: The EGR Valve Position Sensor (EVP) diagnostic procedures in 1985 through 1989 Engine Emissions Diagnosis Shop Manuals, Volume H, have been revised. EVP Sensors may exhibit internal wear problems that can cause driveability symptoms and display a Continuous Self-Test Code 32. This is not associated to correcting the problem using the existing diagnostic procedures. ACTION: Refer to the pages following this TSB article for the revised diagnostic procedures. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 680000 1985 Pinpoint Tests - DM - EGR, EVP and EVR Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2161 1985 EEC IV - Pinpoint Tests - All Vehicles 22-77 EGR Valve Position Sensor (EVP) EGR Valve Regulator (EVR) Pinpoint DM Test 1985 Pinpoint Tests - Fa - Neutral Drive Switch -A/C Input Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2162 1985 22-78 EEC IV - Pinpoint Tests - All Vehicles Neutral Drive Switch FA A/C Input PinpointTest 1986 (EGR) Systems Functional Diagnosis 1986 Exhaust Gas Recirculation (EGR) Systems 6-11 Functional Diagnosis Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2163 PORTED EGR VALVE 1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked, crimped or broken hoses. 2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating temperature. 3. Install a tachometer. 4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (EFI engines only). 5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose. 6. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If necessary, adjust idle speed to the emission decal specification. 7. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand vacuum pump. 8. When vacuum is applied to the EGR valve and any of the following occur, replace the valve: ^ Engine does not stall. ^ Idle speed does not drop more than 100 rpm. ^ Idle speed does not return to normal (+/- 25 rpm) after the vacuum is removed. 9. Reconnect the idle air bypass valve electrical connector. 10. Unplug and reconnect the EGR vacuum supply hose. 11. The EGR system is OK, refer to the Diagnostic Routines in Section 2. 1986 6-12 Exhaust Gas Recirculation (EGR) Systems Functional Diagnosis ELECTRONIC VALVE 1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked, crimped or broken hoses. 2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating temperature. 3. Install a tachometer. 4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (EFI engines only). Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2164 5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose. 6. Disconnect the 9G428 EVP sensor electrical connector mounted on top of the 9H473 valve. 7. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If necessary, adjust idle speed to the emission decal specification. 8. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand vacuum pump. 9. When vacuum is applied to the EGR valve and any of the following occur, replace the valve: ^ Engine does not stall. ^ Idle speed does not drop more than 100 rpm. ^ Idle speed does not return to normal (+/- 25 rpm) after the vacuum is removed. 10. Reconnect the idle air bypass valve electrical connector. 11. Unplug and reconnect the EGR vacuum supply hose. 12. Reconnect the EVP sensor electrical connector. 13. The EGR valve is OK, REPLACE EVP sensor if the Continuous Code 32 was present. If the Continuous Code 32 was not present, refer to the Diagnostic Routines in Section 2. 1986 Quick Test: Continuous Self-Test 6.0 EEC IV - Quick Test - All Engines 18-13 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2165 QUICK TEST: Continuous Self-Test 6.0 1986 18-14 EEC IV-Quick Test-All Engines QUICK TEST: Continuous Self-Test 6.0 Pinpoint Test - DN - EGR - EVP & EVR Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2166 1986 EEC IV-Pinpoint Tests - All Vehicles 21-95 EGR Valve Position Sensor (EVP) PinpointTest DN EGR Valve Regulator (EVR) Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2167 21-96 1986 EEC IV-Pinpoint Tests-All Vehicles EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Valve Regulator (EVR) Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2168 EEC IV-Pinpoint Tests-All Vehicles 1986 21-97A EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Valve Regulator (EVR) Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2169 1986 21-97B EEC IV-Pinpoint Tests-All Vehicles EGR Valve Position Sensor (EVP) EGR Valve Regulator (EVR) Pinpoint Test DN Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2170 1986 EEC IV-Pinpoint Tests-All Vehicles 21-98 EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Valve Regulator (EVR) 1987 (EGR) Systems - Functional Diagnosis 1987 6-11 Exhaust Gas Recirculation (EGR) Systems Functional Diagnosis PORTED EGR VALVE 1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked, crimped or broken hoses. 2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating temperature. 3. Install a tachometer, Rotunda 059-00010 or equivalent. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2171 4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (EFI engines only). 5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose. 6. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If necessary, adjust idle speed according to Section 4. 7. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand vacuum pump, Rotunda 021-00014 or equivalent. 8. When vacuum is applied to the EGR valve and any of the following occur, replace the valve: ^ Engine does not stall. ^ Idle speed does not drop more than 100 rpm. ^ Idle speed does not return to normal (+/- 25 rpm) after the vacuum is removed. 9. Reconnect the idle air bypass valve electrical connector. 10. Unplug and reconnect the EGR vacuum supply hose. 11. The EGR system is OK, refer to the Diagnostic Routines in Section 2. 1987 6-12 Exhaust Gas Recirculation (EGR) Systems Functional Diagnosis ELECTRONIC EGR (EEGR) VALVE 1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked, crimped or broken hoses. 2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating temperature. 3. Install a tachometer, Rotunda 059-00010 or equivalent. 4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (EFI engines only). 5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose. 6. Disconnect the 9G428 EVP sensor electrical connector mounted on top of the 9H473 valve. 7. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If necessary, adjust idle speed according to Section 4. 8. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand vacuum pump, Rotunda 021-00014 or equivalent. 9. When vacuum is applied to the EGR valve and any of the following occur, replace the valve: ^ Engine does not stall. ^ Idle speed does not drop more than 100 rpm. ^ Idle speed does not return to normal (+/- 25 rpm) after the vacuum is removed. 10. Reconnect the idle air bypass valve electrical connector. 11. Unplug and reconnect the EGR vacuum supply hose. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2172 12. Reconnect the EVP sensor electrical connector. 13. The EGR valve is OK, REPLACE EVP sensor if the Continuous Code 32 was present. If the Continous Code 32 was not present, refer to the Diagnostic Routines in Section 2. 1987 Quick Test: Continuous Self-Test - 6.0 1987 EEC-IV Quick Test-All Engines 16-15 QUICK TEST: Continuous 6.0 Self-Test Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2173 16-16 1987 EEC-IV Quick Test-All Engines QUICK TEST: Continuous 6.0 Self-Test Pinpoint Test - DN - EGR - EVP & EVR 1987 EEC IV - Pinpoint Tests - All Vehicles 19-91 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2174 EGR VALVE Position Sensor (EVP) EGR Valve Regulator (EVR) - 2.3L HSC, 2.5L, 5.0L SEFI Passenger Car and 4.9L and 5.0L Truck Pinpoint Test DN 19-92A 1987 EEC IV Pinpoint Tests-All Vehicles EGR Valve Position Sensor (EVP) EGR Valve Regulator (EVR) - 2.3L HSC, 2.5L, Pinpoint Test DN 5.0L SEFI Passenger Car and 4.9L and 5.0L Truck Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2175 1987 EEC IV-Pinpoint Tests-All Vehicles 19-92B EGR Valve Position Sensor (EVP) EGR Valve Regulator (EVR) - 2.3L HSC, 2.5L, 5.0L SEFI Passenger Car and 4.9L and 5.0L Truck Pinpoint Test DN Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2176 1987 19-93-A EEC IV-Pinpoint Tests-All Vehicles EGR Valve Position Sensor (EVP) EGR Valve Regulator (EVR) - 2.3L HSC, 2.5L, 5.0L SEFI Passenger Car 4.9L and 5.0L Truck Pinpoint Test DN Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2177 EEC IV-Pinpoint Tests-All Vehicles 1987 19-94 EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Valve Regulator (EVR) (EGR) Systems - Functional Diagnosis 1988 Exhaust Gas Recirculation (EGR) Systems 6-11 Functional Diagnosis Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2178 PORTED EGR VALVE 1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked, crimped or broken hoses. 2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating temperature. 3. Install a tachometer, Rotunda 059-00010 or equivalent. 4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (EFI engines only). 5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose. 6. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If necessary, adjust idle speed according to Section 4. 7. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand vacuum pump, Rotunda 021-00014 or equivalent. 8. When vacuum is fully applied to the EGR valve: ^ If idle speed drops more than 100 rpm or if engine stalls, perform the next step. Otherwise, replace the EGR valve. ^ Remove the vacuum from the EGR valve. If idle speed does not return to normal (+/- 25 rpm), replace the EGR valve. 9. Reconnect the idle air bypass valve electrical connector. 10. Unplug and reconnect the EGR vacuum supply hose. 11. The EGR system is OK, refer to the Diagnostic Routines in Section 2. 6-12 1988 Exhaust Gas Recirculation (EGR) Systems Functional Diagnosis ELECTRONIC EGR (EEGR) VALVE 1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked, crimped or broken hoses. 2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating temperature. NOTE: The EVR solenoid has a constant internal leak. You will notice a small vacuum signal. This signal should be less than 2-1/2 in-Hg at idle. 3. Install a tachometer, Rotunda 059-00010 or equivalent. 4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (1.9L EFI engines only). 5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose. 6. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If necessary, adjust idle speed according to Section 4. 7. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand vacuum pump, Rotunda 021-00014 or equivalent. 8. When vacuum is applied to the EGR valve and any of the following occur, replace the valve: ^ Engine does not stall. ^ Idle speed does not drop more than 100 rpm. ^ Idle speed does not return to normal (+/- 25 rpm) after the vacuum is removed. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2179 9. Reconnect the idle air bypass valve electrical connector. 10. Unplug and reconnect the EGR vacuum supply hose. 11. The EGR is OK, REPLACE EVP sensor if the Continuous Code 32 was present. If the Continuous Code 32 was not present, refer to the Diagnostic Routines in Section 2. Quick Test:Continuous Self-Test - 6.0 1988 EEC-IV - Quick Test - All Engines 16-15 QUICK TEST: Continuous Self-Test 6.0 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2180 1988 16-16 EEC-IV - Quick Test - All Engines QUICK TEST: Continuous 6.0 Self-Test Pinpoint Test - DN - EGR - EVP & EVR Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2181 EEC-IV - Pinpoint Tests - All Vehicles 1988 19-101 EGR Valve Position Sensor (EVP) EGR Valve Regulator (EVR) Pinpoint Test DN Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2182 19-102 1988 EEC-IV - Pinpoint Tests - All Vehicles EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Valve Regulator (EVR) Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2183 1988 EEC-IV - Pinpoint Tests - All Vehicles 19-102A EGR Valve Position Sensor (EVP) EGR Valve Regulator (EVR) Pinpoint Test DN Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2184 1988 19-103 EEC-IV - Pinpoint Tests - All Vehicles EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Valve Regulator (EVR) Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2185 1988 EEC-IV - Pinpoint Tests - All Vehicles 19-104 EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Valve Regulator (EVR) (EGR) Systems - Functional Diagnosis 1989 6-11 Exhaust Gas Recirculation (EGR) Systems Functional Diagnosis Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2186 PORTED EGR VALVE 1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked, crimped or broken hoses. 2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating temperature. 3. Install a tachometer, Rotunda 059-00010 or equivalent. 4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (EFI engines only). 5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose. 6. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If necessary, adjust idle speed according to Section 4. 7. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand vacuum pump, Rotunda 021-00014 or equivalent. 8. When vacuum is fully applied to the EGR valve: ^ If idle speed drops more than 100 rpm or if engine stalls, perform the next step. Otherwise, for vacuum leak at EGR valve, replace the valve. ^ If EGR passages are blocked, clean the valve using Rotunda 021-80056 EGR valve cleaner. ^ Remove the vacuum from the EGR valve. If idle speed does not return to normal (+/- 25 rpm), check for contamination, clean the valve. ^ Make sure there is no sand left in the valve or pick-up tube. Replace the valve if necessary. 9. Reconnect the idle air bypass valve electrical connector. 10. Unplug and reconnect the EGR vacuum supply hose. 11. The EGR system is OK, refer to the Diagnostic Routines in Section 2. 1989 6-12 Exhaust Gas Recirculation (EGR) Systems Functional Diagnosis ELECTRONIC EGR (EEGR) VALVE 1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked, crimped or broken hoses. 2. Make certain there is less than 2.5 in-Hg vacuum to the EGR valve at idle with the engine at normal operating temperature. NOTE: The EVR solenoid has a constant internal leak. You will notice a small vacuum signal. This signal should be less than 1.0 in-Hg at idle. 3. Install a tachometer, Rotunda 059-00010 or equivalent. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2187 4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (1.9L EFI engines only). 5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose. 6. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If necessary, adjust idle speed according to Section 4. 7. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand vacuum pump, Rotunda 021-00014 or equivalent. 8. When vacuum is applied to the EGR valve and any of the following occur: ^ Engine does not stall ^ Idle speed does not drop more than 100 rpm ^ Idle speed does not return to normal (+/- 25 rpm) after the vacuum is removed Then: ^ For vacuum leak at EGR valve, replace the valve. ^ Check for contamination, clean the EGR valve, using Rotunda 021-80056 EGR valve cleaner or equivalent. ^ Make sure there is no sand left in the valve. ^ Replace the EGR valve if necessary. 9. Reconnect the idle air bypass valve electrical connector. Unplug and reconnect the EGR vacuum supply hose. 10. If EGR valve is OK, REPLACE EVP sensor if Continuous Code 32 was present. If the Continuous Code 32 was not present, refer to the Diagnostic Routines in Section 2. Quick Test:Continuous Self-Test - 6.0 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2188 1989 EEC-IV - Quick Test - All Engines 14-17 QUICK TEST: Continuous 6.0 Self-Test Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2189 1989 14-18 EEC-IV - Quick Test - All Engines QUICK TEST: Continuous 6.0 Self-Test 1989 EEC-IV - Quick Test - All Engines 14-19 QUICK TEST: Continuous 6.0 Self-Test Quick Test:Diagnostic By Symptom - 7.0 1989 14-20 EEC-IV - Quick Test - All Engines QUICK TEST: Diagnostic By Symptom 7.0 A DIAGNOSTIC BY SYMPTOM SPECIAL NOTES: ^ Verify that a Pass Code 11 was received in Key On Engine Off, Engine Running and Continuous Self-Tests before continuing with this test. ^ If a symptom is present and the EEC system is suspected, Go to part B of Diagnostic By Symptom. If the EEC system is not suspected, GO to Section 2, Diagnostic Routines. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2190 Pinpoint Test - DN - EGR - EVP & EVR 1989 EEC-IV - Pinpoint Tests-All Vehicles 17-133 EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Vacuum Regulator Solenoid (EVR) Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2191 1989 17-134 EEC-IV - Pinpoint Tests - All Vehicles EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Vacuum Regulator Solenoid (EVR) Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2192 1989 EEC-IV-Pinpoint Tests - All Vehicles 17-134A Pinpoint Test DN EGR Valve Position Sensor (EVP) EGR Vacuum Regulator Solenoid (EVR) Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2193 1989 17-135 EEC-IV - Pinpoint Tests - All Vehicles EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Vacuum Regulator Solenoid (EVR) Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2194 1989 EEC-IV - Pinpoint Tests - All Vehicles 17-136A EGR Valve Position Sensor (EVP) 04GPinpoint Test DN EGR Vacuum Regulator Solenoid (EVR) Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > Page 2195 EGR Valve Position Sensor: Locations Attached To EGR Valve Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > Page 2196 EGR Valve Position Sensor: Description and Operation The EVP Sensor provides EEC System with a signal indicating position of the EGR valve. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Description and Operation Knock Sensor: Description and Operation The Knock Sensor, is a piezoelectric accelerometer with the sensor designed to resonate at approximately the same frequency as the engine knock frequency. The sensor uses the resonant frequency to mechanically amplify the vibrations. This method allows relatively large signals to be achieved without electrical amplification and with small package size. The sensor has a thin circular piezoelectric ceramic disk which is bonded to a metal diaphragm. Electrical connections are made through a two pin integral connector. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Description and Operation > Page 2200 Knock Sensor: Testing and Inspection Ford provides trouble code/symptom driven diagnostics for this component. For complete diagnosis and pinpoint testing, refer to Computers and Control Systems, Testing and Inspection. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications MANIFOLD ABSOLUTE AND BAROMETRIC PRESSURE SENSORS Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 2204 Right Hand Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 2205 Manifold Pressure/Vacuum Sensor: Testing and Inspection Ford provides trouble code/symptom driven diagnostics for this component. For complete diagnosis and pinpoint testing, refer to Computers and Control Systems, Testing and Inspection. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Engine - Lack of Power/No Start Diagnosis Oxygen Sensor: Technical Service Bulletins Engine - Lack of Power/No Start Diagnosis Article No. 91-12-11 06/12/91 LACK OF POWER 7.5L, 5.8L, 5.0L, 4.9L - CATALYTIC CONVERTER DIAGNOSTIC TIPS LIGHT TRUCK: 1986-91 BRONCO, ECONOLINE, F-150-350 SERIES 1988-91 F SUPER DUTY, F47 ISSUE: Lack of power or a no start condition may be diagnosed as an exhaust restriction caused by a plugged catalytic converter. A plugged catalytic converter (internal deterioration) is usually caused by abnormal engine operation. ACTION: Diagnose the catalytic converter to confirm internal failure. Refer to the Catalyst and Exhaust System Diagnostic Section, in the Engine/Emissions Diagnostic Shop Manual and the following procedures for service details. 1. Lack of proper HEGO operation may cause, or be the result of a rich or lean fuel condition, which could cause additional heat in the catalyst. Perform self test KOEO and KOER, service any codes. NOTE: IF TWO DIGIT CODES 41, 42, 85 OR THREE DIGIT CODES 171, 172, 173, 179, 181, 182, 183 AND 565 ARE RECEIVED, CHECK FOR PROPER HEGO GROUND. If the HEGO ground is good, the following areas may be at fault: ^ Ignition Coil ^ Distributor Cap ^ Distributor Rotor ^ Fouled Spark Plug ^ Spark Plug Wires ^ Air Filter ^ Stuck Open Injector ^ Fuel Contamination Engine OIL ^ Manifold Leaks Intake/ Exhaust ^ Fuel Pressure ^ Poor Power Ground ^ Engine Not At Normal Operating Temperature ^ HEGO Sensor 2. Spark timing that is retarded from specification may increase exhaust gas temperature and shorten catalyst life. Refer to the following procedure for service details. a. Check spark timing. Check base timing with spout disconnected. Set base timing to the specification on the vehicle emission decal. b. Check computed timing with spout connected. NOTE: COMPUTED TIMING IS EQUAL TO BASE TIMING PLUS 20~ BTDC +/- 3~. 3. Misfiring spark plugs may cause an unburned fuel air mixture to pass through the catalyst, which could cause higher than normal catalyst temperatures. Refer to the following procedure for service details. a. Check secondary ignition, hook the vehicle up to an engine analyzer and check for a secondary ignition misfire. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Engine - Lack of Power/No Start Diagnosis > Page 2210 NOTE: SERVICE ANY ITEM THAT IS NOT PERFORMING AT PROPER SPECIFICATIONS BEFORE CONTINUING. 4. Fuel pressure that is too high may cause rich air fuel mixtures to pass through the catalyst which could cause higher than normal catalyst temperatures. Refer to the following procedure for service details. a. Check fuel pressure, install fuel pressure gauge, start and run the engine at idle. Fuel pressures between 28 and 34 PSI are typical (4.9L typically is 15 PSI higher). b. Disconnect the vacuum line going to the fuel pressure regulator. Fuel pressure typically jumps to 40 PSI +/- 3 PSI (4.9L typically is 15 PSI higher). Visually inspect vacuum line for raw fuel. NOTE: FUEL PRESSURES ABOVE THESE VALUES SHOULD BE CORRECTED. HOWEVER, THIS MAY NOT BE THE CAUSE OF THE CONCERN. SERVICE AS NECESSARY. 5. Throttle plates in the throttle body not returning to the proper closed position may cause excessive catalyst temperatures during downhill grades. Refer to the following procedure for service details. a. Visually inspect the throttle body and linkage for: ^ Binding or sticking throttle linkage. ^ Tight speed control linkage or cable. ^ Vacuum line interference. ^ Electrical harness interference. NOTE: AFTERMARKET GOVERNORS, THROTTLE LINKAGE AND CABLES ASSOCIATED WITH POWER TAKE-OFF UNITS, MAY ALSO INTERFERE WITH PROPER THROTTLE RETURN. SERVICE AS NECESSARY. 6. It is extremely important that all systems related to the engine and emission systems operate properly. a. Visually inspect the engine compartment to make sure all vacuum hoses and spark plug wires are properly routed and securely connected. b. Inspect all wiring harnesses and connectors for insulation damage, burned, overheated, loose or broken conditions. c. Verify proper operation of the thermactor system. Thermactor systems that fail to dump thermactor air to the atmosphere properly or at the correct time can cause high catalyst temperatures. d. Visually inspect thermactor system for damaged or kinked hoses and perform a function test on following components: air control valve, check valve, silencer, filter and the air bypass solenoid. e. Verify proper operation of the engine cooling system thermostat. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under Basic Warranty Coverage, Emissions Warranty Coverage OPERATION DESCRIPTION TIME 911211A Diagnostics - Perform 0.5 Hrs. KOEO And KOER Self Tests 911211B Timing - Check Or Adjust 0.5 Hrs. Spark Timing, Check Computed Timing And Check Secondary Ignition System With Engine Analyzer. 911211C Check - Fuel Pressure And 0.2 Hrs. Inspect Vacuum Line For Raw Fuel. 911211D Inspect - Throttle Body And 0.1 Hrs. Linkage. 911211E Inspect - Vacuum Hoses, 0.1 Hrs. Electrical Harnesses, Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Engine - Lack of Power/No Start Diagnosis > Page 2211 Connectors And Spark Plug Wires For Routing Damage. 911211F Thermactor System - 0.3 Hrs. Inspect For Proper Operation And Damaged Component. Includes Function Check Of Air Control Valve, Thermactor Air Bypass Solenoid, Check Valves, Silencer And Filter. 911211G Thermostat - Check For 0.2 Hrs. Proper Operation. DEALER CODING BASIC PART NO. CONDITION CODE 5E212 25 OASIS CODES: 403000, 603300, 614000 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Engine - Lack of Power/No Start Diagnosis > Page 2212 Oxygen Sensor: Technical Service Bulletins EGO Sensors - Silicone Contamination Article No. 93-23-6 11/10/93 ^ EGO SENSORS - SILICONE CONTAMINATION ^ ENGINE - SEALANTS, LOW VOLATILITY SILICONE REQUIRED ^ EXHAUST SYSTEM - SILICONE CONTAMINATION OF EXHAUST GAS OXYGEN (EGO) SENSORS FORD: 1984-86 LTD 1984-88 EXP 1984-94 CROWN VICTORIA, ESCORT, MUSTANG, TEMPO, THUNDERBIRD 1986-94 TAURUS 1988-93 FESTIVA 1989-94 PROBE 1994 ASPIRE LINCOLN-MERCURY: 1984-86 CAPRI, MARQUIS 1984-87 LYNX 1984-92 MARK VII 1984-94 CONTINENTAL, COUGAR, GRAND MARQUIS, TOPAZ, TOWN CAR 1986-94 SABLE 1988-89 TRACER 1991-94 CAPRI, TRACER 1993-94 MARK VIII MERKUR: 1985-89 XR4TI 1988-89 SCORPIO LIGHT TRUCK: 1983-94 RANGER 1984-90 BRONCO II 1984-94 BRONCO, ECONOLINE, F-150-350 SERIES 1986-94 AEROSTAR 1988-94 F-47, F-53 1991-94 EXPLORER 1993-94 VILLAGER This TSB article is being republished in its entirety to update model applicability and to revise the part number of the Low Volatility Sealant. ISSUE: EGO sensors can be contaminated if volatile types of silicone are used when servicing the engine. Volatile silicones can migrate throughout the system during the first one hundred hours of service. They are commonly found in liquid "silicone rubber" sealants and gasket material. These products are commonly sold in tubes and caulking-type cartridges. ACTION: When service is performed on the engine, only use new low volatility silicone sealant (F1AZ-19662-A) where specified. Also replace the contaminated EGO sensor if required. CAUTION: DO NOT SUBSTITUTE CONVENTIONAL SILICONE RUBBER SEALANTS WHEN LOW VOLATILITY SILICONE SEALANT IS SPECIFIED. PART NUMBER PART NAME CLASS F1AZ-19662-A Low Volatility RTV Sealant B OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 89-14-5 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Engine - Lack of Power/No Start Diagnosis > Page 2213 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 403000, 490000, 499000 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Page 2214 Engine View Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Description and Operation > Exhaust Gas Oxygen Sensor Oxygen Sensor: Description and Operation Exhaust Gas Oxygen Sensor The EGO Sensor supplies ECA with a signal which indicates either a rich or lean condition during engine operation. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Description and Operation > Exhaust Gas Oxygen Sensor > Page 2217 Oxygen Sensor: Description and Operation Heated Exhaust Gas Oxygen Sensor The Heated Exhaust Gas Oxygen Sensor (HEGO), supplies the ECA with a signal which indicates a rich or lean condition during engine operation. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Description and Operation > Page 2218 Oxygen Sensor: Testing and Inspection Ford provides trouble code/symptom driven diagnostics for this component. For complete diagnosis and pinpoint testing, refer to Computers and Control Systems, Testing and Inspection. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Locations Power Steering Pressure Switch: Locations In Power Steering Hose, Near Steering Gear Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Locations > Page 2222 Power Steering Pressure Switch: Testing and Inspection Ford provides trouble code/symptom driven diagnostics for this component. For complete diagnosis and pinpoint testing, refer to Computers and Control Systems, Testing and Inspection. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Description and Operation Pressure Feedback Exhaust Sensor: Description and Operation The Pressure Feedback Electronic (PFE) EGR transducer converts a varying exhaust pressure signal into a proportional analog voltage which is digitized by the EEC IV processor. The EEC IV processor uses the signal received from the PFE transducer to complete the optimum EGR flow. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Throttle Position Sensor - Request For Return Throttle Position Sensor: Technical Service Bulletins Throttle Position Sensor - Request For Return Number: 92686 To: All Ford and Lincoln-Mercury Dealers Subject: Request for Return of Throttle Position Sensor E5ZZ-9B989-B (CX-1022) and E6ZZ-9B989-B (CX-1130) Because the subject parts may not meet Ford's high quality requirements, they should be withdrawn from all inventories. All used E5ZZ-9B989-B (CX-1022) and E6ZZ-9B989-B (CX-1130) should be returned to your facing PDC within 30 days from the date of this letter. Use the least expensive mode of transportation for your return. The subject parts are obsolete and replaced by E7SZ-9B989-B (CX-1200), which is available for ordering immediately. You are requested to complete a separate FPS-340 form in accordance with the instructions on the front of the form. Annotate "Return Per FPSD Instructions Purge No. PN 1026" in the Customer's Detail Explanation Section and use Reason Code J (Unsatisfactory Service Stock). You will receive full credit in your parts statement for the price of each unused part returned, plus the prepaid transportation cost. In order to receive credit, all parts must be received at the Parts Distribution Center within 30 days from the date of this letter. Material other than subject parts received on this return will be sent back to you freight collect. Any questions should be referred to your Zone Manager or facing PDC Manager. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Throttle Position Sensor - Request For Return > Page 2230 Throttle Position Sensor: Technical Service Bulletins Throttle Position Sensor - Diagnostic Tips Article No. 85-20-11 SELF-TEST CODE 53 - EEC IV - THROTTLE POSITION SENSOR DIAGNOSTIC TIP FORD 1985-86 ESCORT, EXP, TEMPO, MUSTANG, LTD, THUNDERBIRD LINCOLN-MERCURY 1985-86 LYNX, TOPAZ, CAPRI, MARQUIS, COUGAR LIGHT TRUCK 1985-86 RANGER, BRONCO II, ECONOLINE, F-SERIES CALIBRATION: All with EEC IV WARNING: This modification is authorized only for the listed engines. Performing this modification on other engine calibrations is unauthorized and could create liability under applicable federal or local laws. A new design Throttle Position Sensor (TPS) has been released for all 1986 EEC IV applications. The new TPS is designed to eliminate a false Self-Test Code 53. A Code 53 indicates the TPS system has failed at the wide open throttle position (approximately 5.0 volts), The new TPS eliminates false Code 53 by limiting the wide open throttle voltage to 4.75 volts. With the new TPS, Code 53 will only result from a circuit or TPS malfunction. The new Throttle Position Sensors can be used to replace faulty sensors on 1985 vehicles. If the old design service part is used, a false Code 53 may result. PART NUMBER PART NAME CLASS E6DZ-9B989-A Throttle Position Sensor C E6TZ-9B989-C Throttle Position Sensor WC E6DZ-9B989-C Throttle Position Sensor WC E6FZ-9B989-A Throttle Position Sensor B E6ZZ-9B989-A Throttle Position Sensor B E6ZZ-9B989-B Throttle Position Sensor WC E6TZ-9B989-A Throttle Position Sensor C OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Throttle Position Sensor - Request For Return > Page 2231 Throttle Position Sensor: Technical Service Bulletins Throttle Position Sensor - Application Chart EEC-IV THROTTLE POSITION SENSOR-APPLICATION CHART-SERVICE TIP Article No. 89-16-4 FORD: 1984-88 CROWN VICTORIA, ESCORT, EXP, MUSTANG, TAURUS, TEMPO, THUNDERBIRD LINCOLN-MERCURY: 1984-88 COUGAR, GRAND MARQUIS, LYNX, MARK VI, MARK VII, SABLE, TOPAZ, TOWN CAR LIGHT TRUCK: 1984-88 ALL LIGHT TRUCK LINES ISSUE: A quick reference throttle position sensor (TPS) application chart has been put together to assist technicians in correct part useage. If the wrong TPS is installed, it could fail prematurely. ACTION: Refer to one of the following TPS service replacement charts to make sure that the correct service part is installed. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Throttle Position Sensor - Request For Return > Page 2232 OASIS CODES: 680000 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Throttle Position Sensor - Request For Return > Page 2233 Throttle Position Sensor: Technical Service Bulletins TPS Mounting Screws - Hard to Remove THROTTLE POSITION SENSOR-MOUNTING SCREWS HARD TO REMOVE-SERVICE TIP Article No. 89-14-7 FORD: 1983-89 CROWN VICTORIA, MUSTANG, TEMPO, THUNDERBIRD 1984-89 ESCORT 1986-89 TAURUS LINCOLN-MERCURY: 1983-89 CONTINENTAL, COUGAR, GRAND MARQUIS, MARK VII, TOPAZ, TOWN CAR 1984-87 LYNX MERKUR: 1985-89 ALL MERKUR LINES LIGHT TRUCK: 1983-89 ALL LIGHT TRUCK LINES ISSUE: All Throttle Position Sensor (TPS) mounting screws have a "Pozidrive" head. The "Pozidrive" head looks a lot like a Phillips screw head. Use of a Phillips head screwdriver to remove a "Pozidrive" screw will normally result in a rounded or damaged screw head. Many technicians think it is an overtorqued or "frozen" screw. An adhesive was also used as a thread sealant starting with the 1988 model year. This adhesive requires still more effort to loosen and remove the screw. ACTION: To prevent rounded or damages screw heads when servicing the TPS mounting screws, technicians should always use a # 2 "Pozidrive" screwdriver. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 4800, 680000 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 2234 THROTTLE POSITION SENSOR SPECIFICATIONS Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 2235 Engine View Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 2236 Throttle Position Sensor: Description and Operation The Throttle Position (TP) Sensor (Rotary), Figure 1 supplies the ECA with a signal proportional to opening angle of carburetor throttle plates. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 2237 Throttle Position Sensor: Testing and Inspection Ford provides trouble code/symptom driven diagnostics for this component. For complete diagnosis and pinpoint testing, refer to Computers and Control Systems, Testing and Inspection. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 2238 Throttle Position Sensor: Adjustments ADJUSTMENT This procedure can be used to check and/or adjust level C sensors only: 1. Install an EEC-IV Breakout Box, Rotunda T83L-50 EEC-IV, or equivalent. 2. Attach a DVOM, Rotunda 014-00407 or equivalent, on 20V scale. Connect the positive lead (+) to test Pin 47 and the negative lead (-) to test Pin 46. 3. Turn ignition key to Run position (do not start engine). 4. Adjust TP Sensor (rotate) until the DVOM reads 1.0V (0.9-1.1). 5. Tighten TP Sensor screws to 1.2-1.8 N-m (11-16 lb-in). 6. While watching the DVOM, move the throttle to wide open and back to idle position. For proper operation, the DVOM should move from 1.0 to at least 4.0 and back to 1.0V. 7, Perform EEC-IV Quick Test. Refer to Powertrain Management/Computers and Control Systems/System Diagnosis Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Specifications VEHICLE SPEED SENSOR Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Specifications > Page 2242 Vehicle Speed Sensor: Locations At Transmission Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Testing and Inspection > Speed Control/Speedometer Vehicle Speed Sensor: Testing and Inspection Speed Control/Speedometer 1980-87 Models Exc. 1983-87 Ranger, 1984-87 Bronco II & 1986-87 Aerostar 1. Disconnect 6 way connector from amplifier assembly, then connect an ohmmeter between dark green wire w/white stripe and black wire on 1980 E-100-350, 1981-83 F-100-350 models and Bronco, and 1984-87 F-150-350 and Bronco, or green and black wire on 1980 F-100-350 and 1981-83 E-100-350 models and 1984-87 E-150-350 at the speed sensor end. A reading of 40 ohms should be obtained. A reading of 0 ohms indicates a shorted coil and an infinity reading indicates an open coil. 2. Replace sensor if a correct reading has not been obtained. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Testing and Inspection > Speed Control/Speedometer > Page 2245 Vehicle Speed Sensor: Testing and Inspection Computer Related Diagnostic Information Ford provides trouble code/symptom driven diagnostics for this component. For complete diagnosis and pinpoint testing, refer to Computers and Control Systems, Testing and Inspection. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Testing and Inspection > Page 2246 Vehicle Speed Sensor: Service and Repair 1. Separate electrical connector leading to the amplifier assembly. 2. Disconnect upper and lower speedometer cables at the speed sensor. Remove speed sensor. 3. Reverse procedure to install. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision Technical Service Bulletin # 8918A9 Date: 890915 EVP Sensor - Manual Revision ENGINE EMISSIONS DIAGNOSTIC MANUALS, VOLUME H - 1985 THROUGH 1989 - EGR VALVE POSITION SENSOR (EVP) DIAGNOSTIC PROCEDURES REVISED Article No. 89-18A-9 FORD: 1985-89 CROWN VICTORIA, ESCORT 1985-88 EXP 1985-86 LTD 1985-89 MUSTANG, TEMPO, THUNDERBIRD 1986-89 TAURUS 1988-89 FESTIVA 1989 PROBE LINCOLN-MERCURY: 1985-86 CAPRI 1985-89 CONTINENTAL, COUGAR, GRAND MARQUIS 1985-87 LYNX 1985-89 MARK VII 1985-86 MARQUIS 1985-89 TOPAZ, TOWN CAR 1986-89 SABLE 1987-89 TRACER MERKUR: 1986-89 XR4TI 1988-89 SCORPIO LIGHT TRUCK: 1985-89 BRONCO, BRONCO II, ECONOLINE, F-150, F-250, F-350, RANGER 1986-89 AEROSTAR ISSUE: The EGR Valve Position Sensor (EVP) diagnostic procedures in 1985 through 1989 Engine Emissions Diagnosis Shop Manuals, Volume H, have been revised. EVP Sensors may exhibit internal wear problems that can cause driveability symptoms and display a Continuous Self-Test Code 32. This is not associated to correcting the problem using the existing diagnostic procedures. ACTION: Refer to the pages following this TSB article for the revised diagnostic procedures. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 680000 1985 Pinpoint Tests - DM - EGR, EVP and EVR Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2252 1985 EEC IV - Pinpoint Tests - All Vehicles 22-77 EGR Valve Position Sensor (EVP) EGR Valve Regulator (EVR) Pinpoint DM Test 1985 Pinpoint Tests - Fa - Neutral Drive Switch -A/C Input Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2253 1985 22-78 EEC IV - Pinpoint Tests - All Vehicles Neutral Drive Switch FA A/C Input PinpointTest 1986 (EGR) Systems Functional Diagnosis 1986 Exhaust Gas Recirculation (EGR) Systems 6-11 Functional Diagnosis Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2254 PORTED EGR VALVE 1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked, crimped or broken hoses. 2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating temperature. 3. Install a tachometer. 4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (EFI engines only). 5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose. 6. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If necessary, adjust idle speed to the emission decal specification. 7. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand vacuum pump. 8. When vacuum is applied to the EGR valve and any of the following occur, replace the valve: ^ Engine does not stall. ^ Idle speed does not drop more than 100 rpm. ^ Idle speed does not return to normal (+/- 25 rpm) after the vacuum is removed. 9. Reconnect the idle air bypass valve electrical connector. 10. Unplug and reconnect the EGR vacuum supply hose. 11. The EGR system is OK, refer to the Diagnostic Routines in Section 2. 1986 6-12 Exhaust Gas Recirculation (EGR) Systems Functional Diagnosis ELECTRONIC VALVE 1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked, crimped or broken hoses. 2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating temperature. 3. Install a tachometer. 4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (EFI engines only). Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2255 5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose. 6. Disconnect the 9G428 EVP sensor electrical connector mounted on top of the 9H473 valve. 7. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If necessary, adjust idle speed to the emission decal specification. 8. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand vacuum pump. 9. When vacuum is applied to the EGR valve and any of the following occur, replace the valve: ^ Engine does not stall. ^ Idle speed does not drop more than 100 rpm. ^ Idle speed does not return to normal (+/- 25 rpm) after the vacuum is removed. 10. Reconnect the idle air bypass valve electrical connector. 11. Unplug and reconnect the EGR vacuum supply hose. 12. Reconnect the EVP sensor electrical connector. 13. The EGR valve is OK, REPLACE EVP sensor if the Continuous Code 32 was present. If the Continuous Code 32 was not present, refer to the Diagnostic Routines in Section 2. 1986 Quick Test: Continuous Self-Test 6.0 EEC IV - Quick Test - All Engines 18-13 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2256 QUICK TEST: Continuous Self-Test 6.0 1986 18-14 EEC IV-Quick Test-All Engines QUICK TEST: Continuous Self-Test 6.0 Pinpoint Test - DN - EGR - EVP & EVR Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2257 1986 EEC IV-Pinpoint Tests - All Vehicles 21-95 EGR Valve Position Sensor (EVP) PinpointTest DN EGR Valve Regulator (EVR) Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2258 21-96 1986 EEC IV-Pinpoint Tests-All Vehicles EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Valve Regulator (EVR) Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2259 EEC IV-Pinpoint Tests-All Vehicles 1986 21-97A EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Valve Regulator (EVR) Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2260 1986 21-97B EEC IV-Pinpoint Tests-All Vehicles EGR Valve Position Sensor (EVP) EGR Valve Regulator (EVR) Pinpoint Test DN Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2261 1986 EEC IV-Pinpoint Tests-All Vehicles 21-98 EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Valve Regulator (EVR) 1987 (EGR) Systems - Functional Diagnosis 1987 6-11 Exhaust Gas Recirculation (EGR) Systems Functional Diagnosis PORTED EGR VALVE 1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked, crimped or broken hoses. 2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating temperature. 3. Install a tachometer, Rotunda 059-00010 or equivalent. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2262 4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (EFI engines only). 5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose. 6. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If necessary, adjust idle speed according to Section 4. 7. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand vacuum pump, Rotunda 021-00014 or equivalent. 8. When vacuum is applied to the EGR valve and any of the following occur, replace the valve: ^ Engine does not stall. ^ Idle speed does not drop more than 100 rpm. ^ Idle speed does not return to normal (+/- 25 rpm) after the vacuum is removed. 9. Reconnect the idle air bypass valve electrical connector. 10. Unplug and reconnect the EGR vacuum supply hose. 11. The EGR system is OK, refer to the Diagnostic Routines in Section 2. 1987 6-12 Exhaust Gas Recirculation (EGR) Systems Functional Diagnosis ELECTRONIC EGR (EEGR) VALVE 1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked, crimped or broken hoses. 2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating temperature. 3. Install a tachometer, Rotunda 059-00010 or equivalent. 4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (EFI engines only). 5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose. 6. Disconnect the 9G428 EVP sensor electrical connector mounted on top of the 9H473 valve. 7. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If necessary, adjust idle speed according to Section 4. 8. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand vacuum pump, Rotunda 021-00014 or equivalent. 9. When vacuum is applied to the EGR valve and any of the following occur, replace the valve: ^ Engine does not stall. ^ Idle speed does not drop more than 100 rpm. ^ Idle speed does not return to normal (+/- 25 rpm) after the vacuum is removed. 10. Reconnect the idle air bypass valve electrical connector. 11. Unplug and reconnect the EGR vacuum supply hose. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2263 12. Reconnect the EVP sensor electrical connector. 13. The EGR valve is OK, REPLACE EVP sensor if the Continuous Code 32 was present. If the Continous Code 32 was not present, refer to the Diagnostic Routines in Section 2. 1987 Quick Test: Continuous Self-Test - 6.0 1987 EEC-IV Quick Test-All Engines 16-15 QUICK TEST: Continuous 6.0 Self-Test Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2264 16-16 1987 EEC-IV Quick Test-All Engines QUICK TEST: Continuous 6.0 Self-Test Pinpoint Test - DN - EGR - EVP & EVR 1987 EEC IV - Pinpoint Tests - All Vehicles 19-91 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2265 EGR VALVE Position Sensor (EVP) EGR Valve Regulator (EVR) - 2.3L HSC, 2.5L, 5.0L SEFI Passenger Car and 4.9L and 5.0L Truck Pinpoint Test DN 19-92A 1987 EEC IV Pinpoint Tests-All Vehicles EGR Valve Position Sensor (EVP) EGR Valve Regulator (EVR) - 2.3L HSC, 2.5L, Pinpoint Test DN 5.0L SEFI Passenger Car and 4.9L and 5.0L Truck Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2266 1987 EEC IV-Pinpoint Tests-All Vehicles 19-92B EGR Valve Position Sensor (EVP) EGR Valve Regulator (EVR) - 2.3L HSC, 2.5L, 5.0L SEFI Passenger Car and 4.9L and 5.0L Truck Pinpoint Test DN Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2267 1987 19-93-A EEC IV-Pinpoint Tests-All Vehicles EGR Valve Position Sensor (EVP) EGR Valve Regulator (EVR) - 2.3L HSC, 2.5L, 5.0L SEFI Passenger Car 4.9L and 5.0L Truck Pinpoint Test DN Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2268 EEC IV-Pinpoint Tests-All Vehicles 1987 19-94 EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Valve Regulator (EVR) (EGR) Systems - Functional Diagnosis 1988 Exhaust Gas Recirculation (EGR) Systems 6-11 Functional Diagnosis Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2269 PORTED EGR VALVE 1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked, crimped or broken hoses. 2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating temperature. 3. Install a tachometer, Rotunda 059-00010 or equivalent. 4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (EFI engines only). 5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose. 6. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If necessary, adjust idle speed according to Section 4. 7. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand vacuum pump, Rotunda 021-00014 or equivalent. 8. When vacuum is fully applied to the EGR valve: ^ If idle speed drops more than 100 rpm or if engine stalls, perform the next step. Otherwise, replace the EGR valve. ^ Remove the vacuum from the EGR valve. If idle speed does not return to normal (+/- 25 rpm), replace the EGR valve. 9. Reconnect the idle air bypass valve electrical connector. 10. Unplug and reconnect the EGR vacuum supply hose. 11. The EGR system is OK, refer to the Diagnostic Routines in Section 2. 6-12 1988 Exhaust Gas Recirculation (EGR) Systems Functional Diagnosis ELECTRONIC EGR (EEGR) VALVE 1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked, crimped or broken hoses. 2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating temperature. NOTE: The EVR solenoid has a constant internal leak. You will notice a small vacuum signal. This signal should be less than 2-1/2 in-Hg at idle. 3. Install a tachometer, Rotunda 059-00010 or equivalent. 4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (1.9L EFI engines only). 5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose. 6. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If necessary, adjust idle speed according to Section 4. 7. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand vacuum pump, Rotunda 021-00014 or equivalent. 8. When vacuum is applied to the EGR valve and any of the following occur, replace the valve: ^ Engine does not stall. ^ Idle speed does not drop more than 100 rpm. ^ Idle speed does not return to normal (+/- 25 rpm) after the vacuum is removed. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2270 9. Reconnect the idle air bypass valve electrical connector. 10. Unplug and reconnect the EGR vacuum supply hose. 11. The EGR is OK, REPLACE EVP sensor if the Continuous Code 32 was present. If the Continuous Code 32 was not present, refer to the Diagnostic Routines in Section 2. Quick Test:Continuous Self-Test - 6.0 1988 EEC-IV - Quick Test - All Engines 16-15 QUICK TEST: Continuous Self-Test 6.0 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2271 1988 16-16 EEC-IV - Quick Test - All Engines QUICK TEST: Continuous 6.0 Self-Test Pinpoint Test - DN - EGR - EVP & EVR Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2272 EEC-IV - Pinpoint Tests - All Vehicles 1988 19-101 EGR Valve Position Sensor (EVP) EGR Valve Regulator (EVR) Pinpoint Test DN Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2273 19-102 1988 EEC-IV - Pinpoint Tests - All Vehicles EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Valve Regulator (EVR) Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2274 1988 EEC-IV - Pinpoint Tests - All Vehicles 19-102A EGR Valve Position Sensor (EVP) EGR Valve Regulator (EVR) Pinpoint Test DN Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2275 1988 19-103 EEC-IV - Pinpoint Tests - All Vehicles EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Valve Regulator (EVR) Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2276 1988 EEC-IV - Pinpoint Tests - All Vehicles 19-104 EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Valve Regulator (EVR) (EGR) Systems - Functional Diagnosis 1989 6-11 Exhaust Gas Recirculation (EGR) Systems Functional Diagnosis Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2277 PORTED EGR VALVE 1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked, crimped or broken hoses. 2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating temperature. 3. Install a tachometer, Rotunda 059-00010 or equivalent. 4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (EFI engines only). 5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose. 6. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If necessary, adjust idle speed according to Section 4. 7. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand vacuum pump, Rotunda 021-00014 or equivalent. 8. When vacuum is fully applied to the EGR valve: ^ If idle speed drops more than 100 rpm or if engine stalls, perform the next step. Otherwise, for vacuum leak at EGR valve, replace the valve. ^ If EGR passages are blocked, clean the valve using Rotunda 021-80056 EGR valve cleaner. ^ Remove the vacuum from the EGR valve. If idle speed does not return to normal (+/- 25 rpm), check for contamination, clean the valve. ^ Make sure there is no sand left in the valve or pick-up tube. Replace the valve if necessary. 9. Reconnect the idle air bypass valve electrical connector. 10. Unplug and reconnect the EGR vacuum supply hose. 11. The EGR system is OK, refer to the Diagnostic Routines in Section 2. 1989 6-12 Exhaust Gas Recirculation (EGR) Systems Functional Diagnosis ELECTRONIC EGR (EEGR) VALVE 1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked, crimped or broken hoses. 2. Make certain there is less than 2.5 in-Hg vacuum to the EGR valve at idle with the engine at normal operating temperature. NOTE: The EVR solenoid has a constant internal leak. You will notice a small vacuum signal. This signal should be less than 1.0 in-Hg at idle. 3. Install a tachometer, Rotunda 059-00010 or equivalent. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2278 4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (1.9L EFI engines only). 5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose. 6. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If necessary, adjust idle speed according to Section 4. 7. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand vacuum pump, Rotunda 021-00014 or equivalent. 8. When vacuum is applied to the EGR valve and any of the following occur: ^ Engine does not stall ^ Idle speed does not drop more than 100 rpm ^ Idle speed does not return to normal (+/- 25 rpm) after the vacuum is removed Then: ^ For vacuum leak at EGR valve, replace the valve. ^ Check for contamination, clean the EGR valve, using Rotunda 021-80056 EGR valve cleaner or equivalent. ^ Make sure there is no sand left in the valve. ^ Replace the EGR valve if necessary. 9. Reconnect the idle air bypass valve electrical connector. Unplug and reconnect the EGR vacuum supply hose. 10. If EGR valve is OK, REPLACE EVP sensor if Continuous Code 32 was present. If the Continuous Code 32 was not present, refer to the Diagnostic Routines in Section 2. Quick Test:Continuous Self-Test - 6.0 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2279 1989 EEC-IV - Quick Test - All Engines 14-17 QUICK TEST: Continuous 6.0 Self-Test Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2280 1989 14-18 EEC-IV - Quick Test - All Engines QUICK TEST: Continuous 6.0 Self-Test 1989 EEC-IV - Quick Test - All Engines 14-19 QUICK TEST: Continuous 6.0 Self-Test Quick Test:Diagnostic By Symptom - 7.0 1989 14-20 EEC-IV - Quick Test - All Engines QUICK TEST: Diagnostic By Symptom 7.0 A DIAGNOSTIC BY SYMPTOM SPECIAL NOTES: ^ Verify that a Pass Code 11 was received in Key On Engine Off, Engine Running and Continuous Self-Tests before continuing with this test. ^ If a symptom is present and the EEC system is suspected, Go to part B of Diagnostic By Symptom. If the EEC system is not suspected, GO to Section 2, Diagnostic Routines. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2281 Pinpoint Test - DN - EGR - EVP & EVR 1989 EEC-IV - Pinpoint Tests-All Vehicles 17-133 EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Vacuum Regulator Solenoid (EVR) Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2282 1989 17-134 EEC-IV - Pinpoint Tests - All Vehicles EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Vacuum Regulator Solenoid (EVR) Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2283 1989 EEC-IV-Pinpoint Tests - All Vehicles 17-134A Pinpoint Test DN EGR Valve Position Sensor (EVP) EGR Vacuum Regulator Solenoid (EVR) Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2284 1989 17-135 EEC-IV - Pinpoint Tests - All Vehicles EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Vacuum Regulator Solenoid (EVR) Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2285 1989 EEC-IV - Pinpoint Tests - All Vehicles 17-136A EGR Valve Position Sensor (EVP) 04GPinpoint Test DN EGR Vacuum Regulator Solenoid (EVR) Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > Page 2286 EGR Valve Position Sensor: Locations Attached To EGR Valve Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > Page 2287 EGR Valve Position Sensor: Description and Operation The EVP Sensor provides EEC System with a signal indicating position of the EGR valve. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Description and Operation Pressure Feedback Exhaust Sensor: Description and Operation The Pressure Feedback Electronic (PFE) EGR transducer converts a varying exhaust pressure signal into a proportional analog voltage which is digitized by the EEC IV processor. The EEC IV processor uses the signal received from the PFE transducer to complete the optimum EGR flow. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Tank Selector Switch > Component Information > Locations > Fuel Tank Selector Switch Fuel Tank Selector Switch: Locations Fuel Tank Selector Switch On Instrument Panel Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Tank Selector Switch > Component Information > Locations > Fuel Tank Selector Switch > Page 2296 Fuel Tank Selector Switch: Locations Fuel Tank Selector Relay LH Corner Of Dash Panel Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Tank Selector Switch > Component Information > Diagrams > Diagram Information and Instructions Fuel Tank Selector Switch: Diagram Information and Instructions Symbol Identification Wire Color Code Identification Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Tank Selector Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2299 NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Tank Selector Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2300 Fuel Tank Selector Switch: Electrical Diagrams Fig. 26 Fuel Tank Selector & Gauges Wiring Circuit. Models W/6-300 (4.9L) & V8-351 (5.8L) Engines With 8,500 GVW Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Tank Selector Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 2301 Fig. 27 Fuel Tank Selector & Gauges Wiring Circuit. F150-350 W/V8-351 (5.8L) & V8-460 (7.5L) Engines & Dual Tanks (Less Electric Fuel Pumps) Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pump Inertia Switch <--> [Inertia Fuel Shutoff Switch] > Component Information > Locations Fuel Pump Inertia Switch: Locations The inertia switch is located below the heater duct on the right hand side. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pump Inertia Switch <--> [Inertia Fuel Shutoff Switch] > Component Information > Diagrams > Diagram Information and Instructions Fuel Pump Inertia Switch: Diagram Information and Instructions Symbol Identification Wire Color Code Identification Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pump Inertia Switch <--> [Inertia Fuel Shutoff Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 2307 NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pump Inertia Switch <--> [Inertia Fuel Shutoff Switch] > Component Information > Diagrams > Page 2308 Fuel Pump Inertia Switch: Description and Operation The inertia Switch, is used in conjunction with an electric fuel pump. The purpose of the inertia switch is to shut off the fuel pump in the event of an accident. It consists of a steel ball held in place by a magnet. When a sharp impact occurs, the ball breaks loose from the magnet, rolls up a conical ramp and strikes a target plate which opens the electrical contacts of the switch and thereby shuts off the electric fuel pump. Once the switch is open, it must be manually reset before re-starting the vehicle. The location of the switch is discussed in the owners guide. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pump Inertia Switch <--> [Inertia Fuel Shutoff Switch] > Component Information > Diagrams > Page 2309 Fuel Pump Inertia Switch: Testing and Inspection Push down on the reset button to make sure the switch is closed. Use DVOM with LOS button On and measure voltage across both terminals of the inertia switch. If DVOM reading is greater than 0.3V, replace the inertia switch. NOTE: In the closed position, the button can be depressed an additional 1/16-inch against a spring. This is a normal condition and does not adversely effect the switch operation. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pump Inertia Switch <--> [Inertia Fuel Shutoff Switch] > Component Information > Diagrams > Page 2310 Fuel Pump Inertia Switch: Service and Repair 1. Turn ignition to Off. 2. Check for leaking fuel in the engine compartment, fuel lines and tank(s). 3. If no fuel leak is apparent, reset the switch by pushing the reset button on the top of the switch. 4. Turn ignition switch to Start for a few seconds, then to Off. 5. Again, check for leaking fuel. WARNING: It you see or smell gasoline at any time other than during fueling, do not reset the switch. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Full Open Switch HVAC > Component Information > Description and Operation Throttle Full Open Switch HVAC: Description and Operation A switch assembly, Figure 1 is mounted on the carburetor on some gasoline engines and on the fuel injector pump on the 2.0L Diesel engine to sense a wide open throttle condition. When maximum engine power is required, this switch assembly cuts off the air conditioning compressor to reduce engine loading. Switch closed at throttle opening less than wide open throttle. Switch open at wide open throttle condition. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Throttle Position Sensor - Request For Return Throttle Position Sensor: Technical Service Bulletins Throttle Position Sensor - Request For Return Number: 92686 To: All Ford and Lincoln-Mercury Dealers Subject: Request for Return of Throttle Position Sensor E5ZZ-9B989-B (CX-1022) and E6ZZ-9B989-B (CX-1130) Because the subject parts may not meet Ford's high quality requirements, they should be withdrawn from all inventories. All used E5ZZ-9B989-B (CX-1022) and E6ZZ-9B989-B (CX-1130) should be returned to your facing PDC within 30 days from the date of this letter. Use the least expensive mode of transportation for your return. The subject parts are obsolete and replaced by E7SZ-9B989-B (CX-1200), which is available for ordering immediately. You are requested to complete a separate FPS-340 form in accordance with the instructions on the front of the form. Annotate "Return Per FPSD Instructions Purge No. PN 1026" in the Customer's Detail Explanation Section and use Reason Code J (Unsatisfactory Service Stock). You will receive full credit in your parts statement for the price of each unused part returned, plus the prepaid transportation cost. In order to receive credit, all parts must be received at the Parts Distribution Center within 30 days from the date of this letter. Material other than subject parts received on this return will be sent back to you freight collect. Any questions should be referred to your Zone Manager or facing PDC Manager. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Throttle Position Sensor - Request For Return > Page 2318 Throttle Position Sensor: Technical Service Bulletins Throttle Position Sensor - Diagnostic Tips Article No. 85-20-11 SELF-TEST CODE 53 - EEC IV - THROTTLE POSITION SENSOR DIAGNOSTIC TIP FORD 1985-86 ESCORT, EXP, TEMPO, MUSTANG, LTD, THUNDERBIRD LINCOLN-MERCURY 1985-86 LYNX, TOPAZ, CAPRI, MARQUIS, COUGAR LIGHT TRUCK 1985-86 RANGER, BRONCO II, ECONOLINE, F-SERIES CALIBRATION: All with EEC IV WARNING: This modification is authorized only for the listed engines. Performing this modification on other engine calibrations is unauthorized and could create liability under applicable federal or local laws. A new design Throttle Position Sensor (TPS) has been released for all 1986 EEC IV applications. The new TPS is designed to eliminate a false Self-Test Code 53. A Code 53 indicates the TPS system has failed at the wide open throttle position (approximately 5.0 volts), The new TPS eliminates false Code 53 by limiting the wide open throttle voltage to 4.75 volts. With the new TPS, Code 53 will only result from a circuit or TPS malfunction. The new Throttle Position Sensors can be used to replace faulty sensors on 1985 vehicles. If the old design service part is used, a false Code 53 may result. PART NUMBER PART NAME CLASS E6DZ-9B989-A Throttle Position Sensor C E6TZ-9B989-C Throttle Position Sensor WC E6DZ-9B989-C Throttle Position Sensor WC E6FZ-9B989-A Throttle Position Sensor B E6ZZ-9B989-A Throttle Position Sensor B E6ZZ-9B989-B Throttle Position Sensor WC E6TZ-9B989-A Throttle Position Sensor C OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Throttle Position Sensor - Request For Return > Page 2319 Throttle Position Sensor: Technical Service Bulletins Throttle Position Sensor - Application Chart EEC-IV THROTTLE POSITION SENSOR-APPLICATION CHART-SERVICE TIP Article No. 89-16-4 FORD: 1984-88 CROWN VICTORIA, ESCORT, EXP, MUSTANG, TAURUS, TEMPO, THUNDERBIRD LINCOLN-MERCURY: 1984-88 COUGAR, GRAND MARQUIS, LYNX, MARK VI, MARK VII, SABLE, TOPAZ, TOWN CAR LIGHT TRUCK: 1984-88 ALL LIGHT TRUCK LINES ISSUE: A quick reference throttle position sensor (TPS) application chart has been put together to assist technicians in correct part useage. If the wrong TPS is installed, it could fail prematurely. ACTION: Refer to one of the following TPS service replacement charts to make sure that the correct service part is installed. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Throttle Position Sensor - Request For Return > Page 2320 OASIS CODES: 680000 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Throttle Position Sensor - Request For Return > Page 2321 Throttle Position Sensor: Technical Service Bulletins TPS Mounting Screws - Hard to Remove THROTTLE POSITION SENSOR-MOUNTING SCREWS HARD TO REMOVE-SERVICE TIP Article No. 89-14-7 FORD: 1983-89 CROWN VICTORIA, MUSTANG, TEMPO, THUNDERBIRD 1984-89 ESCORT 1986-89 TAURUS LINCOLN-MERCURY: 1983-89 CONTINENTAL, COUGAR, GRAND MARQUIS, MARK VII, TOPAZ, TOWN CAR 1984-87 LYNX MERKUR: 1985-89 ALL MERKUR LINES LIGHT TRUCK: 1983-89 ALL LIGHT TRUCK LINES ISSUE: All Throttle Position Sensor (TPS) mounting screws have a "Pozidrive" head. The "Pozidrive" head looks a lot like a Phillips screw head. Use of a Phillips head screwdriver to remove a "Pozidrive" screw will normally result in a rounded or damaged screw head. Many technicians think it is an overtorqued or "frozen" screw. An adhesive was also used as a thread sealant starting with the 1988 model year. This adhesive requires still more effort to loosen and remove the screw. ACTION: To prevent rounded or damages screw heads when servicing the TPS mounting screws, technicians should always use a # 2 "Pozidrive" screwdriver. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 4800, 680000 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 2322 THROTTLE POSITION SENSOR SPECIFICATIONS Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 2323 Engine View Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 2324 Throttle Position Sensor: Description and Operation The Throttle Position (TP) Sensor (Rotary), Figure 1 supplies the ECA with a signal proportional to opening angle of carburetor throttle plates. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 2325 Throttle Position Sensor: Testing and Inspection Ford provides trouble code/symptom driven diagnostics for this component. For complete diagnosis and pinpoint testing, refer to Computers and Control Systems, Testing and Inspection. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 2326 Throttle Position Sensor: Adjustments ADJUSTMENT This procedure can be used to check and/or adjust level C sensors only: 1. Install an EEC-IV Breakout Box, Rotunda T83L-50 EEC-IV, or equivalent. 2. Attach a DVOM, Rotunda 014-00407 or equivalent, on 20V scale. Connect the positive lead (+) to test Pin 47 and the negative lead (-) to test Pin 46. 3. Turn ignition key to Run position (do not start engine). 4. Adjust TP Sensor (rotate) until the DVOM reads 1.0V (0.9-1.1). 5. Tighten TP Sensor screws to 1.2-1.8 N-m (11-16 lb-in). 6. While watching the DVOM, move the throttle to wide open and back to idle position. For proper operation, the DVOM should move from 1.0 to at least 4.0 and back to 1.0V. 7, Perform EEC-IV Quick Test. Refer to Powertrain Management/Computers and Control Systems/System Diagnosis Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Camshaft Position Sensor: Diagram Information and Instructions Symbol Identification Wire Color Code Identification Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2332 NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Crankshaft Position Sensor: Diagram Information and Instructions Symbol Identification Wire Color Code Identification Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2337 NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Description and Operation Hall Effect Sensor: Description and Operation Profile Ignition Pickup The PIP signal is created in the Hall Effect and Stator assembly and indicates crankshaft position and engine RPM Fig. 21. The PIP signal is fed to both the TFI module and the ECA. PIP Sensor COMPONENTS The Hall Effect device is made up of a voltage regulator, a Hall voltage generator, Darlington amplifier, Schmitt trigger, and an open collector output stage integrated in a single monolithic silicon chip Fig. 22. A signal is produced when a ferrous material is passed through the opening and the flux lines decrease. The Hall generator (Hall device) sends a sine wave signal to the Darlington amplifier. The Darlington amplifier inverts the signal. When the signal is low the output is high. When the signal is high the output is low. This output then goes to the Schmitt trigger. The Schmitt trigger shapes the signal into a square wave (digital high) signal. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Description and Operation > Page 2341 PIP Signal Operation OPERATION The output signal to the Darlington amplifier is high when the window (on the armature) allows the magnetic field to reach the Hall device (switch off) Fig. 23. When the TAB shunts the magnetic field (closes) away from the Hall device the signal is low to the Darlington amplifier (switch on). Hall Effect Sensor In other words when one of the windows or openings is in the gap between the Hall device and the permanent magnet, the field stays strong and the voltage is high since the magnetic path is complete from the magnet, through the Hall device, and back to the magnet. In this case the switch is off and the Hall Effect does not send a signal. When the TAB enters the gap, the armature cuts off the magnetic path to the Hall device and its voltage drops. In this case the switch is on and the Hall Effect device sends a signal. The signal is switched On and Off as long as the armature is rotating (distributor is turning) and opening and closing the magnetic path. This is the signal used by the ECA to interpret crankshaft position and engine RPM. The signal can also be used by the TFI module if the SPOUT signal from the ECA is lost. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Description and Operation > Page 2342 Signature PIP SIGNATURE PIP Some Electronic Engine Control (EEC) vehicles are equipped with a signature profile ignition pickup signal. The regular type armature used for the PIP signal has the same size tabs and windows. In a signature PIP signal armature, one of the tabs is narrower than the others Fig. 25. The narrower tab provides a different signal to the ECA when it passes through the Hall Effect switch. When the ECA sees the narrow tab it knows when to properly pulse the fuel injectors. This system is used on cars and trucks where the ECA needs to know when to pulse certain injectors. For example, on sequential electronic fuel injection (SEFI) systems, each injector is pulsed to coincide with its intake valve opening. With the signature PIP, the ECA knows when the No. 1 cylinder needs to be supplied with fuel. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Description and Operation > Page 2343 Hall Effect Sensor: Service and Repair Removal Do not attempt to replace stator without an arbor press. 1. Remove distributor. Remove rotor, then the TFI module. 2. If distributor uses push on type rotor, remove two retaining screws holding armature, then the armature. Hold gear to loosen armature screws, do not hold armature. 3. Mark stator, armature, gear and collar with felt tip pen to aid in reassembly. 4. Remove and discard pins in gear and collar if equipped. 5. Invert distributor and place in Axle Bearing Seal Plate and press off gear using Bearing Removal Tool. 6. Deburr and polish shaft with emery paper and wipe clean so that shaft slides out freely from distributor base. 7. Remove shaft assembly, then the thrust washer from shaft. Next remove octane rod. 8. Remove stator assembly screws, then the stator assembly from top of bowl. 9. Inspect base bushing for wear of signs of excess heat concentration, replace distributor assembly if damaged. 10. Inspect base O-ring for cuts or damage and replace as necessary. 11. Inspect base for cracks and wear, replace distributor assembly if damage is found. Installation 1. Place stator assembly over bushing and press down to seat. 2. Place stator connector in position, tab should fit in notch on base with fastening eyelets aligned with screw holes. 3. Install stator screws and Torque to 15-35 inch lbs. Next install octane rod. 4. Install thrust washer on top of bushing, then apply lubricant to distributor shaft below armature. Do not over lubricate. 5. Insert shaft through base bushing, then place collar, if equipped, over shaft and line up mark on armature and collar to aid alignment with original drill hole. Use a suitable drift punch to assure proper alignment. 6. Drill holes through shaft and collar should align on both sides of shaft. If holes do not align, collar may be 180 degrees out of alignment on shaft. Rotate collar on shaft one half rotation, then check. 7. Insert new roll pin through collar and shaft, pin should be flush with both sides of collar when seated. 8. If distributor uses push on type rotor, place a 1/2 inch deep well socket over shaft, invert and place on arbor plate. 9. If distributor uses screw down type rotor, invert and place on arbor plate. 10. Place distributor gear on shaft and line up marks on armature and gear. Hole in shaft and gear must line up as accurately as possible to assure ease of roll pin insertion. 11. Place a 5/8 inch deep well socket over shaft and gear, then press gear to align with original drill hole. 12. If gear holes do not align, gear must be removed and repressed on. Drift punch will not align holes, as in collar, holes should align. 13. Insert new roll pin through gear and shaft, pin should extrude evenly on both sides. 14. Install armature, if removed, and Torque screws to 25-35 inch lbs. 15. Install TFI module, rotor, then distributor. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Technical Service Bulletins > Customer Interest for Ignition Switch: > 932410 > Nov > 93 > Instrument Cluster Warning Lights - Dimly Lit Ignition Switch: Customer Interest Instrument Cluster Warning Lights - Dimly Lit Article No. 93-24-10 11/24/93 ^ LAMP - MALFUNCTION OF FOUR PIN LOW OIL LEVEL RELAY - VEHICLES BUILT AFTER 8/1/92 OR 1983-1993 VEHICLES THAT HAVE HAD SERVICE REPLACEMENT IGNITION SWITCHES AFTER 8/1/92 ^ LAMPS - INSTRUMENT CLUSTER WARNING LIGHTS DIMLY LIT - VEHICLES BUILT AFTER 8/1/92 OR 1983-1993 VEHICLES THAT HAVE HAD SERVICE REPLACEMENT IGNITION SWITCHES AFTER 8/1/92 FORD: 1983 FAIRMONT 1983-89 CROWN VICTORIA, ESCORT 1983-93 MUSTANG, THUNDERBIRD 1983-94 PROBE 1984-86 LTD 1984-94 TEMPO LINCOLN-MERCURY: 1983 LN7, ZEPHYR 1983-87 CONTINENTAL, LYNX 1983-89 GRAND MARQUIS, TOWN CAR 1983-93 COUGAR 1984-86 CAPRI, MARQUIS 1984-94 TOPAZ LIGHT TRUCK: 1983-91 BRONCO 1983-93 ECONOLINE, F-150-350 SERIES, RANGER 1986-91 AEROSTAR 1991-93 EXPLORER ISSUE: The instrument cluster warning light(s) may be dimly lit or there may be a malfunction of the four pin low oil relay on vehicles so equipped. This could be due to the ignition switch. ACTION: If the vehicle displays the subject symptoms and meets the following conditions, replace the ignition switch. Refer to the appropriate Car or Light Truck Service Manual (Section 13-04 for 1983-1990 Cars, Section 11-04 for 1991-1993 Cars and Section 13-05 for 1983-1990 Light Trucks, Section 11-05 for 1991-1993 Light Trucks) for removal and installation procedures. Refer to the Parts Block in this article for correct parts usage. CONDITIONS ^ The vehicle has 14401 wiring attached to the P2 terminal of the ignition switch. Refer to the wiring schematic and/or Electrical And Vacuum Troubleshooting Manual (EVTM) for the concern vehicle. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Technical Service Bulletins > Customer Interest for Ignition Switch: > 932410 > Nov > 93 > Instrument Cluster Warning Lights - Dimly Lit > Page 2352 ^ The vehicle is equipped with one of the ignition switches identified in the Ignition Switch Part Number Chart. NOTE: THE SERVICE PART NUMBERS FOR THE REPLACEMENT IGNITION SWITCHES WILL HAVE THE SAME PART NUMBERS AS THOSE REPLACED. THE NEW SWITCH HAS BEEN IMPROVED TO CORRECT THE SUBJECT ISSUE. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of The Bumper To Bumper For 1992/93 Models, Basic Warranty Coverage For All Other Models Except Lincolns. Major Component Warranty Coverage For Lincolns OPERATION DESCRIPTION TIME 932410A Replace Ignition Switch - 0.5 Hr. All Light and Compact Trucks DEALER CODING BASIC PART NO. CONDITION CODE 11572 X1 OASIS CODES: 201000, 201100, 206000 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch: > 932410 > Nov > 93 > Instrument Cluster Warning Lights - Dimly Lit Ignition Switch: All Technical Service Bulletins Instrument Cluster Warning Lights - Dimly Lit Article No. 93-24-10 11/24/93 ^ LAMP - MALFUNCTION OF FOUR PIN LOW OIL LEVEL RELAY - VEHICLES BUILT AFTER 8/1/92 OR 1983-1993 VEHICLES THAT HAVE HAD SERVICE REPLACEMENT IGNITION SWITCHES AFTER 8/1/92 ^ LAMPS - INSTRUMENT CLUSTER WARNING LIGHTS DIMLY LIT - VEHICLES BUILT AFTER 8/1/92 OR 1983-1993 VEHICLES THAT HAVE HAD SERVICE REPLACEMENT IGNITION SWITCHES AFTER 8/1/92 FORD: 1983 FAIRMONT 1983-89 CROWN VICTORIA, ESCORT 1983-93 MUSTANG, THUNDERBIRD 1983-94 PROBE 1984-86 LTD 1984-94 TEMPO LINCOLN-MERCURY: 1983 LN7, ZEPHYR 1983-87 CONTINENTAL, LYNX 1983-89 GRAND MARQUIS, TOWN CAR 1983-93 COUGAR 1984-86 CAPRI, MARQUIS 1984-94 TOPAZ LIGHT TRUCK: 1983-91 BRONCO 1983-93 ECONOLINE, F-150-350 SERIES, RANGER 1986-91 AEROSTAR 1991-93 EXPLORER ISSUE: The instrument cluster warning light(s) may be dimly lit or there may be a malfunction of the four pin low oil relay on vehicles so equipped. This could be due to the ignition switch. ACTION: If the vehicle displays the subject symptoms and meets the following conditions, replace the ignition switch. Refer to the appropriate Car or Light Truck Service Manual (Section 13-04 for 1983-1990 Cars, Section 11-04 for 1991-1993 Cars and Section 13-05 for 1983-1990 Light Trucks, Section 11-05 for 1991-1993 Light Trucks) for removal and installation procedures. Refer to the Parts Block in this article for correct parts usage. CONDITIONS ^ The vehicle has 14401 wiring attached to the P2 terminal of the ignition switch. Refer to the wiring schematic and/or Electrical And Vacuum Troubleshooting Manual (EVTM) for the concern vehicle. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch: > 932410 > Nov > 93 > Instrument Cluster Warning Lights - Dimly Lit > Page 2358 ^ The vehicle is equipped with one of the ignition switches identified in the Ignition Switch Part Number Chart. NOTE: THE SERVICE PART NUMBERS FOR THE REPLACEMENT IGNITION SWITCHES WILL HAVE THE SAME PART NUMBERS AS THOSE REPLACED. THE NEW SWITCH HAS BEEN IMPROVED TO CORRECT THE SUBJECT ISSUE. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of The Bumper To Bumper For 1992/93 Models, Basic Warranty Coverage For All Other Models Except Lincolns. Major Component Warranty Coverage For Lincolns OPERATION DESCRIPTION TIME 932410A Replace Ignition Switch - 0.5 Hr. All Light and Compact Trucks DEALER CODING BASIC PART NO. CONDITION CODE 11572 X1 OASIS CODES: 201000, 201100, 206000 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Technical Service Bulletins > Page 2359 Ignition Switch: Service and Repair Fig. 3 Ignition switch replacement 1. Disconnect battery ground cable. 2. Remove steering column shroud and lower the steering column. 3. Disconnect electrical connector from switch, then remove 2 switch attaching nuts. 4. Lift switch up to disengage actuator rod, then remove switch from vehicle, Fig. 3. 5. Reverse procedure to install. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Description and Operation Knock Sensor: Description and Operation The Knock Sensor, is a piezoelectric accelerometer with the sensor designed to resonate at approximately the same frequency as the engine knock frequency. The sensor uses the resonant frequency to mechanically amplify the vibrations. This method allows relatively large signals to be achieved without electrical amplification and with small package size. The sensor has a thin circular piezoelectric ceramic disk which is bonded to a metal diaphragm. Electrical connections are made through a two pin integral connector. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Description and Operation > Page 2363 Knock Sensor: Testing and Inspection Ford provides trouble code/symptom driven diagnostics for this component. For complete diagnosis and pinpoint testing, refer to Computers and Control Systems, Testing and Inspection. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Technical Service Bulletins > By Symptom Fuel Pressure: By Symptom Technical Service Bulletin # 911211 Date: 910612 Engine - Lack of Power/No Start Diagnosis Article No. 91-12-11 06/12/91 LACK OF POWER 7.5L, 5.8L, 5.0L, 4.9L - CATALYTIC CONVERTER DIAGNOSTIC TIPS LIGHT TRUCK: 1986-91 BRONCO, ECONOLINE, F-150-350 SERIES 1988-91 F SUPER DUTY, F47 ISSUE: Lack of power or a no start condition may be diagnosed as an exhaust restriction caused by a plugged catalytic converter. A plugged catalytic converter (internal deterioration) is usually caused by abnormal engine operation. ACTION: Diagnose the catalytic converter to confirm internal failure. Refer to the Catalyst and Exhaust System Diagnostic Section, in the Engine/Emissions Diagnostic Shop Manual and the following procedures for service details. 1. Lack of proper HEGO operation may cause, or be the result of a rich or lean fuel condition, which could cause additional heat in the catalyst. Perform self test KOEO and KOER, service any codes. NOTE: IF TWO DIGIT CODES 41, 42, 85 OR THREE DIGIT CODES 171, 172, 173, 179, 181, 182, 183 AND 565 ARE RECEIVED, CHECK FOR PROPER HEGO GROUND. If the HEGO ground is good, the following areas may be at fault: ^ Ignition Coil ^ Distributor Cap ^ Distributor Rotor ^ Fouled Spark Plug ^ Spark Plug Wires ^ Air Filter ^ Stuck Open Injector ^ Fuel Contamination Engine OIL ^ Manifold Leaks Intake/ Exhaust ^ Fuel Pressure ^ Poor Power Ground ^ Engine Not At Normal Operating Temperature ^ HEGO Sensor 2. Spark timing that is retarded from specification may increase exhaust gas temperature and shorten catalyst life. Refer to the following procedure for service details. a. Check spark timing. Check base timing with spout disconnected. Set base timing to the specification on the vehicle emission decal. b. Check computed timing with spout connected. NOTE: COMPUTED TIMING IS EQUAL TO BASE TIMING PLUS 20~ BTDC +/- 3~. 3. Misfiring spark plugs may cause an unburned fuel air mixture to pass through the catalyst, which could cause higher than normal catalyst Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Technical Service Bulletins > By Symptom > Page 2369 temperatures. Refer to the following procedure for service details. a. Check secondary ignition, hook the vehicle up to an engine analyzer and check for a secondary ignition misfire. NOTE: SERVICE ANY ITEM THAT IS NOT PERFORMING AT PROPER SPECIFICATIONS BEFORE CONTINUING. 4. Fuel pressure that is too high may cause rich air fuel mixtures to pass through the catalyst which could cause higher than normal catalyst temperatures. Refer to the following procedure for service details. a. Check fuel pressure, install fuel pressure gauge, start and run the engine at idle. Fuel pressures between 28 and 34 PSI are typical (4.9L typically is 15 PSI higher). b. Disconnect the vacuum line going to the fuel pressure regulator. Fuel pressure typically jumps to 40 PSI +/- 3 PSI (4.9L typically is 15 PSI higher). Visually inspect vacuum line for raw fuel. NOTE: FUEL PRESSURES ABOVE THESE VALUES SHOULD BE CORRECTED. HOWEVER, THIS MAY NOT BE THE CAUSE OF THE CONCERN. SERVICE AS NECESSARY. 5. Throttle plates in the throttle body not returning to the proper closed position may cause excessive catalyst temperatures during downhill grades. Refer to the following procedure for service details. a. Visually inspect the throttle body and linkage for: ^ Binding or sticking throttle linkage. ^ Tight speed control linkage or cable. ^ Vacuum line interference. ^ Electrical harness interference. NOTE: AFTERMARKET GOVERNORS, THROTTLE LINKAGE AND CABLES ASSOCIATED WITH POWER TAKE-OFF UNITS, MAY ALSO INTERFERE WITH PROPER THROTTLE RETURN. SERVICE AS NECESSARY. 6. It is extremely important that all systems related to the engine and emission systems operate properly. a. Visually inspect the engine compartment to make sure all vacuum hoses and spark plug wires are properly routed and securely connected. b. Inspect all wiring harnesses and connectors for insulation damage, burned, overheated, loose or broken conditions. c. Verify proper operation of the thermactor system. Thermactor systems that fail to dump thermactor air to the atmosphere properly or at the correct time can cause high catalyst temperatures. d. Visually inspect thermactor system for damaged or kinked hoses and perform a function test on following components: air control valve, check valve, silencer, filter and the air bypass solenoid. e. Verify proper operation of the engine cooling system thermostat. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under Basic Warranty Coverage, Emissions Warranty Coverage OPERATION DESCRIPTION TIME 911211A Diagnostics - Perform 0.5 Hrs. KOEO And KOER Self Tests 911211B Timing - Check Or Adjust 0.5 Hrs. Spark Timing, Check Computed Timing And Check Secondary Ignition System With Engine Analyzer. 911211C Check - Fuel Pressure And 0.2 Hrs. Inspect Vacuum Line For Raw Fuel. 911211D Inspect - Throttle Body And 0.1 Hrs. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Technical Service Bulletins > By Symptom > Page 2370 Linkage. 911211E Inspect - Vacuum Hoses, 0.1 Hrs. Electrical Harnesses, Connectors And Spark Plug Wires For Routing Damage. 911211F Thermactor System - 0.3 Hrs. Inspect For Proper Operation And Damaged Component. Includes Function Check Of Air Control Valve, Thermactor Air Bypass Solenoid, Check Valves, Silencer And Filter. 911211G Thermostat - Check For 0.2 Hrs. Proper Operation. DEALER CODING BASIC PART NO. CONDITION CODE 5E212 25 OASIS CODES: 403000, 603300, 614000 Technical Service Bulletin # 911211 Date: 910612 Engine - Lack of Power/No Start Diagnosis Article No. 91-12-11 06/12/91 LACK OF POWER 7.5L, 5.8L, 5.0L, 4.9L - CATALYTIC CONVERTER DIAGNOSTIC TIPS LIGHT TRUCK: 1986-91 BRONCO, ECONOLINE, F-150-350 SERIES 1988-91 F SUPER DUTY, F47 ISSUE: Lack of power or a no start condition may be diagnosed as an exhaust restriction caused by a plugged catalytic converter. A plugged catalytic converter (internal deterioration) is usually caused by abnormal engine operation. ACTION: Diagnose the catalytic converter to confirm internal failure. Refer to the Catalyst and Exhaust System Diagnostic Section, in the Engine/Emissions Diagnostic Shop Manual and the following procedures for service details. 1. Lack of proper HEGO operation may cause, or be the result of a rich or lean fuel condition, which could cause additional heat in the catalyst. Perform self test KOEO and KOER, service any codes. NOTE: IF TWO DIGIT CODES 41, 42, 85 OR THREE DIGIT CODES 171, 172, 173, 179, 181, 182, 183 AND 565 ARE RECEIVED, CHECK FOR PROPER HEGO GROUND. If the HEGO ground is good, the following areas may be at fault: ^ Ignition Coil ^ Distributor Cap ^ Distributor Rotor ^ Fouled Spark Plug ^ Spark Plug Wires ^ Air Filter ^ Stuck Open Injector ^ Fuel Contamination Engine OIL ^ Manifold Leaks Intake/ Exhaust Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Technical Service Bulletins > By Symptom > Page 2371 ^ Fuel Pressure ^ Poor Power Ground ^ Engine Not At Normal Operating Temperature ^ HEGO Sensor 2. Spark timing that is retarded from specification may increase exhaust gas temperature and shorten catalyst life. Refer to the following procedure for service details. a. Check spark timing. Check base timing with spout disconnected. Set base timing to the specification on the vehicle emission decal. b. Check computed timing with spout connected. NOTE: COMPUTED TIMING IS EQUAL TO BASE TIMING PLUS 20~ BTDC +/- 3~. 3. Misfiring spark plugs may cause an unburned fuel air mixture to pass through the catalyst, which could cause higher than normal catalyst temperatures. Refer to the following procedure for service details. a. Check secondary ignition, hook the vehicle up to an engine analyzer and check for a secondary ignition misfire. NOTE: SERVICE ANY ITEM THAT IS NOT PERFORMING AT PROPER SPECIFICATIONS BEFORE CONTINUING. 4. Fuel pressure that is too high may cause rich air fuel mixtures to pass through the catalyst which could cause higher than normal catalyst temperatures. Refer to the following procedure for service details. a. Check fuel pressure, install fuel pressure gauge, start and run the engine at idle. Fuel pressures between 28 and 34 PSI are typical (4.9L typically is 15 PSI higher). b. Disconnect the vacuum line going to the fuel pressure regulator. Fuel pressure typically jumps to 40 PSI +/- 3 PSI (4.9L typically is 15 PSI higher). Visually inspect vacuum line for raw fuel. NOTE: FUEL PRESSURES ABOVE THESE VALUES SHOULD BE CORRECTED. HOWEVER, THIS MAY NOT BE THE CAUSE OF THE CONCERN. SERVICE AS NECESSARY. 5. Throttle plates in the throttle body not returning to the proper closed position may cause excessive catalyst temperatures during downhill grades. Refer to the following procedure for service details. a. Visually inspect the throttle body and linkage for: ^ Binding or sticking throttle linkage. ^ Tight speed control linkage or cable. ^ Vacuum line interference. ^ Electrical harness interference. NOTE: AFTERMARKET GOVERNORS, THROTTLE LINKAGE AND CABLES ASSOCIATED WITH POWER TAKE-OFF UNITS, MAY ALSO INTERFERE WITH PROPER THROTTLE RETURN. SERVICE AS NECESSARY. 6. It is extremely important that all systems related to the engine and emission systems operate properly. a. Visually inspect the engine compartment to make sure all vacuum hoses and spark plug wires are properly routed and securely connected. b. Inspect all wiring harnesses and connectors for insulation damage, burned, overheated, loose or broken conditions. c. Verify proper operation of the thermactor system. Thermactor systems that fail to dump thermactor air to the atmosphere properly or at the correct time can cause high catalyst temperatures. d. Visually inspect thermactor system for damaged or kinked hoses and perform a function test on following components: air control valve, check valve, silencer, filter and the air bypass solenoid. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Technical Service Bulletins > By Symptom > Page 2372 e. Verify proper operation of the engine cooling system thermostat. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under Basic Warranty Coverage, Emissions Warranty Coverage OPERATION DESCRIPTION TIME 911211A Diagnostics - Perform 0.5 Hrs. KOEO And KOER Self Tests 911211B Timing - Check Or Adjust 0.5 Hrs. Spark Timing, Check Computed Timing And Check Secondary Ignition System With Engine Analyzer. 911211C Check - Fuel Pressure And 0.2 Hrs. Inspect Vacuum Line For Raw Fuel. 911211D Inspect - Throttle Body And 0.1 Hrs. Linkage. 911211E Inspect - Vacuum Hoses, 0.1 Hrs. Electrical Harnesses, Connectors And Spark Plug Wires For Routing Damage. 911211F Thermactor System - 0.3 Hrs. Inspect For Proper Operation And Damaged Component. Includes Function Check Of Air Control Valve, Thermactor Air Bypass Solenoid, Check Valves, Silencer And Filter. 911211G Thermostat - Check For 0.2 Hrs. Proper Operation. DEALER CODING BASIC PART NO. CONDITION CODE 5E212 25 OASIS CODES: 403000, 603300, 614000 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Pressure: > 911211 > Jun > 91 > Engine - Lack of Power/No Start Diagnosis Fuel Pressure: All Technical Service Bulletins Engine - Lack of Power/No Start Diagnosis Article No. 91-12-11 06/12/91 LACK OF POWER 7.5L, 5.8L, 5.0L, 4.9L - CATALYTIC CONVERTER DIAGNOSTIC TIPS LIGHT TRUCK: 1986-91 BRONCO, ECONOLINE, F-150-350 SERIES 1988-91 F SUPER DUTY, F47 ISSUE: Lack of power or a no start condition may be diagnosed as an exhaust restriction caused by a plugged catalytic converter. A plugged catalytic converter (internal deterioration) is usually caused by abnormal engine operation. ACTION: Diagnose the catalytic converter to confirm internal failure. Refer to the Catalyst and Exhaust System Diagnostic Section, in the Engine/Emissions Diagnostic Shop Manual and the following procedures for service details. 1. Lack of proper HEGO operation may cause, or be the result of a rich or lean fuel condition, which could cause additional heat in the catalyst. Perform self test KOEO and KOER, service any codes. NOTE: IF TWO DIGIT CODES 41, 42, 85 OR THREE DIGIT CODES 171, 172, 173, 179, 181, 182, 183 AND 565 ARE RECEIVED, CHECK FOR PROPER HEGO GROUND. If the HEGO ground is good, the following areas may be at fault: ^ Ignition Coil ^ Distributor Cap ^ Distributor Rotor ^ Fouled Spark Plug ^ Spark Plug Wires ^ Air Filter ^ Stuck Open Injector ^ Fuel Contamination Engine OIL ^ Manifold Leaks Intake/ Exhaust ^ Fuel Pressure ^ Poor Power Ground ^ Engine Not At Normal Operating Temperature ^ HEGO Sensor 2. Spark timing that is retarded from specification may increase exhaust gas temperature and shorten catalyst life. Refer to the following procedure for service details. a. Check spark timing. Check base timing with spout disconnected. Set base timing to the specification on the vehicle emission decal. b. Check computed timing with spout connected. NOTE: COMPUTED TIMING IS EQUAL TO BASE TIMING PLUS 20~ BTDC +/- 3~. 3. Misfiring spark plugs may cause an unburned fuel air mixture to pass through the catalyst, which could cause higher than normal catalyst temperatures. Refer to the following procedure for service details. a. Check secondary ignition, hook the vehicle up to an engine analyzer and check for a secondary ignition misfire. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Pressure: > 911211 > Jun > 91 > Engine - Lack of Power/No Start Diagnosis > Page 2378 NOTE: SERVICE ANY ITEM THAT IS NOT PERFORMING AT PROPER SPECIFICATIONS BEFORE CONTINUING. 4. Fuel pressure that is too high may cause rich air fuel mixtures to pass through the catalyst which could cause higher than normal catalyst temperatures. Refer to the following procedure for service details. a. Check fuel pressure, install fuel pressure gauge, start and run the engine at idle. Fuel pressures between 28 and 34 PSI are typical (4.9L typically is 15 PSI higher). b. Disconnect the vacuum line going to the fuel pressure regulator. Fuel pressure typically jumps to 40 PSI +/- 3 PSI (4.9L typically is 15 PSI higher). Visually inspect vacuum line for raw fuel. NOTE: FUEL PRESSURES ABOVE THESE VALUES SHOULD BE CORRECTED. HOWEVER, THIS MAY NOT BE THE CAUSE OF THE CONCERN. SERVICE AS NECESSARY. 5. Throttle plates in the throttle body not returning to the proper closed position may cause excessive catalyst temperatures during downhill grades. Refer to the following procedure for service details. a. Visually inspect the throttle body and linkage for: ^ Binding or sticking throttle linkage. ^ Tight speed control linkage or cable. ^ Vacuum line interference. ^ Electrical harness interference. NOTE: AFTERMARKET GOVERNORS, THROTTLE LINKAGE AND CABLES ASSOCIATED WITH POWER TAKE-OFF UNITS, MAY ALSO INTERFERE WITH PROPER THROTTLE RETURN. SERVICE AS NECESSARY. 6. It is extremely important that all systems related to the engine and emission systems operate properly. a. Visually inspect the engine compartment to make sure all vacuum hoses and spark plug wires are properly routed and securely connected. b. Inspect all wiring harnesses and connectors for insulation damage, burned, overheated, loose or broken conditions. c. Verify proper operation of the thermactor system. Thermactor systems that fail to dump thermactor air to the atmosphere properly or at the correct time can cause high catalyst temperatures. d. Visually inspect thermactor system for damaged or kinked hoses and perform a function test on following components: air control valve, check valve, silencer, filter and the air bypass solenoid. e. Verify proper operation of the engine cooling system thermostat. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under Basic Warranty Coverage, Emissions Warranty Coverage OPERATION DESCRIPTION TIME 911211A Diagnostics - Perform 0.5 Hrs. KOEO And KOER Self Tests 911211B Timing - Check Or Adjust 0.5 Hrs. Spark Timing, Check Computed Timing And Check Secondary Ignition System With Engine Analyzer. 911211C Check - Fuel Pressure And 0.2 Hrs. Inspect Vacuum Line For Raw Fuel. 911211D Inspect - Throttle Body And 0.1 Hrs. Linkage. 911211E Inspect - Vacuum Hoses, 0.1 Hrs. Electrical Harnesses, Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Pressure: > 911211 > Jun > 91 > Engine - Lack of Power/No Start Diagnosis > Page 2379 Connectors And Spark Plug Wires For Routing Damage. 911211F Thermactor System - 0.3 Hrs. Inspect For Proper Operation And Damaged Component. Includes Function Check Of Air Control Valve, Thermactor Air Bypass Solenoid, Check Valves, Silencer And Filter. 911211G Thermostat - Check For 0.2 Hrs. Proper Operation. DEALER CODING BASIC PART NO. CONDITION CODE 5E212 25 OASIS CODES: 403000, 603300, 614000 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Technical Service Bulletins > Page 2380 Fuel Pressure: Specifications FUEL PRESSURE Pump Pressure .................................................................................................................................... ...................................................................... 6 - 8 psi Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Test Fuel Pressure: Testing and Inspection Fuel Pressure Test NOTE: Perform Fuel System Capacity Test prior to performing Pressure Test. See: Fuel System Capacity Test PRESSURE TEST 1. Connect a suitable pressure gauge (0-15 PSI) to the carburetor end of the fuel line. WARNING: Use care to prevent combustion of spilled fuel. 2. Start the engine (it should be able to run for over 30 seconds on the fuel in the carburetor bowl) and read the pressure after 10 seconds. If pump pressure is too low or too high install a new fuel pump. Fuel Pump Pressure ............................................................................................................................ ................................................. 6.0-8.0 PSI 3. Reconnect fuel line at filter and install air cleaner. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Test > Page 2383 Fuel Pressure: Testing and Inspection Fuel System Capacity Test FUEL CAPACITY (VOLUME) TEST - Remove the carburetor air cleaner. - Slowly (fuel line is pressurized) disconnect the fuel line at the fuel filter. WARNING: Use care to prevent combustion of spilled fuel. - Place a suitable non-breakable container (1/2 liter or 1 pint minimum) at the end of the disconnected fuel line (a piece of hose may be needed on the fuel line end). - Disconnect high tension wire from coil. - Crank engine 10 seconds, the fuel pump should deliver 0.158 liters (1/3 pint) of fuel or more. - If fuel flow is to specification perform pressure test. See: Fuel Pressure Test - If fuel flow is low repeat procedure using a non-breakable container of gasoline connected to the fuel pump inlet. If fuel pressure is to specification, the problem is either a plugged in-tank filter, or a kinked or leaking fuel pump inlet hose. - If fuel flow is still below specification, replace fuel pump. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air/Fuel Mixture > System Information > Technical Service Bulletins > Idle Fuel Mixture - Manual Revision Technical Service Bulletin # 8912A26 Date: 890627 Idle Fuel Mixture - Manual Revision ENGINE EMISSIONS DIAGNOSIS SHOP MANUAL- 1986-SECTION 4-IDLE FUEL MIXTURE-PROPANE ENRICHMENT METHOD ENGINE EMISSIONS DIAGNOSIS SHOP MANUAL- 1987-SECTION 4-IDLE FUEL MIXTURE-PROPANE ENRICHMENT METHOD Article No. 89-12A-26 FORD: 1986 ESCORT, LTD, MUSTANG 1986-87 TEMPO 1986 THUNDERBIRD LINCOLN-MERCURY: 1986 CAPRI, COUGAR, MARQUIS 1986-87 TOPAZ LIGHT TRUCK: 1986 AEROSTAR 1986-87 BRONCO, ECONOLINE, F-150, F-250, F-350, RANGER ISSUE: The tachometer reference "or equivalent" as shown in procedure I.-B in both 1986 and 1987 Engine Emissions Diagnosis Manuals is incorrect. This also applies to procedure I.-H in the 1986 Engine Emissions Diagnosis Manual. ACTION: Refer to the pages following this TSB article for the revised Volume H pages which show the correct tachometer designation as: "Connect an analog tachometer, Rotunda 059-000010 or an equivalent analog tachometer." This information should be inserted in your 1986 Engine Emissions Diagnosis Manual, pages 4-83, 4-87, 4-90, 4-93 and the 1987 Manual, pages 4-66 and 4-69. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 680000 Pages 4-83, 4-84 1986 Carburetors, Fuel Charging Assemblies and Throttle Bodies 4-83 Idle Mixture Setting Procedures IDLE FUEL MIXTURE-PROPANE ENRICHMENT METHOD Passenger Car. 1.9L w/740-2V, 2.3L OHC w/YFA-IV FB, 2.3L HSC w/1949-IV, 3.8L w/2150-A-2V and 5.0L w/4180C-4V. Truck, Under 8500 GVW: 5.8L w/4180C-4V. NOTE: This procedure is applicable to the above engines only. If CO and HC are not within specification, perform appropriate electrical diagnostic procedure in Section 15. I. Vehicle Preparation: All Carburetors as noted above. A. Apply the parking brake, and block the wheels. Disconnect the automatic brake release, if so equipped, and plug the vacuum connection. B. Connect an analog tachometer, Rotunda 059-000010 or an equivalent analog tachometer. C. If so equipped, insure that the hot idle compensator is in a closed position and remains so throughout the test. Idle vehicle on kickdown step of fast idle cam for three to five minutes to insure that HIC valve is closed. D. If so equipped, disconnect the fuel evaporative purge hose at the engine or the carburetor, (1.9L engines) and plug the connection. (Not applicable to 5.0L and 5.8L Truck and 5.0L Passenger Car engines). E. If so equipped, disconnect the fuel evaporative purge hose at the air cleaner and plug the nipple. (Not applicable to 5.0L and 5.8L Truck and 5.0L Passenger car engines). F. Disconnect the flexible fresh air tube from the air cleaner duct or adaptor. Using propane enrichment Tool T75L-9600-A or equivalent, insert the tool hose approximately 3/4 of the way into the duct or fresh air tube. If necessary, secure the hose with tape. G. For vehicles equipped with thermactor systems, revise the dump valve vacuum hoses as follows: (Not applicable to 1.9L engines). 1. For dump valves with two vacuum fittings, disconnect and plug the hose(s). Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air/Fuel Mixture > System Information > Technical Service Bulletins > Idle Fuel Mixture - Manual Revision > Page 2388 2. For dump valves with one fitting or combination air bypass/air control valve, remove the hose at the dump valve and plug it. Connect a slave hose from the dump valve vacuum fitting to an intake manifold vacuum fitting. (Not applicable to 5.0L and 5.8L Truck engines with 2150A-2VFB). 3. For 2.3L OHC engines: a. Equipped with a dump valve with two vacuum fittings: Disconnect and plug the hoses. b. Equipped with a combination dump valve and air diverter valve: Disconnect and plug the hoses (2-port) from the dump valve portion. c. Equipped with feedback carburetor: Disconnect electric lead wire from electric PVS. 4. On 3.8L engine Canadian 2150A-2V applications, do not make any thermactor system modifications. 5. For 5.8L 4180C-4V Truck Disconnect and Plug Vacuum Hose to Dump Valve. 1986 4-84 Carburetors, Fuel Charging Assemblies and Throttle Bodies Idle Mixture Setting Procedures H. For 1.9L ATX/MTX vehicles equipped with (Mechanical Vacuum) Idle Speed Control (ISC): 1. With engine off: a. Disconnect and plug the vacuum hose at the MVISC. b. Connect an alternate vacuum source (hand vacuum pump) capable of maintaining 22 inches Hg. to the ISC diaphragm on carburetor, and apply vacuum (retracting ISC plunger clear of throttle linkage). 2. With engine running and transmission in Drive (ATX) or Neutral (MTX): ^ Idle speed should be equal to the ISC retracted speed specified on the emission decal, if not readjust throttle stop adjustment screw under choke housing to specification, (fan On, A/C Off). I. When the above Steps have been completed, proceed to Section II. II. Propane Enrichment Method (Except as Noted) NOTE: Leave all vacuum signal hoses attached to the air cleaner assembly when relocating the assembly to perform carburetor adjustments. The air cleaner assembly must be in place however, when measuring engine speeds. CAUTION: Prolonged engine idling can result in catalyst overheating and excessive underbody temperatures. A. Verify that the timing is set to specification; reset if necessary, Section 15. B. Check engine curb idle rpm or A/C-off rpm, and, if necessary, reset to specification, Section 4. NOTE: Even If the vehicle has less than 160.9 km (100 miles) of operation, set the speed to the normal engine specification. NOTE: Remove PCV valve from grommet, and allow PCV valve to draw underhood air during idle fuel mixture check. (PCV should remain in vertical position). NOTE: Escort/Lynx, has an in-line fixed orifice crankcase vent, not a conventional PCV valve. The fixed orifice is located in the crankcase vent hose located between the vacuum fitting on the intake manifold and the plastic fitting attached to the air cleaner tray. Locate the crankcase vent hose and disconnect at the air cleaner end, allowing the hose to vent to underhood air during idle fuel/air mixture check. C. With the transmission in Neutral, run the engine at approximately 2500 rpm for 15 seconds before each mixture check. NOTE: On Escort/Lynx and Tempo/Topaz, run engine until electric fan comes On. Pages 4-87 Thru 4-90 1986 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air/Fuel Mixture > System Information > Technical Service Bulletins > Idle Fuel Mixture - Manual Revision > Page 2389 Carburetors, Fuel Charging Assemblies and Throttle Bodies 4-87 Idle Mixture Setting Procedures IDLE FUEL MIXTURE-PROPANE ENRICHMENT METHOD 2.0L TRUCK UNDER 8600 GVW w/YFA-IV NOTE: This procedure is for 2.0L Truck engines only, it is not for trucks over 8500 GVW. Propane specifications are not listed for these applications. If CO and HC are not within specification, perform appropriate electrical diagnostic procedure, Section 15. I. Vehicle Preparation A. Apply the parking brake and block the wheels. B. Connect an analog tachometer, Rotunda 059-000010 or an equivalent analog tachometer. C. Disconnect the flexible fresh air tube from the air cleaner duct or adaptor. Using propane enrichment Tool T75L-9600-A or equivalent, insert the tool hose approximately 3/4 of the way into the duct or fresh air tube. If necessary, secure the hose with tape. D. Disconnect and plug the hose at the air bypass valve. E. Disconnect and plug the hose between the purge valve and the spacer at the purge valve. F. When the above Steps have been completed, proceed to Section II. II. Propane Enrichment Method (Except as Noted) NOTE: Leave all vacuum signal hoses attached to the air cleaner assembly when relocating the assembly to perform carburetor adjustments. The air cleaner assembly must be in place, however, when measuring engine speeds. CAUTION: Prolonged engine idling can result in catalyst overheating and excessive underbody temperatures. A. Verify engine timing is set to specification - reset if necessary, Section 15. B. Verify that the curb idle speed is being controlled to specification. Then, electrically disconnect idle speed control (ISC) motor from wiring harness. C. Place A/C-heat selector in the Off position and verify that lamps are Off. NOTE: Remove PCV valve from grommet, locate the crankcase closure hose and disconnect at the air cleaner end (allowing the PCV valve and closure hose to vent to underhood air during idle fuel mixture check). D. With the transmission in Neutral, run the engine at approximately 2500 rpm for 15 seconds before each mixture check. If check is not completed within 60 seconds, repeat this cleanout Step. 1986 4-88 Carburetors, Fuel Charging Assemblies and Throttle Bodies Idle Mixture Setting Procedures E. With the engine idling at normal operating temperature gradually open the propane tool valve and watch for engine speed gain, on the tachometer. When the engine speed reaches a maximum and then begins to drop off, note the amount of speed gain. (Propane cartridge must be in vertical position). NOTE: If the engine speed will not drop off check the propane cartridge gas supply. If necessary repeat Steps D & E with a new propane cartridge gas supply. F. Compare measured speed gain to specified speed gain.* 1. If the measured speed gain is within specification, proceed to Step H. NOTE: The carburetor assembly is equipped with a tamper-resistant idle adjustment feature, the carburetor must be removed from the vehicle. Refer to Shop Manual, Group 24 for removal of the above feature. NOTE: If it is determined that idle fuel mixture adjustment will be necessary, adjust the mixture according to the reset rpm specification. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air/Fuel Mixture > System Information > Technical Service Bulletins > Idle Fuel Mixture - Manual Revision > Page 2390 2. If the measured speed gain is higher than the speed gain specification:* Turn the mixture screw counterclockwise (rich) and simultaneously repeat Steps D and E until the measured speed rise meets the reset rpm specification.* After final adjustment, proceed to Step G. 3. If the measured speed gain is lower than the speed gain specification:* Turn the mixture screw clockwise (lean) and simultaneously repeat Steps D and E until the measured speed rise meets the reset rpm specification.* After final adjustment, proceed to Step G. 4. If there is no rpm rise and the minimum speed gain specification is "0" rpm, perform the following speed drop test: NOTE: Speed drop test information is specified with the artificial enrichment requirements whenever the minimum speed gain specification is "0" rpm. * a. While watching the tachometer, adjust the mixture screw 1/4 turn clockwise (lean). Note the drop in engine speed. b. If the measured speed drop is greater "0" and less than or equal to 30 rpm, proceed to Step G. c. If the measured speed drop is more than 30 rpm, return the mixture screw to the position before adjustment. Proceed to Step G. d. If the measured speed drop is still "0" rpm repeat steps a, b, and c. G. The carburetor fuel air adjustment must have the tamper-resistant feature reinstalled, see Section III. *Refer to the Special Specifications Issue TSB Publications. 1986 Carburetors, Fuel Charging Assemblies and Throttle Bodies 4-89 Idle Mixture Setting Procedures H. Reinstall PCV valve in grommet. Reconnect air bypass valve, purge valve and crankcase closure hose. Reconnect ISC motor to wiring harness. I. Remove all test equipment. Reconnect all system components, reinstall air cleaner, and tighten the air cleaner wing nut(s) to specification. III. Removal and Installation for Tamper-Resistant Fuel Air Adjustment Feature: A. See appropriate carburetor disassembly instructions in Shop Manual, Group 24. 1986 4-90 Carburetors, Fuel Charging Assemblies and Throttle Bodies Idle Mixture Setting Procedures IDLE FUEL MIXTURE-PROPANE ENRICHMENT METHOD 2.8L AEROSTAR w/2150A FB NOTE: This procedure is for the 2.8L engine only. It is not for trucks over 8500 GVW. I. Vehicle Preparation A. Apply the parking brake and block the wheels. B. Verify that timing is set to specification. C. Remove the air cleaner assembly. D. Disconnect wiring harness from carburetor feedback solenoid, located in the rear of carburetor. E. Remove the PCV valve from the rocker cover grommet and move away from the crankcase vapors. F. Disconnect the fuel evaporating purge line (from the intake manifold spacer at the purge solenoid). Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air/Fuel Mixture > System Information > Technical Service Bulletins > Idle Fuel Mixture - Manual Revision > Page 2391 G. Install purge line tester (Tool T84T-9600-A) into the end of purge line that is still connected to the intake manifold spacer. H. Disconnect ISC motor from wiring harness as follows: Simultaneously: 1. Connect tachometer, Rotunda Model 059-00001, 099-00001 or equivalent. 2. Start engine. 3. Manually hold throttle above 1000 rpm. 4. Push ISC plunger until it retracts fully. 5. After plunger retracts, release throttle and quickly unplug the connection. NOTE: Before proceeding, verify that the throttle lever is resting on the speed screw and that the engine idles at specification for anti-dieseling rpm (750 rpm in neutral). I. Install air cleaner assembly, but do not connect the flexible fresh air tube to the air cleaner duct and valve assembly. Using a propane enrichment Tool T75L-9600-A or equivalent, insert the tool hose approximately 3/4 of the way into the duct and valve assembly. If necessary, secure the hose with tape. J. When the above Steps have been completed, proceed to Section II. Pages 4-93 & 4-94 1986 Carburetors, Fuel Charging Assemblies and Throttle Bodies 4-93 Idle Mixture Setting Procedures IDLE FUEL MIXTURE-PROPANE ENRICHMENT METHOD 4.9L TRUCK UNDER 8500 GVW w/YFA-IV FB NOTE: This procedure is for the 4.9L engine only. It is not for trucks over 8600 GVW. Propane specifications are not listed for these applications. If CO and HC are not within specification, perform appropriate electrical diagnostic procedure, Section 15. I. Vehicle Preparation A. Apply the parking brake and block the wheels. Disconnect the automatic brake release (if so equipped), and plug the vacuum connection. B. Connect an analog tachometer, Rotunda 059-000010 or an equivalent analog tachometer. C. Disconnect the flexible fresh air tube from the air cleaner duct or adapter. Using propane enrichment Tool T75L-9600-A or equivalent, insert the tool hose approximately 3/4 of the way into the duct or fresh air tube. If necessary, secure the hose with tape. D. When the above Steps have been completed, proceed to Section II. II. Propane Enrichment Method (Except as Noted) NOTE: Leave all vacuum signal hoses attached to the air cleaner assembly when relocating the assembly to perform carburetor adjustments. The air cleaner assembly must be in place, however, when measuring engine speeds. CAUTION: Prolonged engine idling can result in catalyst overheating and excessive underbody temperatures. A. Verify engine timing is set to specification-reset if necessary, Section 15. B. Place A/C-heat selector in the Off position and verify that all accessories (lamps, defrost, etc.) are Off. 1986 4-94 Carburetors, Fuel Charging Assemblies and Throttle Bodies Idle Mixture Setting Procedures Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air/Fuel Mixture > System Information > Technical Service Bulletins > Idle Fuel Mixture - Manual Revision > Page 2392 Figure 1 - In-Line Base Timing Connector NOTE: Remove PCV valve from grommet locate the crankcase closure hose and disconnect at the air cleaner end (allowing the PCV valve and closure hose to vent to underhood air during idle fuel mixture check). C. Verify that the idle speed control motor and the single wire connector near the distributor (sometimes called the In-Line Base timing connector, Figure 1) are connected electrically. With the transmission in Neutral, run the engine at approximately 2500 rpm for 15 seconds before each mixture check. If check is not completed within 60 seconds, repeat this cleanout Step. D. Return engine to idle and disconnect idle speed control motor from wiring harness. Disconnect single wire connector near the distributor (Fig. 1). With the engine idling at normal operating temperature, place the transmission selector in the position specified for the idle fuel mixture check. Gradually open the propane tool valve and watch for engine speed gain, on the tachometer. When the engine speed reaches a maximum and then begins to drop off, note the amount of speed gain. (Propane cartridge must be in vertical position). NOTE: If the engine speed will not drop off check the propane cartridge gas supply. If necessary repeat Steps C and D with a new propane cartridge gas supply. E. Compare measured speed gain to specified speed gain.* 1. If the measured speed gain is within specification, proceed to Step G. NOTE: The carburetor assembly is equipped with a tamper-resistant idle adjustment feature, the carburetor must be removed from the vehicle. Refer to Group 24, Powertrain Shop manual for removal of the above feature. NOTE: If it is determined that idle fuel mixture adjustment will be necessary, adjust the mixture according to the reset rpm specification. 2. If the measured speed gain is higher than the speed gain specification:* Turn the mixture screw counterclockwise (rich) and simultaneously repeat Steps C and D until the measured speed rise meets the reset rpm specification,* After final adjustment, proceed to Step F. 3. If the measured speed gain is lower than the speed gain specification:* Turn the mixture screw clockwise (lean) and simultaneously repeat Steps C and D until the measured speed rise meets the reset rpm specification.* After final adjustment, proceed to Step F. F. The carburetor fuel air adjustment must have the tamper-resistant feature reinstalled. Refer to appropriate carburetor assembly instructions in Shop Manual, Group 24. G. Reinstall PCV valve in grommet. Reconnect idle speed control motor and crankcase closure system, and the single wire connector near the distributor. H. Remove all test equipment. Reconnect all system components, reinstall air cleaner, and tighten the air cleaner wing nut(s) to specification, *Specified speed gain is 10 to 70 rpm, specified reset is 30 rpm. Pages 4-65 & 4-66 1987 Carburetors, Fuel Charging Assemblies and Throttle Bodies 4-65 Idle Mixture Setting Procedures Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air/Fuel Mixture > System Information > Technical Service Bulletins > Idle Fuel Mixture - Manual Revision > Page 2393 IDLE FUEL MIXTURE-PROPANE ENRICHMENT METHOD Propane Enrichment Procedures Are Not Applicable For The Following: ^ CFI Applications. ^ EFI Applications. ^ Truck Over 8500 GVW Applications. ^ 5.8L MCU Police and Trailer Tow Vehicles w/7200 Carburetors. 1987 4-66 Carburetors, Fuel Charging Assemblies and Throttle Bodies Idle Mixture Setting Procedures IDLE FUEL MIXTURE-PROPANE ENRICHMENT METHOD Passenger Car. 2.3L HSC w/1949-IV Truck, Under 8500 GVW: 5.8L w/418OC-4V. NOTE: This procedure is applicable to the above engines only. If CO and HC are not within specificatlon, perform appropriate electrical diagnostic procedure in Section 15. I. Vehicle Preparation: All Carburetors as noted above. A. Apply the parking brake, and block the wheels, Disconnect the automatic brake release, If so equipped, and plug the vacuum connection. B. Connect an analog tachometer, Rotunda 059-000010 or equivalent analog tachometer. C. If so equipped, ensure that the hot idle compensator is in a closed position and remains so throughout the test. Idle vehicle on kickdown step of fast idle cam for three to five minutes to ensure that HIC valve is closed. D. If so equipped, disconnect the fuel evaporative purge hose at the engine or the carburetor, (1.9L engines) and plug the connection. (Not applicable to 5.8L Truck engines). E. If so equipped, disconnect the fuel evaporative purge hose at the air cleaner and plug the nipple. (Not applicable 5.8L Truck engines.) F. Disconnect the flexible fresh air tube from the air cleaner duct or adaptor. Using propane enrichment Tool T75L-9600-A or equivalent, insert the tool hose approximately 3/4 of the way into the duct or fresh air tube. If necessary, secure the hose with tape. G. For vehicles equipped with Thermactor systems, revise the dump valve vacuum hoses as follows: 1. For dump valves with two vacuum fittings, disconnect and plug the hose(s). 2. For dump valves with one fitting or combination air bypass/air control valve, remove the hose at the dump valve and plug it. Connect a slave hose from the dump valve vacuum fitting to an intake manifold vacuum fitting. (Not applicable to 5.0L and 5.8L Truck engines with 2150A-2VFB). 3. For 5.8L 4180C-4V Truck Disconnect and Plug Vacuum Hose to Dump Valve. H. When the above Steps have been completed, proceed to Section II. Pages 4-69 & 4-70 1987 Carburetors, Fuel Charging Assemblies and Throttle Bodies 4-69 Idle Mixture Setting Procedures IDLE FUEL MIXTURE-PROPANE ENRICHMENT METHOD 2.0L TRUCK UNDER 8500 GVW w/Aisan Carburetor NOTE: This procedure is for 2.0L Truck engines only, it is not for trucks over 8500 GVW. Propane specifications are not listed for these applications. If CO and HC are not within specification, perform appropriate electrical diagnostic procedure, Section 15. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air/Fuel Mixture > System Information > Technical Service Bulletins > Idle Fuel Mixture - Manual Revision > Page 2394 I. Vehicle Preparation A. Apply the parking brake and block the wheels. B. Connect an analog tachometer, Rotunda 059-000010 or an equivalent analog tachometer. C. Disconnect the flexible fresh air tube from the air cleaner duct or adaptor. Using propane enrichment Tool T75L-9600-A or equivalent, insert the tool hose approximately 3/4 of the way into the duct or fresh air tube. If necessary, secure the hose with tape. D. Disconnect and plug the hose at the air bypass valve. E. Disconnect and plug the hose between the purge valve and the spacer at the purge valve. F. When the above Steps have been completed, proceed to Section II. II. Propane Enrichment Method (Except as Noted) NOTE: Leave all vacuum signal hoses attached to the air cleaner assembly when relocating the assembly to perform carburetor adjustments. The air cleaner assembly must be in place, however, when measuring engine speeds. CAUTION: Prolonged engine idling can result in catalyst overheating and excessive underbody temperatures. A. Verify engine timing is set to specification-reset if necessary, Section 15. B. Verify that the curb idle speed is being controlled to specification. Then, electrically disconnect idle speed control (ISC) motor from wiring harness. C. Place A/C-heat selector in the Off position and verify that lamps are Off. NOTE: Remove PCV valve from grommet, locate the crankcase closure hose and disconnect at the air cleaner end (allowing the PCV valve and closure hose to vent to underhood air during idle fuel mixture check). D. With the transmission in Neutral, run the engine at approximately 2500 rpm for 15 seconds before each mixture check. If check is not completed within 60 seconds, repeat this cleanout Step. 1987 4-70 Carburetors, Fuel Charging Assemblies and Throttle Bodies Idle Mixture Setting Procedures E. With the engine idling at normal operating temperature gradually open the propane tool valve and watch for engine speed gain, on the tachometer. When the engine speed reaches a maximum and then begins to drop off, note the amount of speed gain. (Propane cartridge must be in vertical position). NOTE: If the engine speed will not drop off check the propane cartridge gas supply. If necessary repeat Steps D & E with a new propane cartridge gas supply. F. Compare measured speed gain to specified speed gain.* 1. If the measured speed gain is within specification, proceed to Step H. NOTE: The carburetor assembly is equipped with a tamper-resistant idle adjustment feature, the carburetor must be removed from the vehicle. Refer to Shop Manual, Group 24 for removal of the above feature. NOTE: If it is determined that idle fuel mixture adjustment will be necessary, adjust the mixture according to the reset rpm specification. 2. If the measured speed gain is higher than the speed gain specification:* Turn the mixture screw counterclockwise (rich) and simultaneously repeat Steps D and E until the measured speed rise meets the reset rpm specification.* After final adjustment, proceed to Step G. 3. If the measured speed gain is lower than the speed gain specification:* Turn the mixture screw clockwise (lean) and simultaneously repeat Steps D and E until the measured speed rise meets the reset rpm specification.* After final adjustment, proceed to Step G. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air/Fuel Mixture > System Information > Technical Service Bulletins > Idle Fuel Mixture - Manual Revision > Page 2395 4. If there is no rpm rise and the minimum speed gain specification is "0" rpm, perform the following speed drop test: NOTE: Speed drop test information is specified with the artificial enrichment requirements whenever the minimum speed gain specification is "0" rpm.* a. While watching the tachometer, adjust the mixture screw 1/4 turn clockwise (lean). Note the drop in engine speed. b. If the measured speed drop is greater than "0" and less than or equal to 40 rpm, proceed to Step G. c. If the measured speed drop is more than 40 rpm, return the mixture screw to the position before adjustment. Proceed to Step G. d. If the measured speed drop is still "0" rpm repeat steps a, b, and c. G. The carburetor fuel air adjustment must have the tamper-resistant feature reinstalled, see Section III. *Refer to the Special Specifications Issue TSB Publications. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > Customer Interest: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up Technical Service Bulletin # 91257 Date: 911213 Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up Article No. 91-25-7 12/13/91 ^ HARD COLD START - DURING INITIAL START-UP, IDLE OR DECEL - EFI ENGINES SLUDGE IN THROTTLE BODY AND/OR IDLE AIR BY-PASS VALVE ^ HESITATION/STALLS - DURING INITIAL START-UP, IDLE OR DECEL - EFI ENGINES SLUDGE IN THROTTLE BODY AND/OR IDLE AIR BY-PASS VALVE FORD: 1983-87 EXP 1983-91 ESCORT 1984-90 MUSTANG, THUNDERBIRD 1986-90 TAURUS 1986-91 CROWN VICTORIA 1988-90 TEMPO LINCOLN-MERCURY: 1983-85 LN7 1983-87 LYNX 1984-88 CAPRI 1984-90 COUGAR 1986-90 CONTINENTAL, MARK VII, SABLE 1986-91 GRAND MARQUIS, TOWN CAR 1988-90 TOPAZ 1991 TRACER LIGHT TRUCK: 1985-90 BRONCO II, BRONCO 1985-91 ECONOLINE, F-150-350 SERIES 1985-92 RANGER 1986-91 AEROSTAR 1991 EXPLORER ISSUE: Hard cold starts, hesitation and stalls on initial start-up or during idle or decel may be caused by sludge in the throttle body and/or idle by-pass valve. Sludge deposits or oil film on the throttle body bore and plate or the idle air by-pass valve may cause one or more of the following conditions. ^ Hard Cold Start ^ Stall On Initial Start-Up ^ Stall During Idle ^ Stall During Decel ^ Rough Idle ^ Rolling Idle ^ Hesitation During Acceleration ACTION: A new idle air by-pass service kit (F2PZ-9F939-A) is now available for service use to correct sludge contamination concerns of the throttle bore and plate only. It eliminates the need to clean the majority of past model throttle body applications. Cleaning is not required on sludge tolerant throttle body designs released for 1991 and newer model years. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > Customer Interest: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 2404 Figure 1 Install an idle air by-pass service kit (F2PZ-9F939-A) as applicable to provide a permanent correction for symptoms caused by throttle body sludge deposits. Refer to the instruction sheet included in the kit for installation details. Refer to Figure 1 for a specific application list of EFI (port fuel Injection) engines involved in this TSB article. The idle air by-pass service kit (F2PZ-9F939-A) includes the following items. ^ One (1) Idle Adjust Spacer ^ Two (2) Gaskets Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > Customer Interest: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 2405 ^ Two (2) Attaching Bolts ^ One (1) "Attention" Sticker ^ One (1) Instruction Sheet Figure 2 Refer to Figure 2 for a pictorial of the kits components. NOTE: EFFECTIVE WITH THIS TSB, THROTTLE BODY CLEANING IS NO LONGER COVERED UNDER 5/50 EMISSIONS WARRANTY, UNLESS AS SPECIFIED IN THE FOLLOWING APPLICATION CHARTS. FAILURE TO FOLLOW THE CORRECT PROCEDURE MAY RESULT IN THE CLAIM BEING DISALLOWED. The idle air adjust spacer incorporates sludge tolerant design features that eliminate throttle body sludge related conditions. Once installed, throttle body cleaning is not allowed and periodic adjustment of the throttle body is not required. Procedures, Warranty and Labor CHECKS TO MAKE PRIOR TO SERVICE KIT INSTALLATION Confirm that the following items are not causing the idle quality concern before proceeding with the service kit installation. ^ Contamination within the idle air by-pass solenoid ^ Lack of fuel system control (excessively rich or lean) ^ Ignition timing change ^ Incorrect or malfunctioning EGR system ^ Incorrect or malfunctioning cooling system ^ Vacuum leaks (air intake manifold, vacuum hoses, vacuum reservoirs, power brake booster where applicable) ^ EEC diagnostics have been performed and vehicle malfunction indicated service output codes have been resolved and cleared. If any of the areas listed above are found to be at fault, correct them before proceeding with the service kit installation. Idle Speed Adjustment Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > Customer Interest: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 2406 WARNING: BEFORE PROCEEDING WITH THE IDLE SPEED ADJUSTMENT, VERIFY THAT THE FOLLOWING ITEMS ARE TAKEN CARE OF PROPERLY. ^ The transmission is in PARK or Neutral. ^ The parking brake is applied. ^ The wheels are properly blocked. ^ The engine is at operating temperature. ^ The heater, A/C, cooling fan and other accessories are OFF. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > Customer Interest: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 2407 Figure 3 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > Customer Interest: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 2408 Figure 4 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > Customer Interest: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 2409 Figure 5 The EFI throttle body idle speed adjustment procedures for the various model year passenger cars and light trucks are outlined in step-by-step procedures featured in Figures 3, 4 and 5. Select the appropriate procedure for the vehicle involved and adjust the throttle body idle RPM accordingly, after service kit installation. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > Customer Interest: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 2410 Figure 6 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > Customer Interest: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 2411 Figure 7 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > Customer Interest: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 2412 Figure 8 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > Customer Interest: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 2413 Figure 9 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > Customer Interest: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 2414 Figure 10 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > Customer Interest: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 2415 Figure 11 THROTTLE BODY AND IDLE AIR BY-PASS SOLENOID SERVICE PROCEDURE Detailed application charts for throttle body and idle air by-pass solenoid service procedures by engine VIN # /engine displacement/vehicle application and model year are shown in Figures 6 through 11. Refer to these charts to see if the service kit is to be installed and which service cleaning procedure, if any, is to be used. SERVICE CLEANING PROCEDURES The following items should be noted prior to beginning the service cleaning procedure. ^ Confirm that the correct service cleaning procedure is identified in the Application Charts, Figures 6-11, for the vehicle/engine combination being Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > Customer Interest: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 2416 serviced. ^ Do not clean throttle bodies identified to accept service kit (F2PZ-9F939-A), IDLE AIR ADJUST SPACER. ^ Use a 1" (25.4 mm) to 1-1/2" (38.1 mm) wire stemmed horse hair or nylon bottle cleaner type brush. ^ Use rubber gloves and eye protection. ^ Do not clean throttle bodies identified with a yellow/black "ATTENTION" label. ^ Do not clean "Black" plastic air by-pass valves. Refer to TSB 89-13-8 for service details. ^ Do not run vehicles with air flow meters when the air duct is removed. ^ Do not use carburetor cleaner as a cleaning solvent. Use Carburetor Tune-up Cleaner (D9AZ-19579-AA). Procedure # 1 THROTTLE BODY AND IDLE AIR BY-PASS VALVE CLEANING CAUTION: DO NOT RUN VEHICLES EQUIPPED WITH AIR FLOW METERS DURING THE CLEANING PROCEDURE. IF THERE IS A YELLOW/BLACK "ATTENTION" LABEL ON THE THROTTLE BODY ADVISING NOT TO CLEAN, OR IF THE VEHICLE IS IDENTIFIED AS ACCEPTING SERVICE KIT (F2PZ-9F939-A), USE PROCEDURE # 2 FOR IDLE AIR BY-PASS VALVE CLEANING ONLY. 1. Plug the actuator into the connector in the Rotunda Cleaner/Tester, Tool 113-00009. 2. Remove the air duct to the throttle body inlet. 3. Disoonnect the idle air by-pass valve signal lead. 4. Attach the actuator harness plug to the idle air by-pass valve. 5. Start the actuator and then start the engine. Do not start engines that have air flow meters. 6. Spray just enough Carburetor Tune-up Cleaner (D9AZ-19579-AA) into the throttle bore to wet the bore and throttle plate. 7. Spray the Carburetor Tune-up Cleaner for about five (5) seconds into the idle air by-pass valve inlet passage while the actuator is operating. 8. Stop the engine and actuator. Let everything soak for fifteen (15) minutes. 9. After a fifteen (15) minute soak, saturate the cleaning brush with solvent and scrub between the throttle body bore and plate while holding the throttle wide open. NOTE: IT IS NECESSARY TO APPLY SOME PRESSURE ON THE BRUSH WHILE SCRUBBING. 10. Repeat saturating the brush and scrubbing for one (1) to two (2) minutes, making sure to reach into the corners where the throttle shaft meets the bore wall. 11. Start the actuator and the start the engine. Do not start engines that have air flow meters. 12. Spray Carburetor Tune-up Cleaner into the throttle bore for up to one (1) minute to wash away residue. Do not spray for longer than six (6) continuous seconds on engines that have air flow meters and are not running. 13. Spray Carburetor Tune-up Cleaner into the idle by-pass valve passage leading to the inlet of the valve for up to one (1) minute. Do not spray for longer than six (6) continuous seconds on engines that have air flow meters and are not running. 14. Stop actuator and stop engine, if running. NOTE: MAKE SURE THE THROTTLE PLATES OPERATE FREELY AND CLOSE PROPERLY. 15. Reinstall the air duct. 16. Start and run the engine for about one (1) minute to dry out the solvent residue. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > Customer Interest: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 2417 17. Operate the actuator to make sure the solvent is purged from the idle by-pass valve. 18. Disconnect the actuator from the idle air by-pass valve. 19. Reattach the control signal lead to the air by-pass valve. 20. Check engine for normal operation. It may be necessary to reset the idle speed due to a previous adjustment for an idle concern. (Refer to the respective Powertrain/Emissions Diagnosis Service Manual, Throttle Body Section, for idle speed adjust procedure.) Procedure # 2 Idle Air By-Pass Valve Cleaning Only CAUTION: THIS CLEANING PROCEDURE MAY BE USED WITH SLUDGE TOLERANT THROTTLE BODIES WHICH ARE IDENTIFIED WITH A YELLOW/BLACK "ATTENTION" LABEL AND THOSE USING SERVICE KIT (F2PZ-9F939-A). NO ATTEMPT SHOULD BE MADE TO CLEAN THROTTLE BODY BORE/PLATE AREA BY DIRECT SPRAYING OR SCRUBBING. DO NOT RUN VEHICLES WITH AIR FLOW METERS DURING CLEANING PROCEDURE. 1. Plug the actuator into the connector in the Rotunda Air By-Pass Valve Adapter 113-00009, or equivalent. 2. Remove the air duct to the throttle body inlet. 3. Disconnect the idle air by-pass valve signal lead. 4. Attach the actuator harness plug to the idle air by-pass valve. 5. Start the actuator and then start the engine. NOTE: DO NOT START ENGINES THAT HAVE AIR FLOW METERS. 6. Spray the Carburetor Tune-up Cleaner for about five (5) seconds into the idle air by-pass valve inlet passage while the actuator is operating. CAUTION: AVOID DIRECT SPRAYING ON THROTTLE PLATE/BORE AREA. 7. Stop the engine and actuator. Let everything soak for fifteen (15) minutes. 8. Start the actuator and the start the engine. CAUTION: DO NOT START ENGINES THAT HAVE AIR FLOW METERS. 9. Spray Carburetor Tune-up Cleaner into the throttle bore for up to one (1) minute. CAUTION: DO NOT SPRAY FOR LONGER THAN SIX (6) CONTINUOUS SECONDS ON ENGINES THAT HAVE AIR FLOW METERS AND ARE NOT RUNNING. 10. Stop actuator and stop engine if running. 11. Reinstall the air duct. 12. Start and run the engine for about one (1) minute to dry out the solvent residue. 13. Operate the actuator to make sure the solvent is purged from the idle by-pass valve. 14. Disconnect the actuator from the idle air by-pass valve. 15. Reattach the control signal lead to the air by-pass valve. 16. Check engine for normal operation. NOTE: IT SHOULD NOT BE NECESSARY TO RESET THE IDLE SPEED SINCE ONLY THE IDLE AIR BY-PASS VALVE WAS SERVICED IN THIS PROCEDURE Warranty Coverage Throttle bodies and idle air by-pass valves on all EFI (Port Fuel Injection) engines through the 1992 model year that can be cleaned (as identified in the application charts) are covered under 5/50 Emissions Warranty Coverage. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > Customer Interest: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 2418 For those throttle bodies identified as having sludge tolerant designs or using service kit (F2PZ-9F939-A) where cleaning is not allowed per the application charts, the warranty claims for cleaning will not be reimbursed even within the 12/12 warranty coverage period. Cleaning is not allowed. Service kit installation (single time) is covered under 5/50 emission warranty. Labor Standards Operations The labor operations shown in the following Operation/Description/Time columns are identified by procedure number and vehicle line. Specific engines for various vehicles are identified in the sludge cleaning procedure application charts. The throttle body cleaning operations with combinations and the air by-pass valve cleaning combinations will appear in future Labor Manuals under the following operation numbers. ^ 9926 B - Throttle body and idle air by-pass valve cleaning ^ 9926 B2 - Adjust idle speed ^ 9715 A - Air by-pass valve cleaning only ^ 9715 A1 - Adjust idle speed PART NUMBER PART NAME CLASS F2PZ-9F939-A Idle Air By-pass Service Kit B D9AZ-19579-AA Carburstor Tune-Up Cleaner BG OTHER APPLICABLE ARTICLES: 89-13-8 SUPERSEDES: 88-24-5, 88-24-6, 89-16-5, 91-10-9, 91-7-4 Operation Description WARRANTY STATUS: Eligible Under Warranty Coverage As Stated In The Text Of This Article OPERATION DESCRIPTION TIME 912507A Idle Air By-Pass Valve 0.5 Hr. Cleaning - 1983-85 Escort, EXP, LN7, LYNX 1.6L EFI. 912507B Idle Air By-Pass Valve 0.5 Hr. Cleaning - 1986-91 Escort 1.9L EFI, 1986/87 EXP, Lynx 1.9L EFI, 1991 Tracer 1.9L EFI. 912507C Idle Air By Pass Valve 0.5 Hr. Cleaning - 1984-87 Mustang 2.3L T/C, 1986/87 Capri, Cougar 2.3L T/C, 1984-88 T-Bird 2.3L T/C, 1987/92 Mustang 2.3L EFI. 912507D Idle By-Pass Valve Cleaning 0.6 Hr. - 1988-91 Tempo, Topaz 2.3L HSC, 1985-92 Ranger 2.3L EFI. 912507E Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1986/87 Aerostar 2.3L EFI, 1985 Bronco II 2.3L EFI. 912507F Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1986-90 Bronco II 2.9L EFI, 1986-92 Ranger 2.9L EFI. 912507G Idle Air By-Pass Valve 0.6 Hr. Cleaning - 1991/92 Probe 3.0L EFI, 1986-91 Taurus 3.0L EFI, 1987-91 Sable 3.0L EFI. 912507H Idle Air By-Pass Valve 0.7 Hr. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > Customer Interest: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 2419 Cleaning - 1986-91 Aerostar 3.0L EFI, 1991 Ranger 3.0L EFI. 912507I Idle Air By-Pass Valve 0.6 Hr. Cleaning - 1988 Continental, Cougar, Taurus, T-Bird, Sable 3.8L EFI. 1988 Cougar, T-Bird 3.8L S/C. 912507J Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1990-92 Aerostar 4.0L EFI, 1990 Bronco II 4.0L EFI, 1991/92 Explorer 4.0L EFI, 1990-92 Ranger 4.0L EFI. 912507K Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1987-92 Bronco 4.9L EFI, 1987-92 F-Series 4.9L EFI, 1987/90 Econoline (Without Rear Heater) 4.9L EFI, 1991/92 Econoline (All) 4.9L EFI. 912507L Idle Air By-Pass Valve 0.6 Hr. Cleaning - 1986-88 Cougar, T-Bird 5.0L EFI, 1986-87 Continental, Mark VII 5.OL EFI, 1986/91 Crn - Victoria, Grn - Marquis 5.0L EFI, 1986-92 Mark VII 5.0L HO, 1982-92 Mustang 5.0L HO. 912507M Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1985-92 Bronco, E-Series, F-Series 5.0L EFI. 912507N Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1988-90 Bronco, F-Series 5.8L. 1991 Econo, F-Series, Bronco 5.8L (Do not Clean Solenoid, Calib; 1-64E-R10, 1-64H-R10, 1-64J-R10, 1-64K-R10, 1-64M-R10, 1-64P-R10, 1-64R-R10, 1-75A-R00, 1-76A-R00, 1-76B-R00, 1-76C-R00. 912507O Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1991/92 F And B Series, 7.0L EFI. 912507P Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1987-92 E-Series, F-Series 7.5L EFI. 912507Q Throttle Body And Idle Air 0.9 Hr. By-Pass Valve Cleaning - 1989/90 Probe 3.0L EFI. 912507R Throttle Body And Idle Air 0.8 Hr. By-Pass Valve Cleaning - 1987-90 Econoline (With Rear Heat) 4.9L EFI. 912507S Throttle Body And Idle Air 0.9 Hr. By-Pass Valve Cleaning - 1988-90 Econoline 5.8L EFI. 912507T Service Kit Install - All Cars 1.0 Hr. And Light Trucks (Except Aerostar And Econoline) - Refer To The Service Procedure Application Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > Customer Interest: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 2420 Charts, For Vehicle Application. 912507U Service Kit Install - 1.2 Hr. Aerostar, Econoline - Refer To Service Procedure Application Charts - For Vehicle Application. DEALER CODING BASIC PART NO. CONDITION CODE 9E926 49 OASIS CODES: 602300, 607000, 607400, 607700, 608400, 611500, 618400 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine Hard Cold Starts/Hesitation/Stalls On Start-Up Technical Service Bulletin # 91257 Date: 911213 Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up Article No. 91-25-7 12/13/91 ^ HARD COLD START - DURING INITIAL START-UP, IDLE OR DECEL - EFI ENGINES SLUDGE IN THROTTLE BODY AND/OR IDLE AIR BY-PASS VALVE ^ HESITATION/STALLS - DURING INITIAL START-UP, IDLE OR DECEL - EFI ENGINES SLUDGE IN THROTTLE BODY AND/OR IDLE AIR BY-PASS VALVE FORD: 1983-87 EXP 1983-91 ESCORT 1984-90 MUSTANG, THUNDERBIRD 1986-90 TAURUS 1986-91 CROWN VICTORIA 1988-90 TEMPO LINCOLN-MERCURY: 1983-85 LN7 1983-87 LYNX 1984-88 CAPRI 1984-90 COUGAR 1986-90 CONTINENTAL, MARK VII, SABLE 1986-91 GRAND MARQUIS, TOWN CAR 1988-90 TOPAZ 1991 TRACER LIGHT TRUCK: 1985-90 BRONCO II, BRONCO 1985-91 ECONOLINE, F-150-350 SERIES 1985-92 RANGER 1986-91 AEROSTAR 1991 EXPLORER ISSUE: Hard cold starts, hesitation and stalls on initial start-up or during idle or decel may be caused by sludge in the throttle body and/or idle by-pass valve. Sludge deposits or oil film on the throttle body bore and plate or the idle air by-pass valve may cause one or more of the following conditions. ^ Hard Cold Start ^ Stall On Initial Start-Up ^ Stall During Idle ^ Stall During Decel ^ Rough Idle ^ Rolling Idle ^ Hesitation During Acceleration ACTION: A new idle air by-pass service kit (F2PZ-9F939-A) is now available for service use to correct sludge contamination concerns of the throttle bore and plate only. It eliminates the need to clean the majority of past model throttle body applications. Cleaning is not required on sludge tolerant throttle body designs released for 1991 and newer model years. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 2426 Figure 1 Install an idle air by-pass service kit (F2PZ-9F939-A) as applicable to provide a permanent correction for symptoms caused by throttle body sludge deposits. Refer to the instruction sheet included in the kit for installation details. Refer to Figure 1 for a specific application list of EFI (port fuel Injection) engines involved in this TSB article. The idle air by-pass service kit (F2PZ-9F939-A) includes the following items. ^ One (1) Idle Adjust Spacer ^ Two (2) Gaskets Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 2427 ^ Two (2) Attaching Bolts ^ One (1) "Attention" Sticker ^ One (1) Instruction Sheet Figure 2 Refer to Figure 2 for a pictorial of the kits components. NOTE: EFFECTIVE WITH THIS TSB, THROTTLE BODY CLEANING IS NO LONGER COVERED UNDER 5/50 EMISSIONS WARRANTY, UNLESS AS SPECIFIED IN THE FOLLOWING APPLICATION CHARTS. FAILURE TO FOLLOW THE CORRECT PROCEDURE MAY RESULT IN THE CLAIM BEING DISALLOWED. The idle air adjust spacer incorporates sludge tolerant design features that eliminate throttle body sludge related conditions. Once installed, throttle body cleaning is not allowed and periodic adjustment of the throttle body is not required. Procedures, Warranty and Labor CHECKS TO MAKE PRIOR TO SERVICE KIT INSTALLATION Confirm that the following items are not causing the idle quality concern before proceeding with the service kit installation. ^ Contamination within the idle air by-pass solenoid ^ Lack of fuel system control (excessively rich or lean) ^ Ignition timing change ^ Incorrect or malfunctioning EGR system ^ Incorrect or malfunctioning cooling system ^ Vacuum leaks (air intake manifold, vacuum hoses, vacuum reservoirs, power brake booster where applicable) ^ EEC diagnostics have been performed and vehicle malfunction indicated service output codes have been resolved and cleared. If any of the areas listed above are found to be at fault, correct them before proceeding with the service kit installation. Idle Speed Adjustment Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 2428 WARNING: BEFORE PROCEEDING WITH THE IDLE SPEED ADJUSTMENT, VERIFY THAT THE FOLLOWING ITEMS ARE TAKEN CARE OF PROPERLY. ^ The transmission is in PARK or Neutral. ^ The parking brake is applied. ^ The wheels are properly blocked. ^ The engine is at operating temperature. ^ The heater, A/C, cooling fan and other accessories are OFF. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 2429 Figure 3 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 2430 Figure 4 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 2431 Figure 5 The EFI throttle body idle speed adjustment procedures for the various model year passenger cars and light trucks are outlined in step-by-step procedures featured in Figures 3, 4 and 5. Select the appropriate procedure for the vehicle involved and adjust the throttle body idle RPM accordingly, after service kit installation. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 2432 Figure 6 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 2433 Figure 7 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 2434 Figure 8 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 2435 Figure 9 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 2436 Figure 10 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 2437 Figure 11 THROTTLE BODY AND IDLE AIR BY-PASS SOLENOID SERVICE PROCEDURE Detailed application charts for throttle body and idle air by-pass solenoid service procedures by engine VIN # /engine displacement/vehicle application and model year are shown in Figures 6 through 11. Refer to these charts to see if the service kit is to be installed and which service cleaning procedure, if any, is to be used. SERVICE CLEANING PROCEDURES The following items should be noted prior to beginning the service cleaning procedure. ^ Confirm that the correct service cleaning procedure is identified in the Application Charts, Figures 6-11, for the vehicle/engine combination being Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 2438 serviced. ^ Do not clean throttle bodies identified to accept service kit (F2PZ-9F939-A), IDLE AIR ADJUST SPACER. ^ Use a 1" (25.4 mm) to 1-1/2" (38.1 mm) wire stemmed horse hair or nylon bottle cleaner type brush. ^ Use rubber gloves and eye protection. ^ Do not clean throttle bodies identified with a yellow/black "ATTENTION" label. ^ Do not clean "Black" plastic air by-pass valves. Refer to TSB 89-13-8 for service details. ^ Do not run vehicles with air flow meters when the air duct is removed. ^ Do not use carburetor cleaner as a cleaning solvent. Use Carburetor Tune-up Cleaner (D9AZ-19579-AA). Procedure # 1 THROTTLE BODY AND IDLE AIR BY-PASS VALVE CLEANING CAUTION: DO NOT RUN VEHICLES EQUIPPED WITH AIR FLOW METERS DURING THE CLEANING PROCEDURE. IF THERE IS A YELLOW/BLACK "ATTENTION" LABEL ON THE THROTTLE BODY ADVISING NOT TO CLEAN, OR IF THE VEHICLE IS IDENTIFIED AS ACCEPTING SERVICE KIT (F2PZ-9F939-A), USE PROCEDURE # 2 FOR IDLE AIR BY-PASS VALVE CLEANING ONLY. 1. Plug the actuator into the connector in the Rotunda Cleaner/Tester, Tool 113-00009. 2. Remove the air duct to the throttle body inlet. 3. Disoonnect the idle air by-pass valve signal lead. 4. Attach the actuator harness plug to the idle air by-pass valve. 5. Start the actuator and then start the engine. Do not start engines that have air flow meters. 6. Spray just enough Carburetor Tune-up Cleaner (D9AZ-19579-AA) into the throttle bore to wet the bore and throttle plate. 7. Spray the Carburetor Tune-up Cleaner for about five (5) seconds into the idle air by-pass valve inlet passage while the actuator is operating. 8. Stop the engine and actuator. Let everything soak for fifteen (15) minutes. 9. After a fifteen (15) minute soak, saturate the cleaning brush with solvent and scrub between the throttle body bore and plate while holding the throttle wide open. NOTE: IT IS NECESSARY TO APPLY SOME PRESSURE ON THE BRUSH WHILE SCRUBBING. 10. Repeat saturating the brush and scrubbing for one (1) to two (2) minutes, making sure to reach into the corners where the throttle shaft meets the bore wall. 11. Start the actuator and the start the engine. Do not start engines that have air flow meters. 12. Spray Carburetor Tune-up Cleaner into the throttle bore for up to one (1) minute to wash away residue. Do not spray for longer than six (6) continuous seconds on engines that have air flow meters and are not running. 13. Spray Carburetor Tune-up Cleaner into the idle by-pass valve passage leading to the inlet of the valve for up to one (1) minute. Do not spray for longer than six (6) continuous seconds on engines that have air flow meters and are not running. 14. Stop actuator and stop engine, if running. NOTE: MAKE SURE THE THROTTLE PLATES OPERATE FREELY AND CLOSE PROPERLY. 15. Reinstall the air duct. 16. Start and run the engine for about one (1) minute to dry out the solvent residue. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 2439 17. Operate the actuator to make sure the solvent is purged from the idle by-pass valve. 18. Disconnect the actuator from the idle air by-pass valve. 19. Reattach the control signal lead to the air by-pass valve. 20. Check engine for normal operation. It may be necessary to reset the idle speed due to a previous adjustment for an idle concern. (Refer to the respective Powertrain/Emissions Diagnosis Service Manual, Throttle Body Section, for idle speed adjust procedure.) Procedure # 2 Idle Air By-Pass Valve Cleaning Only CAUTION: THIS CLEANING PROCEDURE MAY BE USED WITH SLUDGE TOLERANT THROTTLE BODIES WHICH ARE IDENTIFIED WITH A YELLOW/BLACK "ATTENTION" LABEL AND THOSE USING SERVICE KIT (F2PZ-9F939-A). NO ATTEMPT SHOULD BE MADE TO CLEAN THROTTLE BODY BORE/PLATE AREA BY DIRECT SPRAYING OR SCRUBBING. DO NOT RUN VEHICLES WITH AIR FLOW METERS DURING CLEANING PROCEDURE. 1. Plug the actuator into the connector in the Rotunda Air By-Pass Valve Adapter 113-00009, or equivalent. 2. Remove the air duct to the throttle body inlet. 3. Disconnect the idle air by-pass valve signal lead. 4. Attach the actuator harness plug to the idle air by-pass valve. 5. Start the actuator and then start the engine. NOTE: DO NOT START ENGINES THAT HAVE AIR FLOW METERS. 6. Spray the Carburetor Tune-up Cleaner for about five (5) seconds into the idle air by-pass valve inlet passage while the actuator is operating. CAUTION: AVOID DIRECT SPRAYING ON THROTTLE PLATE/BORE AREA. 7. Stop the engine and actuator. Let everything soak for fifteen (15) minutes. 8. Start the actuator and the start the engine. CAUTION: DO NOT START ENGINES THAT HAVE AIR FLOW METERS. 9. Spray Carburetor Tune-up Cleaner into the throttle bore for up to one (1) minute. CAUTION: DO NOT SPRAY FOR LONGER THAN SIX (6) CONTINUOUS SECONDS ON ENGINES THAT HAVE AIR FLOW METERS AND ARE NOT RUNNING. 10. Stop actuator and stop engine if running. 11. Reinstall the air duct. 12. Start and run the engine for about one (1) minute to dry out the solvent residue. 13. Operate the actuator to make sure the solvent is purged from the idle by-pass valve. 14. Disconnect the actuator from the idle air by-pass valve. 15. Reattach the control signal lead to the air by-pass valve. 16. Check engine for normal operation. NOTE: IT SHOULD NOT BE NECESSARY TO RESET THE IDLE SPEED SINCE ONLY THE IDLE AIR BY-PASS VALVE WAS SERVICED IN THIS PROCEDURE Warranty Coverage Throttle bodies and idle air by-pass valves on all EFI (Port Fuel Injection) engines through the 1992 model year that can be cleaned (as identified in the application charts) are covered under 5/50 Emissions Warranty Coverage. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 2440 For those throttle bodies identified as having sludge tolerant designs or using service kit (F2PZ-9F939-A) where cleaning is not allowed per the application charts, the warranty claims for cleaning will not be reimbursed even within the 12/12 warranty coverage period. Cleaning is not allowed. Service kit installation (single time) is covered under 5/50 emission warranty. Labor Standards Operations The labor operations shown in the following Operation/Description/Time columns are identified by procedure number and vehicle line. Specific engines for various vehicles are identified in the sludge cleaning procedure application charts. The throttle body cleaning operations with combinations and the air by-pass valve cleaning combinations will appear in future Labor Manuals under the following operation numbers. ^ 9926 B - Throttle body and idle air by-pass valve cleaning ^ 9926 B2 - Adjust idle speed ^ 9715 A - Air by-pass valve cleaning only ^ 9715 A1 - Adjust idle speed PART NUMBER PART NAME CLASS F2PZ-9F939-A Idle Air By-pass Service Kit B D9AZ-19579-AA Carburstor Tune-Up Cleaner BG OTHER APPLICABLE ARTICLES: 89-13-8 SUPERSEDES: 88-24-5, 88-24-6, 89-16-5, 91-10-9, 91-7-4 Operation Description WARRANTY STATUS: Eligible Under Warranty Coverage As Stated In The Text Of This Article OPERATION DESCRIPTION TIME 912507A Idle Air By-Pass Valve 0.5 Hr. Cleaning - 1983-85 Escort, EXP, LN7, LYNX 1.6L EFI. 912507B Idle Air By-Pass Valve 0.5 Hr. Cleaning - 1986-91 Escort 1.9L EFI, 1986/87 EXP, Lynx 1.9L EFI, 1991 Tracer 1.9L EFI. 912507C Idle Air By Pass Valve 0.5 Hr. Cleaning - 1984-87 Mustang 2.3L T/C, 1986/87 Capri, Cougar 2.3L T/C, 1984-88 T-Bird 2.3L T/C, 1987/92 Mustang 2.3L EFI. 912507D Idle By-Pass Valve Cleaning 0.6 Hr. - 1988-91 Tempo, Topaz 2.3L HSC, 1985-92 Ranger 2.3L EFI. 912507E Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1986/87 Aerostar 2.3L EFI, 1985 Bronco II 2.3L EFI. 912507F Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1986-90 Bronco II 2.9L EFI, 1986-92 Ranger 2.9L EFI. 912507G Idle Air By-Pass Valve 0.6 Hr. Cleaning - 1991/92 Probe 3.0L EFI, 1986-91 Taurus 3.0L EFI, 1987-91 Sable 3.0L EFI. 912507H Idle Air By-Pass Valve 0.7 Hr. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 2441 Cleaning - 1986-91 Aerostar 3.0L EFI, 1991 Ranger 3.0L EFI. 912507I Idle Air By-Pass Valve 0.6 Hr. Cleaning - 1988 Continental, Cougar, Taurus, T-Bird, Sable 3.8L EFI. 1988 Cougar, T-Bird 3.8L S/C. 912507J Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1990-92 Aerostar 4.0L EFI, 1990 Bronco II 4.0L EFI, 1991/92 Explorer 4.0L EFI, 1990-92 Ranger 4.0L EFI. 912507K Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1987-92 Bronco 4.9L EFI, 1987-92 F-Series 4.9L EFI, 1987/90 Econoline (Without Rear Heater) 4.9L EFI, 1991/92 Econoline (All) 4.9L EFI. 912507L Idle Air By-Pass Valve 0.6 Hr. Cleaning - 1986-88 Cougar, T-Bird 5.0L EFI, 1986-87 Continental, Mark VII 5.OL EFI, 1986/91 Crn - Victoria, Grn - Marquis 5.0L EFI, 1986-92 Mark VII 5.0L HO, 1982-92 Mustang 5.0L HO. 912507M Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1985-92 Bronco, E-Series, F-Series 5.0L EFI. 912507N Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1988-90 Bronco, F-Series 5.8L. 1991 Econo, F-Series, Bronco 5.8L (Do not Clean Solenoid, Calib; 1-64E-R10, 1-64H-R10, 1-64J-R10, 1-64K-R10, 1-64M-R10, 1-64P-R10, 1-64R-R10, 1-75A-R00, 1-76A-R00, 1-76B-R00, 1-76C-R00. 912507O Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1991/92 F And B Series, 7.0L EFI. 912507P Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1987-92 E-Series, F-Series 7.5L EFI. 912507Q Throttle Body And Idle Air 0.9 Hr. By-Pass Valve Cleaning - 1989/90 Probe 3.0L EFI. 912507R Throttle Body And Idle Air 0.8 Hr. By-Pass Valve Cleaning - 1987-90 Econoline (With Rear Heat) 4.9L EFI. 912507S Throttle Body And Idle Air 0.9 Hr. By-Pass Valve Cleaning - 1988-90 Econoline 5.8L EFI. 912507T Service Kit Install - All Cars 1.0 Hr. And Light Trucks (Except Aerostar And Econoline) - Refer To The Service Procedure Application Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 2442 Charts, For Vehicle Application. 912507U Service Kit Install - 1.2 Hr. Aerostar, Econoline - Refer To Service Procedure Application Charts - For Vehicle Application. DEALER CODING BASIC PART NO. CONDITION CODE 9E926 49 OASIS CODES: 602300, 607000, 607400, 607700, 608400, 611500, 618400 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 861516 > Jul > 86 > Vehicle High Altitude Modification Idle Speed: All Technical Service Bulletins Vehicle - High Altitude Modification Article No. 86-15-16 ALTITUDE (5.8L (W)) - MODIFICATION OF SEA LEVEL CALIBRATION FOR ALTITUDE APPLICATION - VEHICLES WITH 4V CARBURETORS ONLY - OVER 8500 LBS. GVWR LIGHT TRUCK 1986 E SERIES, F SERIES CALIBRATION: 5-76J-R17 (Manual Transmission) WARNING: This modification is authorized only for the listed engines. Performing this modification on other engine calibrations is unauthorized and could create liability under applicable federal or local laws. Customers who may have relocated and/or continually operate the subject vehicles in high altitude (above 4,000 ft. alt.) may have the following procedure performed to improve performance. 1. Remove existing PCV valve and replace with new PCV valve (part number D90Z-6A666-A). 2. Advance initial ignition timing 6~ from nominal setting of 8~ BTDC to 14~ BTDC. Refer to 1986 Light Truck Shop Manual, Volume B, Section 23-01. 3. Increase choke pull down hard gauge setting to .193". Refer to 1986 Light Truck Shop Manual, Volume B, Section 24-26. 4. Remove existing choke cap and replace with new choke cap 47R-776-A (part number E5PZ-9848-B). 5. Reset hi-cam and curb idle speeds to specification (refer to Vehicle Emission Control Information Decal). Obtain a Vehicle Emission Control Information Update Decal (available at all Ford or Lincoln-Mercury dealers) and fill in the appropriate information as indicated. If the vehicle is returned to continuous sea level (below 4,000 ft. alt.) operation, the above procedure should be reversed and the Vehicle Emission Control Information Update Decal should be removed from the vehicle. PART NUMBER PART NAME CLASS D90Z-6A666-A PCV Valve A E5PZ-9848-B Choke Cap C OTHER APPLICABLE ARTICLES: 85-21-16 WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION: SP9514A86 TIME: 1.3 Hrs. DLR. CODING: Basic Part No. DRIVE - Code: N4, P6, T5 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Other Service Bulletins for Idle Speed: > 861516 > Jul > 86 > Vehicle - High Altitude Modification Idle Speed: All Technical Service Bulletins Vehicle - High Altitude Modification Article No. 86-15-16 ALTITUDE (5.8L (W)) - MODIFICATION OF SEA LEVEL CALIBRATION FOR ALTITUDE APPLICATION - VEHICLES WITH 4V CARBURETORS ONLY - OVER 8500 LBS. GVWR LIGHT TRUCK 1986 E SERIES, F SERIES CALIBRATION: 5-76J-R17 (Manual Transmission) WARNING: This modification is authorized only for the listed engines. Performing this modification on other engine calibrations is unauthorized and could create liability under applicable federal or local laws. Customers who may have relocated and/or continually operate the subject vehicles in high altitude (above 4,000 ft. alt.) may have the following procedure performed to improve performance. 1. Remove existing PCV valve and replace with new PCV valve (part number D90Z-6A666-A). 2. Advance initial ignition timing 6~ from nominal setting of 8~ BTDC to 14~ BTDC. Refer to 1986 Light Truck Shop Manual, Volume B, Section 23-01. 3. Increase choke pull down hard gauge setting to .193". Refer to 1986 Light Truck Shop Manual, Volume B, Section 24-26. 4. Remove existing choke cap and replace with new choke cap 47R-776-A (part number E5PZ-9848-B). 5. Reset hi-cam and curb idle speeds to specification (refer to Vehicle Emission Control Information Decal). Obtain a Vehicle Emission Control Information Update Decal (available at all Ford or Lincoln-Mercury dealers) and fill in the appropriate information as indicated. If the vehicle is returned to continuous sea level (below 4,000 ft. alt.) operation, the above procedure should be reversed and the Vehicle Emission Control Information Update Decal should be removed from the vehicle. PART NUMBER PART NAME CLASS D90Z-6A666-A PCV Valve A E5PZ-9848-B Choke Cap C OTHER APPLICABLE ARTICLES: 85-21-16 WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION: SP9514A86 TIME: 1.3 Hrs. DLR. CODING: Basic Part No. DRIVE - Code: N4, P6, T5 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Other Service Bulletins for Idle Speed: > Page 2452 Idle Speed: By Symptom Technical Service Bulletin # 91257 Date: 911213 Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up Article No. 91-25-7 12/13/91 ^ HARD COLD START - DURING INITIAL START-UP, IDLE OR DECEL - EFI ENGINES SLUDGE IN THROTTLE BODY AND/OR IDLE AIR BY-PASS VALVE ^ HESITATION/STALLS - DURING INITIAL START-UP, IDLE OR DECEL - EFI ENGINES SLUDGE IN THROTTLE BODY AND/OR IDLE AIR BY-PASS VALVE FORD: 1983-87 EXP 1983-91 ESCORT 1984-90 MUSTANG, THUNDERBIRD 1986-90 TAURUS 1986-91 CROWN VICTORIA 1988-90 TEMPO LINCOLN-MERCURY: 1983-85 LN7 1983-87 LYNX 1984-88 CAPRI 1984-90 COUGAR 1986-90 CONTINENTAL, MARK VII, SABLE 1986-91 GRAND MARQUIS, TOWN CAR 1988-90 TOPAZ 1991 TRACER LIGHT TRUCK: 1985-90 BRONCO II, BRONCO 1985-91 ECONOLINE, F-150-350 SERIES 1985-92 RANGER 1986-91 AEROSTAR 1991 EXPLORER ISSUE: Hard cold starts, hesitation and stalls on initial start-up or during idle or decel may be caused by sludge in the throttle body and/or idle by-pass valve. Sludge deposits or oil film on the throttle body bore and plate or the idle air by-pass valve may cause one or more of the following conditions. ^ Hard Cold Start ^ Stall On Initial Start-Up ^ Stall During Idle ^ Stall During Decel ^ Rough Idle ^ Rolling Idle ^ Hesitation During Acceleration ACTION: A new idle air by-pass service kit (F2PZ-9F939-A) is now available for service use to correct sludge contamination concerns of the throttle bore and plate only. It eliminates the need to clean the majority of past model throttle body applications. Cleaning is not required on sludge tolerant throttle body designs released for 1991 and newer model years. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Other Service Bulletins for Idle Speed: > Page 2453 Figure 1 Install an idle air by-pass service kit (F2PZ-9F939-A) as applicable to provide a permanent correction for symptoms caused by throttle body sludge deposits. Refer to the instruction sheet included in the kit for installation details. Refer to Figure 1 for a specific application list of EFI (port fuel Injection) engines involved in this TSB article. The idle air by-pass service kit (F2PZ-9F939-A) includes the following items. ^ One (1) Idle Adjust Spacer ^ Two (2) Gaskets Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Other Service Bulletins for Idle Speed: > Page 2454 ^ Two (2) Attaching Bolts ^ One (1) "Attention" Sticker ^ One (1) Instruction Sheet Figure 2 Refer to Figure 2 for a pictorial of the kits components. NOTE: EFFECTIVE WITH THIS TSB, THROTTLE BODY CLEANING IS NO LONGER COVERED UNDER 5/50 EMISSIONS WARRANTY, UNLESS AS SPECIFIED IN THE FOLLOWING APPLICATION CHARTS. FAILURE TO FOLLOW THE CORRECT PROCEDURE MAY RESULT IN THE CLAIM BEING DISALLOWED. The idle air adjust spacer incorporates sludge tolerant design features that eliminate throttle body sludge related conditions. Once installed, throttle body cleaning is not allowed and periodic adjustment of the throttle body is not required. Procedures, Warranty and Labor CHECKS TO MAKE PRIOR TO SERVICE KIT INSTALLATION Confirm that the following items are not causing the idle quality concern before proceeding with the service kit installation. ^ Contamination within the idle air by-pass solenoid ^ Lack of fuel system control (excessively rich or lean) ^ Ignition timing change ^ Incorrect or malfunctioning EGR system ^ Incorrect or malfunctioning cooling system ^ Vacuum leaks (air intake manifold, vacuum hoses, vacuum reservoirs, power brake booster where applicable) ^ EEC diagnostics have been performed and vehicle malfunction indicated service output codes have been resolved and cleared. If any of the areas listed above are found to be at fault, correct them before proceeding with the service kit installation. Idle Speed Adjustment Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Other Service Bulletins for Idle Speed: > Page 2455 WARNING: BEFORE PROCEEDING WITH THE IDLE SPEED ADJUSTMENT, VERIFY THAT THE FOLLOWING ITEMS ARE TAKEN CARE OF PROPERLY. ^ The transmission is in PARK or Neutral. ^ The parking brake is applied. ^ The wheels are properly blocked. ^ The engine is at operating temperature. ^ The heater, A/C, cooling fan and other accessories are OFF. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Other Service Bulletins for Idle Speed: > Page 2456 Figure 3 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Other Service Bulletins for Idle Speed: > Page 2457 Figure 4 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Other Service Bulletins for Idle Speed: > Page 2458 Figure 5 The EFI throttle body idle speed adjustment procedures for the various model year passenger cars and light trucks are outlined in step-by-step procedures featured in Figures 3, 4 and 5. Select the appropriate procedure for the vehicle involved and adjust the throttle body idle RPM accordingly, after service kit installation. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Other Service Bulletins for Idle Speed: > Page 2459 Figure 6 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Other Service Bulletins for Idle Speed: > Page 2460 Figure 7 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Other Service Bulletins for Idle Speed: > Page 2461 Figure 8 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Other Service Bulletins for Idle Speed: > Page 2462 Figure 9 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Other Service Bulletins for Idle Speed: > Page 2463 Figure 10 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Other Service Bulletins for Idle Speed: > Page 2464 Figure 11 THROTTLE BODY AND IDLE AIR BY-PASS SOLENOID SERVICE PROCEDURE Detailed application charts for throttle body and idle air by-pass solenoid service procedures by engine VIN # /engine displacement/vehicle application and model year are shown in Figures 6 through 11. Refer to these charts to see if the service kit is to be installed and which service cleaning procedure, if any, is to be used. SERVICE CLEANING PROCEDURES The following items should be noted prior to beginning the service cleaning procedure. ^ Confirm that the correct service cleaning procedure is identified in the Application Charts, Figures 6-11, for the vehicle/engine combination being Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Other Service Bulletins for Idle Speed: > Page 2465 serviced. ^ Do not clean throttle bodies identified to accept service kit (F2PZ-9F939-A), IDLE AIR ADJUST SPACER. ^ Use a 1" (25.4 mm) to 1-1/2" (38.1 mm) wire stemmed horse hair or nylon bottle cleaner type brush. ^ Use rubber gloves and eye protection. ^ Do not clean throttle bodies identified with a yellow/black "ATTENTION" label. ^ Do not clean "Black" plastic air by-pass valves. Refer to TSB 89-13-8 for service details. ^ Do not run vehicles with air flow meters when the air duct is removed. ^ Do not use carburetor cleaner as a cleaning solvent. Use Carburetor Tune-up Cleaner (D9AZ-19579-AA). Procedure # 1 THROTTLE BODY AND IDLE AIR BY-PASS VALVE CLEANING CAUTION: DO NOT RUN VEHICLES EQUIPPED WITH AIR FLOW METERS DURING THE CLEANING PROCEDURE. IF THERE IS A YELLOW/BLACK "ATTENTION" LABEL ON THE THROTTLE BODY ADVISING NOT TO CLEAN, OR IF THE VEHICLE IS IDENTIFIED AS ACCEPTING SERVICE KIT (F2PZ-9F939-A), USE PROCEDURE # 2 FOR IDLE AIR BY-PASS VALVE CLEANING ONLY. 1. Plug the actuator into the connector in the Rotunda Cleaner/Tester, Tool 113-00009. 2. Remove the air duct to the throttle body inlet. 3. Disoonnect the idle air by-pass valve signal lead. 4. Attach the actuator harness plug to the idle air by-pass valve. 5. Start the actuator and then start the engine. Do not start engines that have air flow meters. 6. Spray just enough Carburetor Tune-up Cleaner (D9AZ-19579-AA) into the throttle bore to wet the bore and throttle plate. 7. Spray the Carburetor Tune-up Cleaner for about five (5) seconds into the idle air by-pass valve inlet passage while the actuator is operating. 8. Stop the engine and actuator. Let everything soak for fifteen (15) minutes. 9. After a fifteen (15) minute soak, saturate the cleaning brush with solvent and scrub between the throttle body bore and plate while holding the throttle wide open. NOTE: IT IS NECESSARY TO APPLY SOME PRESSURE ON THE BRUSH WHILE SCRUBBING. 10. Repeat saturating the brush and scrubbing for one (1) to two (2) minutes, making sure to reach into the corners where the throttle shaft meets the bore wall. 11. Start the actuator and the start the engine. Do not start engines that have air flow meters. 12. Spray Carburetor Tune-up Cleaner into the throttle bore for up to one (1) minute to wash away residue. Do not spray for longer than six (6) continuous seconds on engines that have air flow meters and are not running. 13. Spray Carburetor Tune-up Cleaner into the idle by-pass valve passage leading to the inlet of the valve for up to one (1) minute. Do not spray for longer than six (6) continuous seconds on engines that have air flow meters and are not running. 14. Stop actuator and stop engine, if running. NOTE: MAKE SURE THE THROTTLE PLATES OPERATE FREELY AND CLOSE PROPERLY. 15. Reinstall the air duct. 16. Start and run the engine for about one (1) minute to dry out the solvent residue. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Other Service Bulletins for Idle Speed: > Page 2466 17. Operate the actuator to make sure the solvent is purged from the idle by-pass valve. 18. Disconnect the actuator from the idle air by-pass valve. 19. Reattach the control signal lead to the air by-pass valve. 20. Check engine for normal operation. It may be necessary to reset the idle speed due to a previous adjustment for an idle concern. (Refer to the respective Powertrain/Emissions Diagnosis Service Manual, Throttle Body Section, for idle speed adjust procedure.) Procedure # 2 Idle Air By-Pass Valve Cleaning Only CAUTION: THIS CLEANING PROCEDURE MAY BE USED WITH SLUDGE TOLERANT THROTTLE BODIES WHICH ARE IDENTIFIED WITH A YELLOW/BLACK "ATTENTION" LABEL AND THOSE USING SERVICE KIT (F2PZ-9F939-A). NO ATTEMPT SHOULD BE MADE TO CLEAN THROTTLE BODY BORE/PLATE AREA BY DIRECT SPRAYING OR SCRUBBING. DO NOT RUN VEHICLES WITH AIR FLOW METERS DURING CLEANING PROCEDURE. 1. Plug the actuator into the connector in the Rotunda Air By-Pass Valve Adapter 113-00009, or equivalent. 2. Remove the air duct to the throttle body inlet. 3. Disconnect the idle air by-pass valve signal lead. 4. Attach the actuator harness plug to the idle air by-pass valve. 5. Start the actuator and then start the engine. NOTE: DO NOT START ENGINES THAT HAVE AIR FLOW METERS. 6. Spray the Carburetor Tune-up Cleaner for about five (5) seconds into the idle air by-pass valve inlet passage while the actuator is operating. CAUTION: AVOID DIRECT SPRAYING ON THROTTLE PLATE/BORE AREA. 7. Stop the engine and actuator. Let everything soak for fifteen (15) minutes. 8. Start the actuator and the start the engine. CAUTION: DO NOT START ENGINES THAT HAVE AIR FLOW METERS. 9. Spray Carburetor Tune-up Cleaner into the throttle bore for up to one (1) minute. CAUTION: DO NOT SPRAY FOR LONGER THAN SIX (6) CONTINUOUS SECONDS ON ENGINES THAT HAVE AIR FLOW METERS AND ARE NOT RUNNING. 10. Stop actuator and stop engine if running. 11. Reinstall the air duct. 12. Start and run the engine for about one (1) minute to dry out the solvent residue. 13. Operate the actuator to make sure the solvent is purged from the idle by-pass valve. 14. Disconnect the actuator from the idle air by-pass valve. 15. Reattach the control signal lead to the air by-pass valve. 16. Check engine for normal operation. NOTE: IT SHOULD NOT BE NECESSARY TO RESET THE IDLE SPEED SINCE ONLY THE IDLE AIR BY-PASS VALVE WAS SERVICED IN THIS PROCEDURE Warranty Coverage Throttle bodies and idle air by-pass valves on all EFI (Port Fuel Injection) engines through the 1992 model year that can be cleaned (as identified in the application charts) are covered under 5/50 Emissions Warranty Coverage. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Other Service Bulletins for Idle Speed: > Page 2467 For those throttle bodies identified as having sludge tolerant designs or using service kit (F2PZ-9F939-A) where cleaning is not allowed per the application charts, the warranty claims for cleaning will not be reimbursed even within the 12/12 warranty coverage period. Cleaning is not allowed. Service kit installation (single time) is covered under 5/50 emission warranty. Labor Standards Operations The labor operations shown in the following Operation/Description/Time columns are identified by procedure number and vehicle line. Specific engines for various vehicles are identified in the sludge cleaning procedure application charts. The throttle body cleaning operations with combinations and the air by-pass valve cleaning combinations will appear in future Labor Manuals under the following operation numbers. ^ 9926 B - Throttle body and idle air by-pass valve cleaning ^ 9926 B2 - Adjust idle speed ^ 9715 A - Air by-pass valve cleaning only ^ 9715 A1 - Adjust idle speed PART NUMBER PART NAME CLASS F2PZ-9F939-A Idle Air By-pass Service Kit B D9AZ-19579-AA Carburstor Tune-Up Cleaner BG OTHER APPLICABLE ARTICLES: 89-13-8 SUPERSEDES: 88-24-5, 88-24-6, 89-16-5, 91-10-9, 91-7-4 Operation Description WARRANTY STATUS: Eligible Under Warranty Coverage As Stated In The Text Of This Article OPERATION DESCRIPTION TIME 912507A Idle Air By-Pass Valve 0.5 Hr. Cleaning - 1983-85 Escort, EXP, LN7, LYNX 1.6L EFI. 912507B Idle Air By-Pass Valve 0.5 Hr. Cleaning - 1986-91 Escort 1.9L EFI, 1986/87 EXP, Lynx 1.9L EFI, 1991 Tracer 1.9L EFI. 912507C Idle Air By Pass Valve 0.5 Hr. Cleaning - 1984-87 Mustang 2.3L T/C, 1986/87 Capri, Cougar 2.3L T/C, 1984-88 T-Bird 2.3L T/C, 1987/92 Mustang 2.3L EFI. 912507D Idle By-Pass Valve Cleaning 0.6 Hr. - 1988-91 Tempo, Topaz 2.3L HSC, 1985-92 Ranger 2.3L EFI. 912507E Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1986/87 Aerostar 2.3L EFI, 1985 Bronco II 2.3L EFI. 912507F Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1986-90 Bronco II 2.9L EFI, 1986-92 Ranger 2.9L EFI. 912507G Idle Air By-Pass Valve 0.6 Hr. Cleaning - 1991/92 Probe 3.0L EFI, 1986-91 Taurus 3.0L EFI, 1987-91 Sable 3.0L EFI. 912507H Idle Air By-Pass Valve 0.7 Hr. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Other Service Bulletins for Idle Speed: > Page 2468 Cleaning - 1986-91 Aerostar 3.0L EFI, 1991 Ranger 3.0L EFI. 912507I Idle Air By-Pass Valve 0.6 Hr. Cleaning - 1988 Continental, Cougar, Taurus, T-Bird, Sable 3.8L EFI. 1988 Cougar, T-Bird 3.8L S/C. 912507J Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1990-92 Aerostar 4.0L EFI, 1990 Bronco II 4.0L EFI, 1991/92 Explorer 4.0L EFI, 1990-92 Ranger 4.0L EFI. 912507K Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1987-92 Bronco 4.9L EFI, 1987-92 F-Series 4.9L EFI, 1987/90 Econoline (Without Rear Heater) 4.9L EFI, 1991/92 Econoline (All) 4.9L EFI. 912507L Idle Air By-Pass Valve 0.6 Hr. Cleaning - 1986-88 Cougar, T-Bird 5.0L EFI, 1986-87 Continental, Mark VII 5.OL EFI, 1986/91 Crn - Victoria, Grn - Marquis 5.0L EFI, 1986-92 Mark VII 5.0L HO, 1982-92 Mustang 5.0L HO. 912507M Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1985-92 Bronco, E-Series, F-Series 5.0L EFI. 912507N Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1988-90 Bronco, F-Series 5.8L. 1991 Econo, F-Series, Bronco 5.8L (Do not Clean Solenoid, Calib; 1-64E-R10, 1-64H-R10, 1-64J-R10, 1-64K-R10, 1-64M-R10, 1-64P-R10, 1-64R-R10, 1-75A-R00, 1-76A-R00, 1-76B-R00, 1-76C-R00. 912507O Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1991/92 F And B Series, 7.0L EFI. 912507P Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1987-92 E-Series, F-Series 7.5L EFI. 912507Q Throttle Body And Idle Air 0.9 Hr. By-Pass Valve Cleaning - 1989/90 Probe 3.0L EFI. 912507R Throttle Body And Idle Air 0.8 Hr. By-Pass Valve Cleaning - 1987-90 Econoline (With Rear Heat) 4.9L EFI. 912507S Throttle Body And Idle Air 0.9 Hr. By-Pass Valve Cleaning - 1988-90 Econoline 5.8L EFI. 912507T Service Kit Install - All Cars 1.0 Hr. And Light Trucks (Except Aerostar And Econoline) - Refer To The Service Procedure Application Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Other Service Bulletins for Idle Speed: > Page 2469 Charts, For Vehicle Application. 912507U Service Kit Install - 1.2 Hr. Aerostar, Econoline - Refer To Service Procedure Application Charts - For Vehicle Application. DEALER CODING BASIC PART NO. CONDITION CODE 9E926 49 OASIS CODES: 602300, 607000, 607400, 607700, 608400, 611500, 618400 Technical Service Bulletin # 91257 Date: 911213 Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up Article No. 91-25-7 12/13/91 ^ HARD COLD START - DURING INITIAL START-UP, IDLE OR DECEL - EFI ENGINES SLUDGE IN THROTTLE BODY AND/OR IDLE AIR BY-PASS VALVE ^ HESITATION/STALLS - DURING INITIAL START-UP, IDLE OR DECEL - EFI ENGINES SLUDGE IN THROTTLE BODY AND/OR IDLE AIR BY-PASS VALVE FORD: 1983-87 EXP 1983-91 ESCORT 1984-90 MUSTANG, THUNDERBIRD 1986-90 TAURUS 1986-91 CROWN VICTORIA 1988-90 TEMPO LINCOLN-MERCURY: 1983-85 LN7 1983-87 LYNX 1984-88 CAPRI 1984-90 COUGAR 1986-90 CONTINENTAL, MARK VII, SABLE 1986-91 GRAND MARQUIS, TOWN CAR 1988-90 TOPAZ 1991 TRACER LIGHT TRUCK: 1985-90 BRONCO II, BRONCO 1985-91 ECONOLINE, F-150-350 SERIES 1985-92 RANGER 1986-91 AEROSTAR 1991 EXPLORER ISSUE: Hard cold starts, hesitation and stalls on initial start-up or during idle or decel may be caused by sludge in the throttle body and/or idle by-pass valve. Sludge deposits or oil film on the throttle body bore and plate or the idle air by-pass valve may cause one or more of the following conditions. ^ Hard Cold Start ^ Stall On Initial Start-Up ^ Stall During Idle ^ Stall During Decel ^ Rough Idle ^ Rolling Idle Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Other Service Bulletins for Idle Speed: > Page 2470 ^ Hesitation During Acceleration ACTION: A new idle air by-pass service kit (F2PZ-9F939-A) is now available for service use to correct sludge contamination concerns of the throttle bore and plate only. It eliminates the need to clean the majority of past model throttle body applications. Cleaning is not required on sludge tolerant throttle body designs released for 1991 and newer model years. Figure 1 Install an idle air by-pass service kit (F2PZ-9F939-A) as applicable to provide a permanent correction for symptoms caused by throttle body sludge deposits. Refer to the instruction sheet included in the kit for installation details. Refer to Figure 1 for a specific application list of EFI (port fuel Injection) engines involved in this TSB article. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Other Service Bulletins for Idle Speed: > Page 2471 The idle air by-pass service kit (F2PZ-9F939-A) includes the following items. ^ One (1) Idle Adjust Spacer ^ Two (2) Gaskets ^ Two (2) Attaching Bolts ^ One (1) "Attention" Sticker ^ One (1) Instruction Sheet Figure 2 Refer to Figure 2 for a pictorial of the kits components. NOTE: EFFECTIVE WITH THIS TSB, THROTTLE BODY CLEANING IS NO LONGER COVERED UNDER 5/50 EMISSIONS WARRANTY, UNLESS AS SPECIFIED IN THE FOLLOWING APPLICATION CHARTS. FAILURE TO FOLLOW THE CORRECT PROCEDURE MAY RESULT IN THE CLAIM BEING DISALLOWED. The idle air adjust spacer incorporates sludge tolerant design features that eliminate throttle body sludge related conditions. Once installed, throttle body cleaning is not allowed and periodic adjustment of the throttle body is not required. Procedures, Warranty and Labor CHECKS TO MAKE PRIOR TO SERVICE KIT INSTALLATION Confirm that the following items are not causing the idle quality concern before proceeding with the service kit installation. ^ Contamination within the idle air by-pass solenoid ^ Lack of fuel system control (excessively rich or lean) ^ Ignition timing change ^ Incorrect or malfunctioning EGR system ^ Incorrect or malfunctioning cooling system ^ Vacuum leaks (air intake manifold, vacuum hoses, vacuum reservoirs, power brake booster where applicable) ^ EEC diagnostics have been performed and vehicle malfunction indicated service output codes have been resolved and cleared. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Other Service Bulletins for Idle Speed: > Page 2472 If any of the areas listed above are found to be at fault, correct them before proceeding with the service kit installation. Idle Speed Adjustment WARNING: BEFORE PROCEEDING WITH THE IDLE SPEED ADJUSTMENT, VERIFY THAT THE FOLLOWING ITEMS ARE TAKEN CARE OF PROPERLY. ^ The transmission is in PARK or Neutral. ^ The parking brake is applied. ^ The wheels are properly blocked. ^ The engine is at operating temperature. ^ The heater, A/C, cooling fan and other accessories are OFF. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Other Service Bulletins for Idle Speed: > Page 2473 Figure 3 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Other Service Bulletins for Idle Speed: > Page 2474 Figure 4 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Other Service Bulletins for Idle Speed: > Page 2475 Figure 5 The EFI throttle body idle speed adjustment procedures for the various model year passenger cars and light trucks are outlined in step-by-step procedures featured in Figures 3, 4 and 5. Select the appropriate procedure for the vehicle involved and adjust the throttle body idle RPM accordingly, after service kit installation. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Other Service Bulletins for Idle Speed: > Page 2476 Figure 6 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Other Service Bulletins for Idle Speed: > Page 2477 Figure 7 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Other Service Bulletins for Idle Speed: > Page 2478 Figure 8 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Other Service Bulletins for Idle Speed: > Page 2479 Figure 9 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Other Service Bulletins for Idle Speed: > Page 2480 Figure 10 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Other Service Bulletins for Idle Speed: > Page 2481 Figure 11 THROTTLE BODY AND IDLE AIR BY-PASS SOLENOID SERVICE PROCEDURE Detailed application charts for throttle body and idle air by-pass solenoid service procedures by engine VIN # /engine displacement/vehicle application and model year are shown in Figures 6 through 11. Refer to these charts to see if the service kit is to be installed and which service cleaning procedure, if any, is to be used. SERVICE CLEANING PROCEDURES The following items should be noted prior to beginning the service cleaning procedure. ^ Confirm that the correct service cleaning procedure is identified in the Application Charts, Figures 6-11, for the vehicle/engine combination being Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Other Service Bulletins for Idle Speed: > Page 2482 serviced. ^ Do not clean throttle bodies identified to accept service kit (F2PZ-9F939-A), IDLE AIR ADJUST SPACER. ^ Use a 1" (25.4 mm) to 1-1/2" (38.1 mm) wire stemmed horse hair or nylon bottle cleaner type brush. ^ Use rubber gloves and eye protection. ^ Do not clean throttle bodies identified with a yellow/black "ATTENTION" label. ^ Do not clean "Black" plastic air by-pass valves. Refer to TSB 89-13-8 for service details. ^ Do not run vehicles with air flow meters when the air duct is removed. ^ Do not use carburetor cleaner as a cleaning solvent. Use Carburetor Tune-up Cleaner (D9AZ-19579-AA). Procedure # 1 THROTTLE BODY AND IDLE AIR BY-PASS VALVE CLEANING CAUTION: DO NOT RUN VEHICLES EQUIPPED WITH AIR FLOW METERS DURING THE CLEANING PROCEDURE. IF THERE IS A YELLOW/BLACK "ATTENTION" LABEL ON THE THROTTLE BODY ADVISING NOT TO CLEAN, OR IF THE VEHICLE IS IDENTIFIED AS ACCEPTING SERVICE KIT (F2PZ-9F939-A), USE PROCEDURE # 2 FOR IDLE AIR BY-PASS VALVE CLEANING ONLY. 1. Plug the actuator into the connector in the Rotunda Cleaner/Tester, Tool 113-00009. 2. Remove the air duct to the throttle body inlet. 3. Disoonnect the idle air by-pass valve signal lead. 4. Attach the actuator harness plug to the idle air by-pass valve. 5. Start the actuator and then start the engine. Do not start engines that have air flow meters. 6. Spray just enough Carburetor Tune-up Cleaner (D9AZ-19579-AA) into the throttle bore to wet the bore and throttle plate. 7. Spray the Carburetor Tune-up Cleaner for about five (5) seconds into the idle air by-pass valve inlet passage while the actuator is operating. 8. Stop the engine and actuator. Let everything soak for fifteen (15) minutes. 9. After a fifteen (15) minute soak, saturate the cleaning brush with solvent and scrub between the throttle body bore and plate while holding the throttle wide open. NOTE: IT IS NECESSARY TO APPLY SOME PRESSURE ON THE BRUSH WHILE SCRUBBING. 10. Repeat saturating the brush and scrubbing for one (1) to two (2) minutes, making sure to reach into the corners where the throttle shaft meets the bore wall. 11. Start the actuator and the start the engine. Do not start engines that have air flow meters. 12. Spray Carburetor Tune-up Cleaner into the throttle bore for up to one (1) minute to wash away residue. Do not spray for longer than six (6) continuous seconds on engines that have air flow meters and are not running. 13. Spray Carburetor Tune-up Cleaner into the idle by-pass valve passage leading to the inlet of the valve for up to one (1) minute. Do not spray for longer than six (6) continuous seconds on engines that have air flow meters and are not running. 14. Stop actuator and stop engine, if running. NOTE: MAKE SURE THE THROTTLE PLATES OPERATE FREELY AND CLOSE PROPERLY. 15. Reinstall the air duct. 16. Start and run the engine for about one (1) minute to dry out the solvent residue. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Other Service Bulletins for Idle Speed: > Page 2483 17. Operate the actuator to make sure the solvent is purged from the idle by-pass valve. 18. Disconnect the actuator from the idle air by-pass valve. 19. Reattach the control signal lead to the air by-pass valve. 20. Check engine for normal operation. It may be necessary to reset the idle speed due to a previous adjustment for an idle concern. (Refer to the respective Powertrain/Emissions Diagnosis Service Manual, Throttle Body Section, for idle speed adjust procedure.) Procedure # 2 Idle Air By-Pass Valve Cleaning Only CAUTION: THIS CLEANING PROCEDURE MAY BE USED WITH SLUDGE TOLERANT THROTTLE BODIES WHICH ARE IDENTIFIED WITH A YELLOW/BLACK "ATTENTION" LABEL AND THOSE USING SERVICE KIT (F2PZ-9F939-A). NO ATTEMPT SHOULD BE MADE TO CLEAN THROTTLE BODY BORE/PLATE AREA BY DIRECT SPRAYING OR SCRUBBING. DO NOT RUN VEHICLES WITH AIR FLOW METERS DURING CLEANING PROCEDURE. 1. Plug the actuator into the connector in the Rotunda Air By-Pass Valve Adapter 113-00009, or equivalent. 2. Remove the air duct to the throttle body inlet. 3. Disconnect the idle air by-pass valve signal lead. 4. Attach the actuator harness plug to the idle air by-pass valve. 5. Start the actuator and then start the engine. NOTE: DO NOT START ENGINES THAT HAVE AIR FLOW METERS. 6. Spray the Carburetor Tune-up Cleaner for about five (5) seconds into the idle air by-pass valve inlet passage while the actuator is operating. CAUTION: AVOID DIRECT SPRAYING ON THROTTLE PLATE/BORE AREA. 7. Stop the engine and actuator. Let everything soak for fifteen (15) minutes. 8. Start the actuator and the start the engine. CAUTION: DO NOT START ENGINES THAT HAVE AIR FLOW METERS. 9. Spray Carburetor Tune-up Cleaner into the throttle bore for up to one (1) minute. CAUTION: DO NOT SPRAY FOR LONGER THAN SIX (6) CONTINUOUS SECONDS ON ENGINES THAT HAVE AIR FLOW METERS AND ARE NOT RUNNING. 10. Stop actuator and stop engine if running. 11. Reinstall the air duct. 12. Start and run the engine for about one (1) minute to dry out the solvent residue. 13. Operate the actuator to make sure the solvent is purged from the idle by-pass valve. 14. Disconnect the actuator from the idle air by-pass valve. 15. Reattach the control signal lead to the air by-pass valve. 16. Check engine for normal operation. NOTE: IT SHOULD NOT BE NECESSARY TO RESET THE IDLE SPEED SINCE ONLY THE IDLE AIR BY-PASS VALVE WAS SERVICED IN THIS PROCEDURE Warranty Coverage Throttle bodies and idle air by-pass valves on all EFI (Port Fuel Injection) engines through the 1992 model year that can be cleaned (as identified in the application charts) are covered under 5/50 Emissions Warranty Coverage. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Other Service Bulletins for Idle Speed: > Page 2484 For those throttle bodies identified as having sludge tolerant designs or using service kit (F2PZ-9F939-A) where cleaning is not allowed per the application charts, the warranty claims for cleaning will not be reimbursed even within the 12/12 warranty coverage period. Cleaning is not allowed. Service kit installation (single time) is covered under 5/50 emission warranty. Labor Standards Operations The labor operations shown in the following Operation/Description/Time columns are identified by procedure number and vehicle line. Specific engines for various vehicles are identified in the sludge cleaning procedure application charts. The throttle body cleaning operations with combinations and the air by-pass valve cleaning combinations will appear in future Labor Manuals under the following operation numbers. ^ 9926 B - Throttle body and idle air by-pass valve cleaning ^ 9926 B2 - Adjust idle speed ^ 9715 A - Air by-pass valve cleaning only ^ 9715 A1 - Adjust idle speed PART NUMBER PART NAME CLASS F2PZ-9F939-A Idle Air By-pass Service Kit B D9AZ-19579-AA Carburstor Tune-Up Cleaner BG OTHER APPLICABLE ARTICLES: 89-13-8 SUPERSEDES: 88-24-5, 88-24-6, 89-16-5, 91-10-9, 91-7-4 Operation Description WARRANTY STATUS: Eligible Under Warranty Coverage As Stated In The Text Of This Article OPERATION DESCRIPTION TIME 912507A Idle Air By-Pass Valve 0.5 Hr. Cleaning - 1983-85 Escort, EXP, LN7, LYNX 1.6L EFI. 912507B Idle Air By-Pass Valve 0.5 Hr. Cleaning - 1986-91 Escort 1.9L EFI, 1986/87 EXP, Lynx 1.9L EFI, 1991 Tracer 1.9L EFI. 912507C Idle Air By Pass Valve 0.5 Hr. Cleaning - 1984-87 Mustang 2.3L T/C, 1986/87 Capri, Cougar 2.3L T/C, 1984-88 T-Bird 2.3L T/C, 1987/92 Mustang 2.3L EFI. 912507D Idle By-Pass Valve Cleaning 0.6 Hr. - 1988-91 Tempo, Topaz 2.3L HSC, 1985-92 Ranger 2.3L EFI. 912507E Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1986/87 Aerostar 2.3L EFI, 1985 Bronco II 2.3L EFI. 912507F Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1986-90 Bronco II 2.9L EFI, 1986-92 Ranger 2.9L EFI. 912507G Idle Air By-Pass Valve 0.6 Hr. Cleaning - 1991/92 Probe 3.0L EFI, 1986-91 Taurus 3.0L EFI, 1987-91 Sable 3.0L EFI. 912507H Idle Air By-Pass Valve 0.7 Hr. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Other Service Bulletins for Idle Speed: > Page 2485 Cleaning - 1986-91 Aerostar 3.0L EFI, 1991 Ranger 3.0L EFI. 912507I Idle Air By-Pass Valve 0.6 Hr. Cleaning - 1988 Continental, Cougar, Taurus, T-Bird, Sable 3.8L EFI. 1988 Cougar, T-Bird 3.8L S/C. 912507J Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1990-92 Aerostar 4.0L EFI, 1990 Bronco II 4.0L EFI, 1991/92 Explorer 4.0L EFI, 1990-92 Ranger 4.0L EFI. 912507K Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1987-92 Bronco 4.9L EFI, 1987-92 F-Series 4.9L EFI, 1987/90 Econoline (Without Rear Heater) 4.9L EFI, 1991/92 Econoline (All) 4.9L EFI. 912507L Idle Air By-Pass Valve 0.6 Hr. Cleaning - 1986-88 Cougar, T-Bird 5.0L EFI, 1986-87 Continental, Mark VII 5.OL EFI, 1986/91 Crn - Victoria, Grn - Marquis 5.0L EFI, 1986-92 Mark VII 5.0L HO, 1982-92 Mustang 5.0L HO. 912507M Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1985-92 Bronco, E-Series, F-Series 5.0L EFI. 912507N Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1988-90 Bronco, F-Series 5.8L. 1991 Econo, F-Series, Bronco 5.8L (Do not Clean Solenoid, Calib; 1-64E-R10, 1-64H-R10, 1-64J-R10, 1-64K-R10, 1-64M-R10, 1-64P-R10, 1-64R-R10, 1-75A-R00, 1-76A-R00, 1-76B-R00, 1-76C-R00. 912507O Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1991/92 F And B Series, 7.0L EFI. 912507P Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1987-92 E-Series, F-Series 7.5L EFI. 912507Q Throttle Body And Idle Air 0.9 Hr. By-Pass Valve Cleaning - 1989/90 Probe 3.0L EFI. 912507R Throttle Body And Idle Air 0.8 Hr. By-Pass Valve Cleaning - 1987-90 Econoline (With Rear Heat) 4.9L EFI. 912507S Throttle Body And Idle Air 0.9 Hr. By-Pass Valve Cleaning - 1988-90 Econoline 5.8L EFI. 912507T Service Kit Install - All Cars 1.0 Hr. And Light Trucks (Except Aerostar And Econoline) - Refer To The Service Procedure Application Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Other Service Bulletins for Idle Speed: > Page 2486 Charts, For Vehicle Application. 912507U Service Kit Install - 1.2 Hr. Aerostar, Econoline - Refer To Service Procedure Application Charts - For Vehicle Application. DEALER CODING BASIC PART NO. CONDITION CODE 9E926 49 OASIS CODES: 602300, 607000, 607400, 607700, 608400, 611500, 618400 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > Page 2487 IDLE SPEED SPECIFICATIONS Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Adjustments > Curb Idle Speed Idle Speed: Adjustments Curb Idle Speed CURB IDLE SPEED ADJUSTMENT - Set parking brake, block wheels and place the transmission in Neutral (manual) or Park (automatic). - Bring engine to normal operating temperature (upper radiator hose hot). - Place A/C Heat selector to "OFF" (if equipped). - Disconnect and plug vacuum hoses at air bypass valve, EGR valve, and purge control valve. - Place the transmission in the specified gear. See: Specifications - Check curb idle rpm. Adjust to specification. See: Specifications - Place the transmission in Neutral (manual) or Park (automatic). Rev the engine momentarily. Place the transmission in specified position, and recheck curb idle rpm. Readjust if required. - If vehicle is equipped with A/C, perform the following additional steps: Connect an external vacuum source providing a minimum of 33.7 kPA (10 in-Hg) to the Vacuum Operated Throttle Modulator (VOTM) kicker. - Place the transmission selector in specified position. See: Specifications - Check/adjust VOTM kicker speed. If adjustment is required, loosen kicker locknut and turn kicker to required speed, tighten locknut. - Remove plugs and reconnect vacuum hoses. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Adjustments > Curb Idle Speed > Page 2490 Idle Speed: Adjustments Fast Idle Speed FAST IDLE SPEED ADJUSTMENT - Set parking brake, block wheels and place the transmission in Park (automatic) or Neutral (manual). - Bring the engine to normal operating temperature. - Disconnect the vacuum hose at the EGR valve, air bypass valve, and purge control valve and plug. - Place the fast idle adjustment mechanism on specified step of fast idle cam. Check/adjust fast idle rpm to specification. See: Specifications - Recheck for repeatability. - Remove plugs from the EGR valve, air bypass valve, and purge control valve vacuum hoses and reconnect. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Element <--> [Air Filter Element] > Component Information > Technical Service Bulletins > Engine - Lack of Power/No Start Diagnosis Air Cleaner Element: Technical Service Bulletins Engine - Lack of Power/No Start Diagnosis Article No. 91-12-11 06/12/91 LACK OF POWER 7.5L, 5.8L, 5.0L, 4.9L - CATALYTIC CONVERTER DIAGNOSTIC TIPS LIGHT TRUCK: 1986-91 BRONCO, ECONOLINE, F-150-350 SERIES 1988-91 F SUPER DUTY, F47 ISSUE: Lack of power or a no start condition may be diagnosed as an exhaust restriction caused by a plugged catalytic converter. A plugged catalytic converter (internal deterioration) is usually caused by abnormal engine operation. ACTION: Diagnose the catalytic converter to confirm internal failure. Refer to the Catalyst and Exhaust System Diagnostic Section, in the Engine/Emissions Diagnostic Shop Manual and the following procedures for service details. 1. Lack of proper HEGO operation may cause, or be the result of a rich or lean fuel condition, which could cause additional heat in the catalyst. Perform self test KOEO and KOER, service any codes. NOTE: IF TWO DIGIT CODES 41, 42, 85 OR THREE DIGIT CODES 171, 172, 173, 179, 181, 182, 183 AND 565 ARE RECEIVED, CHECK FOR PROPER HEGO GROUND. If the HEGO ground is good, the following areas may be at fault: ^ Ignition Coil ^ Distributor Cap ^ Distributor Rotor ^ Fouled Spark Plug ^ Spark Plug Wires ^ Air Filter ^ Stuck Open Injector ^ Fuel Contamination Engine OIL ^ Manifold Leaks Intake/ Exhaust ^ Fuel Pressure ^ Poor Power Ground ^ Engine Not At Normal Operating Temperature ^ HEGO Sensor 2. Spark timing that is retarded from specification may increase exhaust gas temperature and shorten catalyst life. Refer to the following procedure for service details. a. Check spark timing. Check base timing with spout disconnected. Set base timing to the specification on the vehicle emission decal. b. Check computed timing with spout connected. NOTE: COMPUTED TIMING IS EQUAL TO BASE TIMING PLUS 20~ BTDC +/- 3~. 3. Misfiring spark plugs may cause an unburned fuel air mixture to pass through the catalyst, which could cause higher than normal catalyst temperatures. Refer to the following procedure for service details. a. Check secondary ignition, hook the vehicle up to an engine analyzer and check for a secondary ignition misfire. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Element <--> [Air Filter Element] > Component Information > Technical Service Bulletins > Engine - Lack of Power/No Start Diagnosis > Page 2496 NOTE: SERVICE ANY ITEM THAT IS NOT PERFORMING AT PROPER SPECIFICATIONS BEFORE CONTINUING. 4. Fuel pressure that is too high may cause rich air fuel mixtures to pass through the catalyst which could cause higher than normal catalyst temperatures. Refer to the following procedure for service details. a. Check fuel pressure, install fuel pressure gauge, start and run the engine at idle. Fuel pressures between 28 and 34 PSI are typical (4.9L typically is 15 PSI higher). b. Disconnect the vacuum line going to the fuel pressure regulator. Fuel pressure typically jumps to 40 PSI +/- 3 PSI (4.9L typically is 15 PSI higher). Visually inspect vacuum line for raw fuel. NOTE: FUEL PRESSURES ABOVE THESE VALUES SHOULD BE CORRECTED. HOWEVER, THIS MAY NOT BE THE CAUSE OF THE CONCERN. SERVICE AS NECESSARY. 5. Throttle plates in the throttle body not returning to the proper closed position may cause excessive catalyst temperatures during downhill grades. Refer to the following procedure for service details. a. Visually inspect the throttle body and linkage for: ^ Binding or sticking throttle linkage. ^ Tight speed control linkage or cable. ^ Vacuum line interference. ^ Electrical harness interference. NOTE: AFTERMARKET GOVERNORS, THROTTLE LINKAGE AND CABLES ASSOCIATED WITH POWER TAKE-OFF UNITS, MAY ALSO INTERFERE WITH PROPER THROTTLE RETURN. SERVICE AS NECESSARY. 6. It is extremely important that all systems related to the engine and emission systems operate properly. a. Visually inspect the engine compartment to make sure all vacuum hoses and spark plug wires are properly routed and securely connected. b. Inspect all wiring harnesses and connectors for insulation damage, burned, overheated, loose or broken conditions. c. Verify proper operation of the thermactor system. Thermactor systems that fail to dump thermactor air to the atmosphere properly or at the correct time can cause high catalyst temperatures. d. Visually inspect thermactor system for damaged or kinked hoses and perform a function test on following components: air control valve, check valve, silencer, filter and the air bypass solenoid. e. Verify proper operation of the engine cooling system thermostat. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under Basic Warranty Coverage, Emissions Warranty Coverage OPERATION DESCRIPTION TIME 911211A Diagnostics - Perform 0.5 Hrs. KOEO And KOER Self Tests 911211B Timing - Check Or Adjust 0.5 Hrs. Spark Timing, Check Computed Timing And Check Secondary Ignition System With Engine Analyzer. 911211C Check - Fuel Pressure And 0.2 Hrs. Inspect Vacuum Line For Raw Fuel. 911211D Inspect - Throttle Body And 0.1 Hrs. Linkage. 911211E Inspect - Vacuum Hoses, 0.1 Hrs. Electrical Harnesses, Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Element <--> [Air Filter Element] > Component Information > Technical Service Bulletins > Engine - Lack of Power/No Start Diagnosis > Page 2497 Connectors And Spark Plug Wires For Routing Damage. 911211F Thermactor System - 0.3 Hrs. Inspect For Proper Operation And Damaged Component. Includes Function Check Of Air Control Valve, Thermactor Air Bypass Solenoid, Check Valves, Silencer And Filter. 911211G Thermostat - Check For 0.2 Hrs. Proper Operation. DEALER CODING BASIC PART NO. CONDITION CODE 5E212 25 OASIS CODES: 403000, 603300, 614000 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Service and Repair Fuel Filter: Service and Repair REMOVAL - Remove the air cleaner. - Hold the fuel filter inlet hex nut with a backup wrench and unscrew the fuel line tube nut from the fuel filter inlet. WARNING: Use care to prevent combustion from fuel spillage. - Unscrew the fuel inlet fitting. - Remove the gasket, filter and spring. - Discard the gasket and filter. INSTALLATION - Install the spring, new filter and gasket. - Hand start the fuel inlet fitting into the carburetor then, tighten to 30-35 Nm (22-26 lb-ft). Apply oil, ESE-M2C39-E or equivalent to the fuel tube nut threads and tube flare. - Hand start the fuel line tube nut into the fuel inlet fitting (approximately two threads). - Use a backup wrench on the fuel inlet fitting while tightening the fuel line tube nut to 20-24 Nm (15-18 lb-ft). - Start the engine and check for fuel leak. - Install the air cleaner. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications Firing Order: Specifications Location On Distributor FIRING ORDER: 1-3-7-2-6-5-4-8 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Timing > Ignition Timing Connector > Component Information > Description and Operation Ignition Timing Connector: Description and Operation Fig. 20 Ignition Timing Vacuum Switch Below vacuum setting, this switch, Fig. 20, used on some vehicles, is open and signals the ignition module to retard spark timing. The switch is closed above the vacuum setting and the ignition module is in the non-retard spark timing mode. Calibration resistors inside the switch control the amount of retard. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Timing > Ignition Timing Connector > Component Information > Description and Operation > Page 2508 Ignition Timing Connector: Testing and Inspection Ignition Timing Vacuum Switch Ignition Timing Vacuum Switch Test Chart 1. Disconnect switch from ignition module. 2. Connect suitable ohmmeter across switch terminals and compare resistance measured to ``less than'' values in the Ignition Timing vacuum Switch Test chart. 3. Apply vacuum to switch, using an outside vacuum source. Compare resistance now measured across switch terminals to ``greater than'' values in the Ignition Timing vacuum Switch Test chart. 4. Replace switch if resistance is not within specifications. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Timing > Number One Cylinder > Component Information > Locations Number One Cylinder: Locations Cylinder Numbering And Distributor Location Location On Distributor Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Timing > Timing Marks and Indicators > System Information > Diagrams Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Engine - Lack of Power/No Start Diagnosis Ignition Cable: Technical Service Bulletins Engine - Lack of Power/No Start Diagnosis Article No. 91-12-11 06/12/91 LACK OF POWER 7.5L, 5.8L, 5.0L, 4.9L - CATALYTIC CONVERTER DIAGNOSTIC TIPS LIGHT TRUCK: 1986-91 BRONCO, ECONOLINE, F-150-350 SERIES 1988-91 F SUPER DUTY, F47 ISSUE: Lack of power or a no start condition may be diagnosed as an exhaust restriction caused by a plugged catalytic converter. A plugged catalytic converter (internal deterioration) is usually caused by abnormal engine operation. ACTION: Diagnose the catalytic converter to confirm internal failure. Refer to the Catalyst and Exhaust System Diagnostic Section, in the Engine/Emissions Diagnostic Shop Manual and the following procedures for service details. 1. Lack of proper HEGO operation may cause, or be the result of a rich or lean fuel condition, which could cause additional heat in the catalyst. Perform self test KOEO and KOER, service any codes. NOTE: IF TWO DIGIT CODES 41, 42, 85 OR THREE DIGIT CODES 171, 172, 173, 179, 181, 182, 183 AND 565 ARE RECEIVED, CHECK FOR PROPER HEGO GROUND. If the HEGO ground is good, the following areas may be at fault: ^ Ignition Coil ^ Distributor Cap ^ Distributor Rotor ^ Fouled Spark Plug ^ Spark Plug Wires ^ Air Filter ^ Stuck Open Injector ^ Fuel Contamination Engine OIL ^ Manifold Leaks Intake/ Exhaust ^ Fuel Pressure ^ Poor Power Ground ^ Engine Not At Normal Operating Temperature ^ HEGO Sensor 2. Spark timing that is retarded from specification may increase exhaust gas temperature and shorten catalyst life. Refer to the following procedure for service details. a. Check spark timing. Check base timing with spout disconnected. Set base timing to the specification on the vehicle emission decal. b. Check computed timing with spout connected. NOTE: COMPUTED TIMING IS EQUAL TO BASE TIMING PLUS 20~ BTDC +/- 3~. 3. Misfiring spark plugs may cause an unburned fuel air mixture to pass through the catalyst, which could cause higher than normal catalyst temperatures. Refer to the following procedure for service details. a. Check secondary ignition, hook the vehicle up to an engine analyzer and check for a secondary ignition misfire. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Engine - Lack of Power/No Start Diagnosis > Page 2519 NOTE: SERVICE ANY ITEM THAT IS NOT PERFORMING AT PROPER SPECIFICATIONS BEFORE CONTINUING. 4. Fuel pressure that is too high may cause rich air fuel mixtures to pass through the catalyst which could cause higher than normal catalyst temperatures. Refer to the following procedure for service details. a. Check fuel pressure, install fuel pressure gauge, start and run the engine at idle. Fuel pressures between 28 and 34 PSI are typical (4.9L typically is 15 PSI higher). b. Disconnect the vacuum line going to the fuel pressure regulator. Fuel pressure typically jumps to 40 PSI +/- 3 PSI (4.9L typically is 15 PSI higher). Visually inspect vacuum line for raw fuel. NOTE: FUEL PRESSURES ABOVE THESE VALUES SHOULD BE CORRECTED. HOWEVER, THIS MAY NOT BE THE CAUSE OF THE CONCERN. SERVICE AS NECESSARY. 5. Throttle plates in the throttle body not returning to the proper closed position may cause excessive catalyst temperatures during downhill grades. Refer to the following procedure for service details. a. Visually inspect the throttle body and linkage for: ^ Binding or sticking throttle linkage. ^ Tight speed control linkage or cable. ^ Vacuum line interference. ^ Electrical harness interference. NOTE: AFTERMARKET GOVERNORS, THROTTLE LINKAGE AND CABLES ASSOCIATED WITH POWER TAKE-OFF UNITS, MAY ALSO INTERFERE WITH PROPER THROTTLE RETURN. SERVICE AS NECESSARY. 6. It is extremely important that all systems related to the engine and emission systems operate properly. a. Visually inspect the engine compartment to make sure all vacuum hoses and spark plug wires are properly routed and securely connected. b. Inspect all wiring harnesses and connectors for insulation damage, burned, overheated, loose or broken conditions. c. Verify proper operation of the thermactor system. Thermactor systems that fail to dump thermactor air to the atmosphere properly or at the correct time can cause high catalyst temperatures. d. Visually inspect thermactor system for damaged or kinked hoses and perform a function test on following components: air control valve, check valve, silencer, filter and the air bypass solenoid. e. Verify proper operation of the engine cooling system thermostat. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under Basic Warranty Coverage, Emissions Warranty Coverage OPERATION DESCRIPTION TIME 911211A Diagnostics - Perform 0.5 Hrs. KOEO And KOER Self Tests 911211B Timing - Check Or Adjust 0.5 Hrs. Spark Timing, Check Computed Timing And Check Secondary Ignition System With Engine Analyzer. 911211C Check - Fuel Pressure And 0.2 Hrs. Inspect Vacuum Line For Raw Fuel. 911211D Inspect - Throttle Body And 0.1 Hrs. Linkage. 911211E Inspect - Vacuum Hoses, 0.1 Hrs. Electrical Harnesses, Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Engine - Lack of Power/No Start Diagnosis > Page 2520 Connectors And Spark Plug Wires For Routing Damage. 911211F Thermactor System - 0.3 Hrs. Inspect For Proper Operation And Damaged Component. Includes Function Check Of Air Control Valve, Thermactor Air Bypass Solenoid, Check Valves, Silencer And Filter. 911211G Thermostat - Check For 0.2 Hrs. Proper Operation. DEALER CODING BASIC PART NO. CONDITION CODE 5E212 25 OASIS CODES: 403000, 603300, 614000 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Engine - Lack of Power/No Start Diagnosis > Page 2521 Ignition Cable: Technical Service Bulletins Ignition System - Diagnostics Manual Correction Article No. 89-5A-4 EEC IV - TFI IV - IGNITION SYSTEM - REVISED TIMING PROCEDURES AND DIAGNOSTICS SHOP MANUAL CORRECTION FORD: 1984-86 LTD 1984-88 EXP 1984-88 ESCORT THUNDERBIRD, MUSTANG, TEMPO, AND CROWN VICTORIA LINCOLN-MERCURY: 1984-86 CAPRI, MARQUIS 1984-87 LYNX 1984-88 COUGAR, TOPAZ, GRAND MARQUIS, CONTINENTAL, MARK VII, AND LINCOLN TOWN CAR LIGHT TRUCK: 1984-88 RANGER, BRONCO II, ECONOLINE, BRONCO, AND F-SERIES 1986-88 AEROSTAR ISSUE: The Ignition Coil and Secondary Wire Test Steps on pages 13-51 and 13-65 of the 1989 Engine Emissions Diagnosis Shop Manual, Volume H, have been revised. The new service information directs technicians to use a substitute coil instead of a resistance test. ACTION: Refer to this TSB for revised ignition coil and secondary wire test information. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" OASIS CODES: 680000 1989 Ignition Systems, Timing Procedures and Diagnostics 13-51 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Engine - Lack of Power/No Start Diagnosis > Page 2522 Ignition Coil and Secondary Wire TFI-IV And TFI With CCD Part 2 Test 7 1989 13-52 Ignition Systems, Timing Procedures and Diagnostics Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Engine - Lack of Power/No Start Diagnosis > Page 2523 EEC-IV - TFI-IV TFI-IV And TFI-IV With CCD Part 2 Test 8 1989 Ignition Systems, Timing Procedures and Diagnostics 13-65 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Engine - Lack of Power/No Start Diagnosis > Page 2524 Ignition Coil And Secondary Wire TFI-IV Closed Bowl Distributor Part 2 Test 8 1989 13-66 Ignition Systems, Timing Procedures and Diagnostics Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Engine - Lack of Power/No Start Diagnosis > Page 2525 EEC-IV - Wiring TFI-IV Closed Bowl Distributor Part 2 Test 9 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Page 2526 Ignition Cable: Testing and Inspection Spark Plug Wire Resistance *** UPDATED BY TSB #85-9-33 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Distributor, Ignition > Distributor Advance Unit > Component Information > Specifications DISTRIBUTOR TIMING ADVANCE Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Distributor, Ignition > Distributor Advance Unit > Component Information > Description and Operation > Vacuum Spark Advance Mechanism Distributor Advance Unit: Description and Operation Vacuum Spark Advance Mechanism The vacuum spark control mechanism can provide spark advance if a single diaphragm assembly is used or spark advance and retard if a dual diaphragm assembly is used. The diaphragm assembly used depends on the engine calibration. Single Diaphragm Assembly SINGLE DIAPHRAGM ASSEMBLY The single diaphragm assembly, Fig. 11, also changes the armature to stator relationship to give spark advance. The stator assembly position is changed by means of vacuum being applied to the diaphragm assembly. Vacuum applied to the diaphragm assembly causes the diaphragm and attached diaphragm rod to move, compressing the advance spring, which controls the rate of advance. The movement of the diaphragm rod, which is attached to the stator assembly, makes the the stator assembly move with respect to the armature. This changes the initial armature to stator relationship set during initial timing, causing spark advance. The stator assembly is mounted on the lower plate assembly which with the diaphragm assembly, is attached to the distributor base. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Distributor, Ignition > Distributor Advance Unit > Component Information > Description and Operation > Vacuum Spark Advance Mechanism > Page 2533 Dual Diaphragm Assembly DUAL DIAPHRAGM ASSEMBLY The dual diaphragm assembly, Fig. 12, obtains spark advance in the same manner as the single diaphragm assembly. In this case vacuum applied to the vacuum advance port causes the advance diaphragm and attached rod to move, otherwise the action is the same. Spark retard is done by applying vacuum to the vacuum retard port. This causes the retard diaphragm to move, compressing the retard spring, which controls the rate of spark retard. Compressing the retard spring allows the diaphragm rod stop to move due to the force applied by the advance spring pushing against it by means of the diaphragm rod. The result is the diaphragm rod moves causing the attached stator assembly to change position with respect to the armature. In this instance the direction of the stator assembly movement is opposite that occurring during vacuum advance, resulting in spark retard. NOTE: Any vacuum applied to the advance port overrides any spark retard caused by vacuum being applied to the retard port. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Distributor, Ignition > Distributor Advance Unit > Component Information > Description and Operation > Vacuum Spark Advance Mechanism > Page 2534 Distributor Advance Unit: Description and Operation Centrifugal Spark Advance Mechanism Distributor - Exploded view The centrifugal advance mechanism varies the relationship of the armature to the stator assembly. The armature is mounted to the sleeve and plate assembly which rotates in relation to the distributor shaft. The rotation is a result of the centrifugal weights moving in response to engine RPM. The movement of the weights change the initial relationship of the armature to the stator assembly by rotating the sleeve and plate assembly ahead of its static position on the distributor shaft Fig. 1. This produces spark advance. The rate of movement of the weights is controlled by calibrated springs. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Distributor, Ignition > Distributor Advance Unit > Component Information > Description and Operation > Page 2535 Distributor Advance Unit: Service and Repair 1. Remove distributor cap and rotor. 2. Disconnect vacuum lines, then remove snap ring that secures vacuum advance link to pickup assembly. 3. Remove vacuum advance attaching screws, then tilt unit downward to disconnect link. 4. Carefully remove unit from distributor. 5. Reverse procedure to install. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Distributor, Ignition > Distributor Cap > Component Information > Technical Service Bulletins > Engine - Lack of Power/No Start Diagnosis Distributor Cap: Technical Service Bulletins Engine - Lack of Power/No Start Diagnosis Article No. 91-12-11 06/12/91 LACK OF POWER 7.5L, 5.8L, 5.0L, 4.9L - CATALYTIC CONVERTER DIAGNOSTIC TIPS LIGHT TRUCK: 1986-91 BRONCO, ECONOLINE, F-150-350 SERIES 1988-91 F SUPER DUTY, F47 ISSUE: Lack of power or a no start condition may be diagnosed as an exhaust restriction caused by a plugged catalytic converter. A plugged catalytic converter (internal deterioration) is usually caused by abnormal engine operation. ACTION: Diagnose the catalytic converter to confirm internal failure. Refer to the Catalyst and Exhaust System Diagnostic Section, in the Engine/Emissions Diagnostic Shop Manual and the following procedures for service details. 1. Lack of proper HEGO operation may cause, or be the result of a rich or lean fuel condition, which could cause additional heat in the catalyst. Perform self test KOEO and KOER, service any codes. NOTE: IF TWO DIGIT CODES 41, 42, 85 OR THREE DIGIT CODES 171, 172, 173, 179, 181, 182, 183 AND 565 ARE RECEIVED, CHECK FOR PROPER HEGO GROUND. If the HEGO ground is good, the following areas may be at fault: ^ Ignition Coil ^ Distributor Cap ^ Distributor Rotor ^ Fouled Spark Plug ^ Spark Plug Wires ^ Air Filter ^ Stuck Open Injector ^ Fuel Contamination Engine OIL ^ Manifold Leaks Intake/ Exhaust ^ Fuel Pressure ^ Poor Power Ground ^ Engine Not At Normal Operating Temperature ^ HEGO Sensor 2. Spark timing that is retarded from specification may increase exhaust gas temperature and shorten catalyst life. Refer to the following procedure for service details. a. Check spark timing. Check base timing with spout disconnected. Set base timing to the specification on the vehicle emission decal. b. Check computed timing with spout connected. NOTE: COMPUTED TIMING IS EQUAL TO BASE TIMING PLUS 20~ BTDC +/- 3~. 3. Misfiring spark plugs may cause an unburned fuel air mixture to pass through the catalyst, which could cause higher than normal catalyst temperatures. Refer to the following procedure for service details. a. Check secondary ignition, hook the vehicle up to an engine analyzer and check for a secondary ignition misfire. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Distributor, Ignition > Distributor Cap > Component Information > Technical Service Bulletins > Engine - Lack of Power/No Start Diagnosis > Page 2540 NOTE: SERVICE ANY ITEM THAT IS NOT PERFORMING AT PROPER SPECIFICATIONS BEFORE CONTINUING. 4. Fuel pressure that is too high may cause rich air fuel mixtures to pass through the catalyst which could cause higher than normal catalyst temperatures. Refer to the following procedure for service details. a. Check fuel pressure, install fuel pressure gauge, start and run the engine at idle. Fuel pressures between 28 and 34 PSI are typical (4.9L typically is 15 PSI higher). b. Disconnect the vacuum line going to the fuel pressure regulator. Fuel pressure typically jumps to 40 PSI +/- 3 PSI (4.9L typically is 15 PSI higher). Visually inspect vacuum line for raw fuel. NOTE: FUEL PRESSURES ABOVE THESE VALUES SHOULD BE CORRECTED. HOWEVER, THIS MAY NOT BE THE CAUSE OF THE CONCERN. SERVICE AS NECESSARY. 5. Throttle plates in the throttle body not returning to the proper closed position may cause excessive catalyst temperatures during downhill grades. Refer to the following procedure for service details. a. Visually inspect the throttle body and linkage for: ^ Binding or sticking throttle linkage. ^ Tight speed control linkage or cable. ^ Vacuum line interference. ^ Electrical harness interference. NOTE: AFTERMARKET GOVERNORS, THROTTLE LINKAGE AND CABLES ASSOCIATED WITH POWER TAKE-OFF UNITS, MAY ALSO INTERFERE WITH PROPER THROTTLE RETURN. SERVICE AS NECESSARY. 6. It is extremely important that all systems related to the engine and emission systems operate properly. a. Visually inspect the engine compartment to make sure all vacuum hoses and spark plug wires are properly routed and securely connected. b. Inspect all wiring harnesses and connectors for insulation damage, burned, overheated, loose or broken conditions. c. Verify proper operation of the thermactor system. Thermactor systems that fail to dump thermactor air to the atmosphere properly or at the correct time can cause high catalyst temperatures. d. Visually inspect thermactor system for damaged or kinked hoses and perform a function test on following components: air control valve, check valve, silencer, filter and the air bypass solenoid. e. Verify proper operation of the engine cooling system thermostat. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under Basic Warranty Coverage, Emissions Warranty Coverage OPERATION DESCRIPTION TIME 911211A Diagnostics - Perform 0.5 Hrs. KOEO And KOER Self Tests 911211B Timing - Check Or Adjust 0.5 Hrs. Spark Timing, Check Computed Timing And Check Secondary Ignition System With Engine Analyzer. 911211C Check - Fuel Pressure And 0.2 Hrs. Inspect Vacuum Line For Raw Fuel. 911211D Inspect - Throttle Body And 0.1 Hrs. Linkage. 911211E Inspect - Vacuum Hoses, 0.1 Hrs. Electrical Harnesses, Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Distributor, Ignition > Distributor Cap > Component Information > Technical Service Bulletins > Engine - Lack of Power/No Start Diagnosis > Page 2541 Connectors And Spark Plug Wires For Routing Damage. 911211F Thermactor System - 0.3 Hrs. Inspect For Proper Operation And Damaged Component. Includes Function Check Of Air Control Valve, Thermactor Air Bypass Solenoid, Check Valves, Silencer And Filter. 911211G Thermostat - Check For 0.2 Hrs. Proper Operation. DEALER CODING BASIC PART NO. CONDITION CODE 5E212 25 OASIS CODES: 403000, 603300, 614000 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Distributor, Ignition > Ignition Rotor > Component Information > Technical Service Bulletins > Customer Interest: > 85218 > Oct > 85 > Distributor Rotor - Engine Bucking/Surging Ignition Rotor: Customer Interest Distributor Rotor - Engine Bucking/Surging Article No. 85-21-8 ENGINE MISS - DISTRIBUTOR WITH BLADE ROTOR - SILICONE GREASE ENGINE SURGE - DISTRIBUTOR WITH BLADE ROTOR - SILICONE GREASE RADIO NOISE - DISTRIBUTOR WITH BLADE ROTOR - SILICONE GREASE FORD 1986 ESCORT, EXP, TEMPO, MUSTANG, THUNDERBIRD, TAURUS, LTD, CROWN VICTORIA LINCOLN-MERCURY 1986 LYNX, TOPAZ, CAPRI, COUGAR, SABLE, MARQUIS, CONTINENTAL, MARK VII, LINCOLN LIGHT TRUCK 1986 E/F SERIES, BRONCO, RANGER, BRONCO II, AEROSTAR CALIBRATION: All with EEC IV 1986 vehicles are equipped with a new "blade" design distributor rotor. This design replaces the multi-point rotor used in recent model years. This new rotor requires the use of silicone grease on the blade. Electrical interference can result from a blade rotor that does not have silicone grease. The electrical interference affects the distributor stator assembly and can cause engine "missing", "bucking", or "surging". These drive concerns are usually intermittent and tend to occur during crank and heavy or wide-open throttle. It is important to remember not to remove the silicone grease for radio noise concerns, on 1986 vehicles with EEC IV; removing the grease can cause driveability concerns. A future TSB article will address the radio noise issue. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Distributor, Ignition > Ignition Rotor > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 911211 > Jun > 91 > Engine - Lack of Power/No Start Diagnosis Ignition Rotor: All Technical Service Bulletins Engine - Lack of Power/No Start Diagnosis Article No. 91-12-11 06/12/91 LACK OF POWER 7.5L, 5.8L, 5.0L, 4.9L - CATALYTIC CONVERTER DIAGNOSTIC TIPS LIGHT TRUCK: 1986-91 BRONCO, ECONOLINE, F-150-350 SERIES 1988-91 F SUPER DUTY, F47 ISSUE: Lack of power or a no start condition may be diagnosed as an exhaust restriction caused by a plugged catalytic converter. A plugged catalytic converter (internal deterioration) is usually caused by abnormal engine operation. ACTION: Diagnose the catalytic converter to confirm internal failure. Refer to the Catalyst and Exhaust System Diagnostic Section, in the Engine/Emissions Diagnostic Shop Manual and the following procedures for service details. 1. Lack of proper HEGO operation may cause, or be the result of a rich or lean fuel condition, which could cause additional heat in the catalyst. Perform self test KOEO and KOER, service any codes. NOTE: IF TWO DIGIT CODES 41, 42, 85 OR THREE DIGIT CODES 171, 172, 173, 179, 181, 182, 183 AND 565 ARE RECEIVED, CHECK FOR PROPER HEGO GROUND. If the HEGO ground is good, the following areas may be at fault: ^ Ignition Coil ^ Distributor Cap ^ Distributor Rotor ^ Fouled Spark Plug ^ Spark Plug Wires ^ Air Filter ^ Stuck Open Injector ^ Fuel Contamination Engine OIL ^ Manifold Leaks Intake/ Exhaust ^ Fuel Pressure ^ Poor Power Ground ^ Engine Not At Normal Operating Temperature ^ HEGO Sensor 2. Spark timing that is retarded from specification may increase exhaust gas temperature and shorten catalyst life. Refer to the following procedure for service details. a. Check spark timing. Check base timing with spout disconnected. Set base timing to the specification on the vehicle emission decal. b. Check computed timing with spout connected. NOTE: COMPUTED TIMING IS EQUAL TO BASE TIMING PLUS 20~ BTDC +/- 3~. 3. Misfiring spark plugs may cause an unburned fuel air mixture to pass through the catalyst, which could cause higher than normal catalyst temperatures. Refer to the following procedure for service details. a. Check secondary ignition, hook the vehicle up to an engine analyzer and check for a secondary ignition misfire. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Distributor, Ignition > Ignition Rotor > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 911211 > Jun > 91 > Engine - Lack of Power/No Start Diagnosis > Page 2555 NOTE: SERVICE ANY ITEM THAT IS NOT PERFORMING AT PROPER SPECIFICATIONS BEFORE CONTINUING. 4. Fuel pressure that is too high may cause rich air fuel mixtures to pass through the catalyst which could cause higher than normal catalyst temperatures. Refer to the following procedure for service details. a. Check fuel pressure, install fuel pressure gauge, start and run the engine at idle. Fuel pressures between 28 and 34 PSI are typical (4.9L typically is 15 PSI higher). b. Disconnect the vacuum line going to the fuel pressure regulator. Fuel pressure typically jumps to 40 PSI +/- 3 PSI (4.9L typically is 15 PSI higher). Visually inspect vacuum line for raw fuel. NOTE: FUEL PRESSURES ABOVE THESE VALUES SHOULD BE CORRECTED. HOWEVER, THIS MAY NOT BE THE CAUSE OF THE CONCERN. SERVICE AS NECESSARY. 5. Throttle plates in the throttle body not returning to the proper closed position may cause excessive catalyst temperatures during downhill grades. Refer to the following procedure for service details. a. Visually inspect the throttle body and linkage for: ^ Binding or sticking throttle linkage. ^ Tight speed control linkage or cable. ^ Vacuum line interference. ^ Electrical harness interference. NOTE: AFTERMARKET GOVERNORS, THROTTLE LINKAGE AND CABLES ASSOCIATED WITH POWER TAKE-OFF UNITS, MAY ALSO INTERFERE WITH PROPER THROTTLE RETURN. SERVICE AS NECESSARY. 6. It is extremely important that all systems related to the engine and emission systems operate properly. a. Visually inspect the engine compartment to make sure all vacuum hoses and spark plug wires are properly routed and securely connected. b. Inspect all wiring harnesses and connectors for insulation damage, burned, overheated, loose or broken conditions. c. Verify proper operation of the thermactor system. Thermactor systems that fail to dump thermactor air to the atmosphere properly or at the correct time can cause high catalyst temperatures. d. Visually inspect thermactor system for damaged or kinked hoses and perform a function test on following components: air control valve, check valve, silencer, filter and the air bypass solenoid. e. Verify proper operation of the engine cooling system thermostat. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under Basic Warranty Coverage, Emissions Warranty Coverage OPERATION DESCRIPTION TIME 911211A Diagnostics - Perform 0.5 Hrs. KOEO And KOER Self Tests 911211B Timing - Check Or Adjust 0.5 Hrs. Spark Timing, Check Computed Timing And Check Secondary Ignition System With Engine Analyzer. 911211C Check - Fuel Pressure And 0.2 Hrs. Inspect Vacuum Line For Raw Fuel. 911211D Inspect - Throttle Body And 0.1 Hrs. Linkage. 911211E Inspect - Vacuum Hoses, 0.1 Hrs. Electrical Harnesses, Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Distributor, Ignition > Ignition Rotor > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 911211 > Jun > 91 > Engine - Lack of Power/No Start Diagnosis > Page 2556 Connectors And Spark Plug Wires For Routing Damage. 911211F Thermactor System - 0.3 Hrs. Inspect For Proper Operation And Damaged Component. Includes Function Check Of Air Control Valve, Thermactor Air Bypass Solenoid, Check Valves, Silencer And Filter. 911211G Thermostat - Check For 0.2 Hrs. Proper Operation. DEALER CODING BASIC PART NO. CONDITION CODE 5E212 25 OASIS CODES: 403000, 603300, 614000 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Distributor, Ignition > Ignition Rotor > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 85218 > Oct > 85 > Distributor Rotor - Engine Bucking/Surging Ignition Rotor: All Technical Service Bulletins Distributor Rotor - Engine Bucking/Surging Article No. 85-21-8 ENGINE MISS - DISTRIBUTOR WITH BLADE ROTOR - SILICONE GREASE ENGINE SURGE - DISTRIBUTOR WITH BLADE ROTOR - SILICONE GREASE RADIO NOISE - DISTRIBUTOR WITH BLADE ROTOR - SILICONE GREASE FORD 1986 ESCORT, EXP, TEMPO, MUSTANG, THUNDERBIRD, TAURUS, LTD, CROWN VICTORIA LINCOLN-MERCURY 1986 LYNX, TOPAZ, CAPRI, COUGAR, SABLE, MARQUIS, CONTINENTAL, MARK VII, LINCOLN LIGHT TRUCK 1986 E/F SERIES, BRONCO, RANGER, BRONCO II, AEROSTAR CALIBRATION: All with EEC IV 1986 vehicles are equipped with a new "blade" design distributor rotor. This design replaces the multi-point rotor used in recent model years. This new rotor requires the use of silicone grease on the blade. Electrical interference can result from a blade rotor that does not have silicone grease. The electrical interference affects the distributor stator assembly and can cause engine "missing", "bucking", or "surging". These drive concerns are usually intermittent and tend to occur during crank and heavy or wide-open throttle. It is important to remember not to remove the silicone grease for radio noise concerns, on 1986 vehicles with EEC IV; removing the grease can cause driveability concerns. A future TSB article will address the radio noise issue. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Distributor, Ignition > Ignition Rotor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Rotor: > 88141 > Jul > 88 > Vent Windows - May Stick to Weatherstrip Window Seal: All Technical Service Bulletins Vent Windows - May Stick to Weatherstrip GLASS - VENT WINDOWS - MANUAL - GLASS STICKS TO WEATHERSTRIP - VEHICLES BUILT BEFORE 4/04/88 Article No. 88-14-1 FORD: 1984-88 ALL CAR LINES LINCOLN-MERCURY: 1984-88 ALL CAR LINES MERKUR: 1985-88 ALL CAR LINES LIGHT TRUCK: 1984-88 ALL LIGHT TRUCK LINES MEDIUM/HEAVY TRUCK: 1984-88 ALL MEDIUM/HEAVY TRUCK LINES ISSUE: Manual vent windows that are not opened very often may stick to the vent window weatherstrip making them hard to open. In some cases, the high opening efforts may cause the weatherstrip to pull out of the vent division bar. ACTION: To correct this, apply "Krytox" oil to the vent window weatherstrip using the following service procedure. FIGURE 1 1. Open the vent window all the way. 2. From inside of vehicle, apply "Krytox" oil on the weatherstrip sealing lips of vent window, Figure 1. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Distributor, Ignition > Ignition Rotor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Rotor: > 88141 > Jul > 88 > Vent Windows - May Stick to Weatherstrip > Page 2566 FIGURE 2 3. From outside of vehicle, apply "Krytox" oil on the weatherstrip sealing lips of vent window, Figure 2. 4. Close and open vent window to make sure window operates correctly. NOTE: CONTACT EXCEL INDUSTRIES, INC. TO ORDER "KRYTOX" OIL: (904) 286-8300 EXTENSION 305 REPRESENTATIVE: RACHEL FLYNN. OTHER APPLICABLE ARTICLES: Supersedes 87-11-2 WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION: 881401A TIME: 0.3 Hr. DLR. CODING: Basic Part No. 7022296 - Car 7021448 - Truck Condition Code: 41 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Distributor, Ignition > Ignition Rotor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Rotor: > 88141 > Jul > 88 > Vent Windows - May Stick to Weatherstrip > Page 2572 FIGURE 2 3. From outside of vehicle, apply "Krytox" oil on the weatherstrip sealing lips of vent window, Figure 2. 4. Close and open vent window to make sure window operates correctly. NOTE: CONTACT EXCEL INDUSTRIES, INC. TO ORDER "KRYTOX" OIL: (904) 286-8300 EXTENSION 305 REPRESENTATIVE: RACHEL FLYNN. OTHER APPLICABLE ARTICLES: Supersedes 87-11-2 WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION: 881401A TIME: 0.3 Hr. DLR. CODING: Basic Part No. 7022296 - Car 7021448 - Truck Condition Code: 41 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Distributor, Ignition > Distributor Plate W/ Pick-up Sensor > Component Information > Service and Repair Distributor Plate W/ Pick-up Sensor: Service and Repair 1. Remove distributor cap and rotor. 2. Remove vacuum advance unit and magnetic pickup assembly. 3. Remove attaching screws and lift base plate from distributor. 4. Reverse procedure to install. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Engine - Lack of Power/No Start Diagnosis Spark Plug: Technical Service Bulletins Engine - Lack of Power/No Start Diagnosis Article No. 91-12-11 06/12/91 LACK OF POWER 7.5L, 5.8L, 5.0L, 4.9L - CATALYTIC CONVERTER DIAGNOSTIC TIPS LIGHT TRUCK: 1986-91 BRONCO, ECONOLINE, F-150-350 SERIES 1988-91 F SUPER DUTY, F47 ISSUE: Lack of power or a no start condition may be diagnosed as an exhaust restriction caused by a plugged catalytic converter. A plugged catalytic converter (internal deterioration) is usually caused by abnormal engine operation. ACTION: Diagnose the catalytic converter to confirm internal failure. Refer to the Catalyst and Exhaust System Diagnostic Section, in the Engine/Emissions Diagnostic Shop Manual and the following procedures for service details. 1. Lack of proper HEGO operation may cause, or be the result of a rich or lean fuel condition, which could cause additional heat in the catalyst. Perform self test KOEO and KOER, service any codes. NOTE: IF TWO DIGIT CODES 41, 42, 85 OR THREE DIGIT CODES 171, 172, 173, 179, 181, 182, 183 AND 565 ARE RECEIVED, CHECK FOR PROPER HEGO GROUND. If the HEGO ground is good, the following areas may be at fault: ^ Ignition Coil ^ Distributor Cap ^ Distributor Rotor ^ Fouled Spark Plug ^ Spark Plug Wires ^ Air Filter ^ Stuck Open Injector ^ Fuel Contamination Engine OIL ^ Manifold Leaks Intake/ Exhaust ^ Fuel Pressure ^ Poor Power Ground ^ Engine Not At Normal Operating Temperature ^ HEGO Sensor 2. Spark timing that is retarded from specification may increase exhaust gas temperature and shorten catalyst life. Refer to the following procedure for service details. a. Check spark timing. Check base timing with spout disconnected. Set base timing to the specification on the vehicle emission decal. b. Check computed timing with spout connected. NOTE: COMPUTED TIMING IS EQUAL TO BASE TIMING PLUS 20~ BTDC +/- 3~. 3. Misfiring spark plugs may cause an unburned fuel air mixture to pass through the catalyst, which could cause higher than normal catalyst temperatures. Refer to the following procedure for service details. a. Check secondary ignition, hook the vehicle up to an engine analyzer and check for a secondary ignition misfire. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Engine - Lack of Power/No Start Diagnosis > Page 2580 NOTE: SERVICE ANY ITEM THAT IS NOT PERFORMING AT PROPER SPECIFICATIONS BEFORE CONTINUING. 4. Fuel pressure that is too high may cause rich air fuel mixtures to pass through the catalyst which could cause higher than normal catalyst temperatures. Refer to the following procedure for service details. a. Check fuel pressure, install fuel pressure gauge, start and run the engine at idle. Fuel pressures between 28 and 34 PSI are typical (4.9L typically is 15 PSI higher). b. Disconnect the vacuum line going to the fuel pressure regulator. Fuel pressure typically jumps to 40 PSI +/- 3 PSI (4.9L typically is 15 PSI higher). Visually inspect vacuum line for raw fuel. NOTE: FUEL PRESSURES ABOVE THESE VALUES SHOULD BE CORRECTED. HOWEVER, THIS MAY NOT BE THE CAUSE OF THE CONCERN. SERVICE AS NECESSARY. 5. Throttle plates in the throttle body not returning to the proper closed position may cause excessive catalyst temperatures during downhill grades. Refer to the following procedure for service details. a. Visually inspect the throttle body and linkage for: ^ Binding or sticking throttle linkage. ^ Tight speed control linkage or cable. ^ Vacuum line interference. ^ Electrical harness interference. NOTE: AFTERMARKET GOVERNORS, THROTTLE LINKAGE AND CABLES ASSOCIATED WITH POWER TAKE-OFF UNITS, MAY ALSO INTERFERE WITH PROPER THROTTLE RETURN. SERVICE AS NECESSARY. 6. It is extremely important that all systems related to the engine and emission systems operate properly. a. Visually inspect the engine compartment to make sure all vacuum hoses and spark plug wires are properly routed and securely connected. b. Inspect all wiring harnesses and connectors for insulation damage, burned, overheated, loose or broken conditions. c. Verify proper operation of the thermactor system. Thermactor systems that fail to dump thermactor air to the atmosphere properly or at the correct time can cause high catalyst temperatures. d. Visually inspect thermactor system for damaged or kinked hoses and perform a function test on following components: air control valve, check valve, silencer, filter and the air bypass solenoid. e. Verify proper operation of the engine cooling system thermostat. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under Basic Warranty Coverage, Emissions Warranty Coverage OPERATION DESCRIPTION TIME 911211A Diagnostics - Perform 0.5 Hrs. KOEO And KOER Self Tests 911211B Timing - Check Or Adjust 0.5 Hrs. Spark Timing, Check Computed Timing And Check Secondary Ignition System With Engine Analyzer. 911211C Check - Fuel Pressure And 0.2 Hrs. Inspect Vacuum Line For Raw Fuel. 911211D Inspect - Throttle Body And 0.1 Hrs. Linkage. 911211E Inspect - Vacuum Hoses, 0.1 Hrs. Electrical Harnesses, Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Engine - Lack of Power/No Start Diagnosis > Page 2581 Connectors And Spark Plug Wires For Routing Damage. 911211F Thermactor System - 0.3 Hrs. Inspect For Proper Operation And Damaged Component. Includes Function Check Of Air Control Valve, Thermactor Air Bypass Solenoid, Check Valves, Silencer And Filter. 911211G Thermostat - Check For 0.2 Hrs. Proper Operation. DEALER CODING BASIC PART NO. CONDITION CODE 5E212 25 OASIS CODES: 403000, 603300, 614000 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Page 2582 Spark Plug: Specifications SPARK PLUGS Gap ...................................................................................................................................................... ............................................................ 0.044 in Torque ...................................................................... ................................................................................................................. 9-20 Nm (7-15 ft-lbs) Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Page 2583 Spark Plug: Service and Repair REMOVAL - Remove the wire from each spark plug by grasping the molded boot with tool T74P-6666-A or equivalent. Twist the boot until it loosens and then pull it off the spark plug. Do not pull on the wire, as the connection may become damaged. - Any wire damaged must be replaced. Each original spark plug wire is numbered for the cylinder to which it is designated. If wires are not numbered, each wire should be numbered as to the plug from which it was removed. - Clean the area around each spark plug port with compressed air. - Using the proper size spark plug socket remove the spark plugs. INSTALLATION Check the gap on each new spark plug and set to specification. See: Specifications - Install each spark plug and tighten to 9-20 Nm (7-15 ft-lbs). Cylinder Numbering And Distributor Location Location On Distributor - Coat the inside of each spark plug boot with silicone dielectric compound. Connect each spark plug wire to the plug from which it was removed. Be sure each wire is fully depressed on each plug and molded boot is firmly in place. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Compression Check > System Information > System Diagnosis Compression Check: Testing and Inspection COMPRESSION TEST 1. Ensure oil in crankcase is of the correct viscosity and at proper level and battery is properly charged. Operate vehicle until engine is at normal operating temperature. Turn OFF ignition switch, then remove all spark plugs. 2. Set throttle plates (and choke plates, if equipped) in wide-open position. 3. Install a compression gauge such as Rotunda Compression Tester 059-00009 or equivalent in No. 1 cylinder. 4. Install an auxiliary starter switch in starting circuit. With ignition switch in the OFF position, and using auxiliary starter switch, crank engine at least five compression strokes and record highest reading. Note the approximate number of compression strokes required to obtain the highest reading. 5. Repeat test on each cylinder cranking the engine approximately the same number of compression strokes. TEST CONCLUSION 1. The indicated compression pressures are considered within specification if the lowest reading cylinder is within 75 percent of the highest. 2. If one or more cylinders read low, squirt approximately one tablespoon of heavy SAE 50 weight or equivalent engine oil on top of the pistons in the low reading cylinders. Repeat compression pressure check on these cylinders. a. If compression improves considerably, piston rings are at fault. b. If compression does not improve, valves are sticking or seating poorly. c. If two adjacent cylinders indicate low compression pressures and squirting oil on pistons does not increase compression, cause may be a cylinder head gasket leak between cylinders. Engine oil and/or coolant in cylinders could result from this problem. Compression Pressure Limit Chart NOTE: Refer to the compression pressure limit chart for pressure specifications. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications Valve Clearance: Specifications ENGINE YEAR CLEARANCE V6-232 82-83 .088-.189 V8-255 81-82 .123-.173 6-300 80-87 .125-.175 V8-302 80-87 .096-.165 V8-351M 80-81 .125 V8-351W 80-87 .123-.173 V8-400 80-82 .175 V8-460 80-87 .100-.150 On engines with hydraulic lifters, clearance specified is at valve stem tip with lifter collapsed. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications > Page 2590 Valve Clearance: Locations FRONT TO REAR 6-300 E-I-E-I-E-I-E-I-E-I-E-I V6-232 Right I-E-I-E-I-E V6-232 Left E-I-E-I-E-I V8-255, 302 Left Bank E-I-E-I-E-I-E-I V8-255, 302 Right Bank I-E-I-E-I-E-I-E V8-351, 400 Right Bank I-E-I-E-I-E-I-E V8-351, 400 Left Bank E-I-E-I-E-I-E-I V8-460 Left Bank E-I-E-I-E-I-E-I V8-460 Right Bank I-E-I-E-I-E-I-E Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications > Page 2591 Valve Clearance: Adjustments Fig. 2 Positioning crankshaft for valve clearance check Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications > Page 2592 Fig. 3 Checking collapsed tappet clearance Valves, Adjust To provide a means to compensate for dimensional changes in the valve train and provide for valve adjustment, .060 inch shorter or longer pushrods are available. If the valve clearance is less than the minimum, the .060 inch shorter pushrod should be used. If the clearance is more than the maximum, the longer pushrod should be used. To check the valve clearance, proceed as follows: 1. Mark crankshaft pulley at three locations, with No. 1 location at TDC timing mark (end of compression stroke), location No. 2 one full turn (360°) clockwise from TDC and No. 3 location one quarter turn clockwise (90°) from position No. 2, Fig. 2. 2. Turn crankshaft to number 1 location, then compress valve lifter using tool T71P-6513-A or equivalent, Fig. 3, and check the clearance on the following valves: a. On V8-302 and 460 engines, check intake valve Nos. 1 , 7 and 8; exhaust valve Nos. 1, 4 and 5. b. On V8-351, check intake valve Nos. 1, 4 and No. 8; exhaust valve Nos. 1, 3 and 7. 3. Turn crankshaft to number 2 location, then compress valve lifter using tool T71P-6513-A or equivalent, Fig. 3, and check the clearance on the following valves: a. On V8-301 and 460 engines check intake valve Nos. 4 and 5; exhaust valve Nos. 2 and 6. b. On V8-351 engines, check intake valve Nos. 3 and 7; exhaust valve Nos. 2 and 6. 4. Turn crankshaft to number 3 location, then compress valve lifter using tool T71P-6513-A or equivalent and check the clearance on the following valves: a. V8-302 and 460 engines check intake valve Nos. 2, 3 and 6; exhaust valve Nos. 3, 7 and 8. b. On V8-351 engines, check intake valve Nos. 2, 5 and 6; exhaust valve Nos. 4, 5 and 8. Valve Arrangement Front to Rear V8-302 Left Bank.................................................................................................................................. ...........................................................E-I-E-I-E-I-E-I V8-302 Right Bank............................................. ..............................................................................................................................................I-E-I-E-IE-I-E V8-351 Right Bank...................................................................................................................... .....................................................................I-E-I-E-I-E-I-E V8-351 Left Bank...................................... .......................................................................................................................................................E-IE-I-E-I-E-I V8-460 Left Bank................................................................................................................. ............................................................................E-I-E-I-E-I-E-I V8-460 Right Bank............................ .............................................................................................................................................................. .I-E-I-E-I-E-I-E Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > A L L Diagnostic Trouble Codes Engine Controls > System Information > System Diagnosis > Transmisson Codes A L L Diagnostic Trouble Codes - Engine Controls: Testing and Inspection Transmisson Codes For Transmission related codes, proceed to Computers and Control Systems. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Barometric Pressure Switch > Component Information > Description and Operation Barometric Pressure Switch: Description and Operation The Ignition Barometric Pressure Switch, is used to control spark timing and/or other electrical devices in response to changes in barometric pressure (i.e., altitude). When controlling spark timing, the ignition module (12A244) is made to vary the spark timing by an amount determined by calibration resistors in the switch assembly. In normal operation, spark timing is increased for vehicle operation above the switching point (increasing altitude) and retarded for vehicle operation below the switching point (decreasing altitude). When controlling other electrical devices, only On/Off control is provided; with On (switch closed) above the switching point and Off (switch open) below the switching point. Some switch assemblies control both spark timing and another device (dual switch assembly) and other switch assemblies control only one or the other (single switch assembly). Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Barometric Pressure Switch > Component Information > Testing and Inspection > Component Testing Barometric Pressure Switch: Testing and Inspection Component Testing ^ Dual switch assembly shown. ^ Attaching brackets vary according to installation requirements. ^ Connectors may vary. Either resistance value is correct if altitude is between 3,000 and 4,600 feet. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Barometric Pressure Switch > Component Information > Testing and Inspection > Component Testing > Page 2603 Barometric Pressure Switch: Testing and Inspection Computer Related Diagnostic Information Ford provides trouble code/symptom driven diagnostics for this component. For complete diagnosis and pinpoint testing, refer to Computers and Control Systems, Testing and Inspection. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Camshaft Position Sensor: Diagram Information and Instructions Symbol Identification Wire Color Code Identification Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2608 NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications TEMPERATURE SENSORS Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 2612 Coolant Temperature Sensor/Switch (For Computer): Locations RH Side Of V8-351/5. Front Of Engine, Near Distributor Applicable to: 8L Engine With EEC-IV Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 2613 Coolant Temperature Sensor/Switch (For Computer): Description and Operation The Engine Coolant Temperature (ECT) Sensor, detects the temperature of engine coolant and supplies the Information to Electronic Control Assembly (ECA). The ECT sensor is threaded into the heater outlet fitting or cooling passage on the engine. For engine control applications, the ECT signal is used to modify ignition timing, EGR flow, and air to fuel ratio as a function of engine coolant temperature. On electronic instrument cluster applications, the ECT output is used to control a coolant temperature indicator. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 2614 Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection Ford provides trouble code/symptom driven diagnostics for this component. For complete diagnosis and pinpoint testing, refer to Computers and Control Systems, Testing and Inspection. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Crankshaft Position Sensor: Diagram Information and Instructions Symbol Identification Wire Color Code Identification Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2619 NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Technical Service Bulletins > Diagnostic Connector - Service Bay Diagnostic System Data Link Connector: Technical Service Bulletins Diagnostic Connector - Service Bay Diagnostic System Article No. 93-20-4 09/29/93 ^ SERVICE BAY DIAGNOSTIC SYSTEM - REMOVAL OF TACH WIRE FROM VIP/SELF TEST (DLC) CONNECTOR TO AVOID DAMAGE TO SBDS - THUNDERBIRD/COUGAR WITH 5.0L, BRONCO, F-150-350, ECONOLINE WITH 5.0L/5.8L, AEROSTAR WITH 2.3L, 2.8L, 3.0L ^ WIRING - REMOVAL OF TACH WIRE FROM VIP/SELF TEST (DLC) CONNECTOR TO AVOID DAMAGE TO SBDS - THUNDERBIRD/COUGAR WITH 5.0L, BRONCO, F-150-350, ECONOLINE WITH 5.0L/5.8L, AEROSTAR WITH 2.3L, 2.8L, 3.0L ^ SBDS DAMAGE-REMOVAL OF TACH SIGNAL WIRE FROM VIP/SELF TEST (DLC) CONNECTOR - THUNDERBIRD/COUGAR WITH 5.0L, BRONCO, F-150-350, ECONOLINE WITH 5.0L/5.8L, AEROSTAR WITH 2.3L, 2.8L, 3.0L FORD: 1986-88 THUNDERBIRD LINCOLN-MERCURY: 1986-88 COUGAR LIGHT TRUCK: 1986 BRONCO, F-150-350 SERIES 1986-87 ECONOLINE 1986-91 AEROSTAR ISSUE: The VIP/Self-Test (DLC) connector on certain model year Ford and Lincoln/Mercury vehicles should not be connected to the SBDS without modification or damage will occur to the SBDS. Refer to the following for service details. ACTION: Remove the tach signal wire from the VIP/Self-Test connector before connecting to the SBDS. The VIP/Self-test (DLC) connector on these vehicles contains a tach wire that generates a voltage spike that damages the MCVI circuit board in the SBDS. The damage will become evident when SBDS tools that utilize the Data Communications Link (DCL) are used later, on a vehicle equipped with DCL. Refer to the following detailed service procedure for information. 1. Inspect the vehicle's VIP/Self-Test connector for the presence of a tach signal wire. Refer to Figure 1. 2. If a tach wire is present, remove it. Using a small flat bladed screwdriver, depress the plastic retaining tab that locks the terminal into the Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Technical Service Bulletins > Diagnostic Connector - Service Bay Diagnostic System > Page 2624 connector. Hold down the tab and pull the wire from the connector. 3. Wrap the terminal so that no part of it is exposed, using a moisture proof tape such as Scotch 3M Linerless Splicing Compound (3M # 06155). 4. If the terminal contains two wires, loop the tape between and around the terminal and the wires to completely seal the wire terminal from moisture. 5. Secure the wrapped terminal to the wiring harness using a wire-tie (95832-S) to prevent it from being damaged. Parts Block NOTE: 1985 AND PRIOR MODEL YEAR VEHICLES ARE NOT TOTALLY SUPPORTED BY SBDS AND HAVE A HIGH PROBABILITY OF DAMAGING THE SBDS MVCI HARDWARE DUE TO THIS ISSUE. DO NOT CONNECT THE VIP/SELF-TEST CONNECTOR TO SBDS TO RUN ELECTRONIC ENGINE CONTROL OR FUEL SYSTEM TESTS. ALL OTHER TOOLS THAT DO NOT REQUIRE HOOK-UP TO THE VIP/SELF-TEST CONNECTOR WILL FUNCTION NORMALLY. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 932004A Remove Tach Wire From 0.2 Hr. VIP Self-Test Connector DEALER CODING BASIC PART NO. CONDITION CODE 14488 X1 OASIS CODES: 203000, 203200 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > EGR Backpressure Transducer > Component Information > Description and Operation EGR Backpressure Transducer: Description and Operation Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision Technical Service Bulletin # 8918A9 Date: 890915 EVP Sensor - Manual Revision ENGINE EMISSIONS DIAGNOSTIC MANUALS, VOLUME H - 1985 THROUGH 1989 - EGR VALVE POSITION SENSOR (EVP) DIAGNOSTIC PROCEDURES REVISED Article No. 89-18A-9 FORD: 1985-89 CROWN VICTORIA, ESCORT 1985-88 EXP 1985-86 LTD 1985-89 MUSTANG, TEMPO, THUNDERBIRD 1986-89 TAURUS 1988-89 FESTIVA 1989 PROBE LINCOLN-MERCURY: 1985-86 CAPRI 1985-89 CONTINENTAL, COUGAR, GRAND MARQUIS 1985-87 LYNX 1985-89 MARK VII 1985-86 MARQUIS 1985-89 TOPAZ, TOWN CAR 1986-89 SABLE 1987-89 TRACER MERKUR: 1986-89 XR4TI 1988-89 SCORPIO LIGHT TRUCK: 1985-89 BRONCO, BRONCO II, ECONOLINE, F-150, F-250, F-350, RANGER 1986-89 AEROSTAR ISSUE: The EGR Valve Position Sensor (EVP) diagnostic procedures in 1985 through 1989 Engine Emissions Diagnosis Shop Manuals, Volume H, have been revised. EVP Sensors may exhibit internal wear problems that can cause driveability symptoms and display a Continuous Self-Test Code 32. This is not associated to correcting the problem using the existing diagnostic procedures. ACTION: Refer to the pages following this TSB article for the revised diagnostic procedures. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 680000 1985 Pinpoint Tests - DM - EGR, EVP and EVR Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2632 1985 EEC IV - Pinpoint Tests - All Vehicles 22-77 EGR Valve Position Sensor (EVP) EGR Valve Regulator (EVR) Pinpoint DM Test 1985 Pinpoint Tests - Fa - Neutral Drive Switch -A/C Input Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2633 1985 22-78 EEC IV - Pinpoint Tests - All Vehicles Neutral Drive Switch FA A/C Input PinpointTest 1986 (EGR) Systems Functional Diagnosis 1986 Exhaust Gas Recirculation (EGR) Systems 6-11 Functional Diagnosis Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2634 PORTED EGR VALVE 1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked, crimped or broken hoses. 2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating temperature. 3. Install a tachometer. 4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (EFI engines only). 5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose. 6. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If necessary, adjust idle speed to the emission decal specification. 7. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand vacuum pump. 8. When vacuum is applied to the EGR valve and any of the following occur, replace the valve: ^ Engine does not stall. ^ Idle speed does not drop more than 100 rpm. ^ Idle speed does not return to normal (+/- 25 rpm) after the vacuum is removed. 9. Reconnect the idle air bypass valve electrical connector. 10. Unplug and reconnect the EGR vacuum supply hose. 11. The EGR system is OK, refer to the Diagnostic Routines in Section 2. 1986 6-12 Exhaust Gas Recirculation (EGR) Systems Functional Diagnosis ELECTRONIC VALVE 1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked, crimped or broken hoses. 2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating temperature. 3. Install a tachometer. 4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (EFI engines only). Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2635 5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose. 6. Disconnect the 9G428 EVP sensor electrical connector mounted on top of the 9H473 valve. 7. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If necessary, adjust idle speed to the emission decal specification. 8. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand vacuum pump. 9. When vacuum is applied to the EGR valve and any of the following occur, replace the valve: ^ Engine does not stall. ^ Idle speed does not drop more than 100 rpm. ^ Idle speed does not return to normal (+/- 25 rpm) after the vacuum is removed. 10. Reconnect the idle air bypass valve electrical connector. 11. Unplug and reconnect the EGR vacuum supply hose. 12. Reconnect the EVP sensor electrical connector. 13. The EGR valve is OK, REPLACE EVP sensor if the Continuous Code 32 was present. If the Continuous Code 32 was not present, refer to the Diagnostic Routines in Section 2. 1986 Quick Test: Continuous Self-Test 6.0 EEC IV - Quick Test - All Engines 18-13 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2636 QUICK TEST: Continuous Self-Test 6.0 1986 18-14 EEC IV-Quick Test-All Engines QUICK TEST: Continuous Self-Test 6.0 Pinpoint Test - DN - EGR - EVP & EVR Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2637 1986 EEC IV-Pinpoint Tests - All Vehicles 21-95 EGR Valve Position Sensor (EVP) PinpointTest DN EGR Valve Regulator (EVR) Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2638 21-96 1986 EEC IV-Pinpoint Tests-All Vehicles EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Valve Regulator (EVR) Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2639 EEC IV-Pinpoint Tests-All Vehicles 1986 21-97A EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Valve Regulator (EVR) Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2640 1986 21-97B EEC IV-Pinpoint Tests-All Vehicles EGR Valve Position Sensor (EVP) EGR Valve Regulator (EVR) Pinpoint Test DN Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2641 1986 EEC IV-Pinpoint Tests-All Vehicles 21-98 EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Valve Regulator (EVR) 1987 (EGR) Systems - Functional Diagnosis 1987 6-11 Exhaust Gas Recirculation (EGR) Systems Functional Diagnosis PORTED EGR VALVE 1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked, crimped or broken hoses. 2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating temperature. 3. Install a tachometer, Rotunda 059-00010 or equivalent. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2642 4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (EFI engines only). 5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose. 6. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If necessary, adjust idle speed according to Section 4. 7. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand vacuum pump, Rotunda 021-00014 or equivalent. 8. When vacuum is applied to the EGR valve and any of the following occur, replace the valve: ^ Engine does not stall. ^ Idle speed does not drop more than 100 rpm. ^ Idle speed does not return to normal (+/- 25 rpm) after the vacuum is removed. 9. Reconnect the idle air bypass valve electrical connector. 10. Unplug and reconnect the EGR vacuum supply hose. 11. The EGR system is OK, refer to the Diagnostic Routines in Section 2. 1987 6-12 Exhaust Gas Recirculation (EGR) Systems Functional Diagnosis ELECTRONIC EGR (EEGR) VALVE 1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked, crimped or broken hoses. 2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating temperature. 3. Install a tachometer, Rotunda 059-00010 or equivalent. 4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (EFI engines only). 5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose. 6. Disconnect the 9G428 EVP sensor electrical connector mounted on top of the 9H473 valve. 7. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If necessary, adjust idle speed according to Section 4. 8. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand vacuum pump, Rotunda 021-00014 or equivalent. 9. When vacuum is applied to the EGR valve and any of the following occur, replace the valve: ^ Engine does not stall. ^ Idle speed does not drop more than 100 rpm. ^ Idle speed does not return to normal (+/- 25 rpm) after the vacuum is removed. 10. Reconnect the idle air bypass valve electrical connector. 11. Unplug and reconnect the EGR vacuum supply hose. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2643 12. Reconnect the EVP sensor electrical connector. 13. The EGR valve is OK, REPLACE EVP sensor if the Continuous Code 32 was present. If the Continous Code 32 was not present, refer to the Diagnostic Routines in Section 2. 1987 Quick Test: Continuous Self-Test - 6.0 1987 EEC-IV Quick Test-All Engines 16-15 QUICK TEST: Continuous 6.0 Self-Test Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2644 16-16 1987 EEC-IV Quick Test-All Engines QUICK TEST: Continuous 6.0 Self-Test Pinpoint Test - DN - EGR - EVP & EVR 1987 EEC IV - Pinpoint Tests - All Vehicles 19-91 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2645 EGR VALVE Position Sensor (EVP) EGR Valve Regulator (EVR) - 2.3L HSC, 2.5L, 5.0L SEFI Passenger Car and 4.9L and 5.0L Truck Pinpoint Test DN 19-92A 1987 EEC IV Pinpoint Tests-All Vehicles EGR Valve Position Sensor (EVP) EGR Valve Regulator (EVR) - 2.3L HSC, 2.5L, Pinpoint Test DN 5.0L SEFI Passenger Car and 4.9L and 5.0L Truck Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2646 1987 EEC IV-Pinpoint Tests-All Vehicles 19-92B EGR Valve Position Sensor (EVP) EGR Valve Regulator (EVR) - 2.3L HSC, 2.5L, 5.0L SEFI Passenger Car and 4.9L and 5.0L Truck Pinpoint Test DN Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2647 1987 19-93-A EEC IV-Pinpoint Tests-All Vehicles EGR Valve Position Sensor (EVP) EGR Valve Regulator (EVR) - 2.3L HSC, 2.5L, 5.0L SEFI Passenger Car 4.9L and 5.0L Truck Pinpoint Test DN Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2648 EEC IV-Pinpoint Tests-All Vehicles 1987 19-94 EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Valve Regulator (EVR) (EGR) Systems - Functional Diagnosis 1988 Exhaust Gas Recirculation (EGR) Systems 6-11 Functional Diagnosis Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2649 PORTED EGR VALVE 1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked, crimped or broken hoses. 2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating temperature. 3. Install a tachometer, Rotunda 059-00010 or equivalent. 4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (EFI engines only). 5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose. 6. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If necessary, adjust idle speed according to Section 4. 7. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand vacuum pump, Rotunda 021-00014 or equivalent. 8. When vacuum is fully applied to the EGR valve: ^ If idle speed drops more than 100 rpm or if engine stalls, perform the next step. Otherwise, replace the EGR valve. ^ Remove the vacuum from the EGR valve. If idle speed does not return to normal (+/- 25 rpm), replace the EGR valve. 9. Reconnect the idle air bypass valve electrical connector. 10. Unplug and reconnect the EGR vacuum supply hose. 11. The EGR system is OK, refer to the Diagnostic Routines in Section 2. 6-12 1988 Exhaust Gas Recirculation (EGR) Systems Functional Diagnosis ELECTRONIC EGR (EEGR) VALVE 1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked, crimped or broken hoses. 2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating temperature. NOTE: The EVR solenoid has a constant internal leak. You will notice a small vacuum signal. This signal should be less than 2-1/2 in-Hg at idle. 3. Install a tachometer, Rotunda 059-00010 or equivalent. 4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (1.9L EFI engines only). 5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose. 6. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If necessary, adjust idle speed according to Section 4. 7. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand vacuum pump, Rotunda 021-00014 or equivalent. 8. When vacuum is applied to the EGR valve and any of the following occur, replace the valve: ^ Engine does not stall. ^ Idle speed does not drop more than 100 rpm. ^ Idle speed does not return to normal (+/- 25 rpm) after the vacuum is removed. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2650 9. Reconnect the idle air bypass valve electrical connector. 10. Unplug and reconnect the EGR vacuum supply hose. 11. The EGR is OK, REPLACE EVP sensor if the Continuous Code 32 was present. If the Continuous Code 32 was not present, refer to the Diagnostic Routines in Section 2. Quick Test:Continuous Self-Test - 6.0 1988 EEC-IV - Quick Test - All Engines 16-15 QUICK TEST: Continuous Self-Test 6.0 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2651 1988 16-16 EEC-IV - Quick Test - All Engines QUICK TEST: Continuous 6.0 Self-Test Pinpoint Test - DN - EGR - EVP & EVR Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2652 EEC-IV - Pinpoint Tests - All Vehicles 1988 19-101 EGR Valve Position Sensor (EVP) EGR Valve Regulator (EVR) Pinpoint Test DN Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2653 19-102 1988 EEC-IV - Pinpoint Tests - All Vehicles EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Valve Regulator (EVR) Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2654 1988 EEC-IV - Pinpoint Tests - All Vehicles 19-102A EGR Valve Position Sensor (EVP) EGR Valve Regulator (EVR) Pinpoint Test DN Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2655 1988 19-103 EEC-IV - Pinpoint Tests - All Vehicles EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Valve Regulator (EVR) Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2656 1988 EEC-IV - Pinpoint Tests - All Vehicles 19-104 EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Valve Regulator (EVR) (EGR) Systems - Functional Diagnosis 1989 6-11 Exhaust Gas Recirculation (EGR) Systems Functional Diagnosis Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2657 PORTED EGR VALVE 1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked, crimped or broken hoses. 2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating temperature. 3. Install a tachometer, Rotunda 059-00010 or equivalent. 4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (EFI engines only). 5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose. 6. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If necessary, adjust idle speed according to Section 4. 7. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand vacuum pump, Rotunda 021-00014 or equivalent. 8. When vacuum is fully applied to the EGR valve: ^ If idle speed drops more than 100 rpm or if engine stalls, perform the next step. Otherwise, for vacuum leak at EGR valve, replace the valve. ^ If EGR passages are blocked, clean the valve using Rotunda 021-80056 EGR valve cleaner. ^ Remove the vacuum from the EGR valve. If idle speed does not return to normal (+/- 25 rpm), check for contamination, clean the valve. ^ Make sure there is no sand left in the valve or pick-up tube. Replace the valve if necessary. 9. Reconnect the idle air bypass valve electrical connector. 10. Unplug and reconnect the EGR vacuum supply hose. 11. The EGR system is OK, refer to the Diagnostic Routines in Section 2. 1989 6-12 Exhaust Gas Recirculation (EGR) Systems Functional Diagnosis ELECTRONIC EGR (EEGR) VALVE 1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked, crimped or broken hoses. 2. Make certain there is less than 2.5 in-Hg vacuum to the EGR valve at idle with the engine at normal operating temperature. NOTE: The EVR solenoid has a constant internal leak. You will notice a small vacuum signal. This signal should be less than 1.0 in-Hg at idle. 3. Install a tachometer, Rotunda 059-00010 or equivalent. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2658 4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (1.9L EFI engines only). 5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose. 6. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If necessary, adjust idle speed according to Section 4. 7. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand vacuum pump, Rotunda 021-00014 or equivalent. 8. When vacuum is applied to the EGR valve and any of the following occur: ^ Engine does not stall ^ Idle speed does not drop more than 100 rpm ^ Idle speed does not return to normal (+/- 25 rpm) after the vacuum is removed Then: ^ For vacuum leak at EGR valve, replace the valve. ^ Check for contamination, clean the EGR valve, using Rotunda 021-80056 EGR valve cleaner or equivalent. ^ Make sure there is no sand left in the valve. ^ Replace the EGR valve if necessary. 9. Reconnect the idle air bypass valve electrical connector. Unplug and reconnect the EGR vacuum supply hose. 10. If EGR valve is OK, REPLACE EVP sensor if Continuous Code 32 was present. If the Continuous Code 32 was not present, refer to the Diagnostic Routines in Section 2. Quick Test:Continuous Self-Test - 6.0 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2659 1989 EEC-IV - Quick Test - All Engines 14-17 QUICK TEST: Continuous 6.0 Self-Test Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2660 1989 14-18 EEC-IV - Quick Test - All Engines QUICK TEST: Continuous 6.0 Self-Test 1989 EEC-IV - Quick Test - All Engines 14-19 QUICK TEST: Continuous 6.0 Self-Test Quick Test:Diagnostic By Symptom - 7.0 1989 14-20 EEC-IV - Quick Test - All Engines QUICK TEST: Diagnostic By Symptom 7.0 A DIAGNOSTIC BY SYMPTOM SPECIAL NOTES: ^ Verify that a Pass Code 11 was received in Key On Engine Off, Engine Running and Continuous Self-Tests before continuing with this test. ^ If a symptom is present and the EEC system is suspected, Go to part B of Diagnostic By Symptom. If the EEC system is not suspected, GO to Section 2, Diagnostic Routines. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2661 Pinpoint Test - DN - EGR - EVP & EVR 1989 EEC-IV - Pinpoint Tests-All Vehicles 17-133 EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Vacuum Regulator Solenoid (EVR) Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2662 1989 17-134 EEC-IV - Pinpoint Tests - All Vehicles EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Vacuum Regulator Solenoid (EVR) Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2663 1989 EEC-IV-Pinpoint Tests - All Vehicles 17-134A Pinpoint Test DN EGR Valve Position Sensor (EVP) EGR Vacuum Regulator Solenoid (EVR) Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2664 1989 17-135 EEC-IV - Pinpoint Tests - All Vehicles EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Vacuum Regulator Solenoid (EVR) Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2665 1989 EEC-IV - Pinpoint Tests - All Vehicles 17-136A EGR Valve Position Sensor (EVP) 04GPinpoint Test DN EGR Vacuum Regulator Solenoid (EVR) Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > Page 2666 EGR Valve Position Sensor: Locations Attached To EGR Valve Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > Page 2667 EGR Valve Position Sensor: Description and Operation The EVP Sensor provides EEC System with a signal indicating position of the EGR valve. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Electronic Throttle Control Module > Component Information > Locations Electronic Throttle Control Module: Locations Under LH Side Of I/P Under LH Side Of I/P Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Electronic Throttle Control Module > Component Information > Locations > Page 2671 Electronic Throttle Control Module: Testing and Inspection Ford provides trouble code/symptom driven diagnostics for this component. For complete diagnosis and pinpoint testing, refer to Computers and Control Systems, Testing and Inspection. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Body/Frame - Arc Welding Precautions Engine Control Module: Technical Service Bulletins Body/Frame - Arc Welding Precautions Article No. 90-11-6 EEC IV-ELECTRONIC CONTROL MODULES AND PROCESSORS-POSSIBLE DAMAGE FROM ARC WELDING FORD: 1985-90 CROWN VICTORIA, ESCORT, MUSTANG, TEMPO, THUNDERBIRD 1986-90 TAURUS LINCOLN-MERCURY: 1985-86 CAPRI 1985-90 CONTINENTAL, COUGAR, GRAND MARQUIS, MARK VII, TOPAZ, TOWN CAR 1986-90 SABLE MERKUR: 1985-89 XR4Ti 1988-90 SCORPIO LIGHT TRUCK: 1985-90 BRONCO II, BRONCO, ECONOLINE, F-150, F-250, F-350, RANGER 1986-90 AEROSTAR 1989-90 F SUPER DUTY 1991 EXPLORER ISSUE: Electronic control modules, including EEC processors, may be damaged if the negative battery ground cable is not disconnected before arc welding is done to the vehicle, This occurs because the arc welding process can produce high electrical currents in the body of a vehicle when the negative battery ground cable is left connected. ACTION: If arc welding procedures are to be performed, be sure to disconnect the battery ground cable, CAUTION: DISCONNECT THE NEGATIVE BATTERY GROUND CABLE BEFORE USING ANY ELECTRIC WELDING EQUIPMENT OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 2800, 680000 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 2676 Right Hand Instrument Panel Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions Engine Control Module: Diagram Information and Instructions Symbol Identification Wire Color Code Identification Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2679 NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Page 2680 Engine Control Module: Description and Operation The center of the EEC IV system is a microprocessor called the Electronic Control Assembly (ECA). The ECA, receives data from a number of sensors and other electronic components (switches, relays, etc.). The ECA contains a specific calibration for optimizing emissions, fuel economy, and driveability. Based on information received and programmed into its memory, the ECA generates output signals to control various relays, solenoids, and other actuators. The ECA in the EEC IV system is a microprocessor like the one in the other EEC systems. One significant difference is that this ECA has the calibration module located inside the ECA assembly, unlike the EEC III system. The ECA is found in different locations, depending on the model. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Page 2681 Engine Control Module: Testing and Inspection Ford provides trouble code/symptom driven diagnostics for this component. For complete diagnosis and pinpoint testing, refer to Computers and Control Systems, Testing and Inspection. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Feedback Control Solenoid > Component Information > Locations Engine View Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Feedback Control Solenoid > Component Information > Description and Operation > Carburetor Feedback Motor - 7200 Feedback Control Solenoid: Description and Operation Carburetor Feedback Motor - 7200 The Actuator is part of the Carburetor Feedback Control System, used on 7200 model carburetors. The actuator is threaded into the carburetor body, and its actuator shaft moves a fuel metering pintle valve to produce a richer or leaner air/fuel mixture at the carburetor. In response to an electronic signal coming from the Exhaust Gas Oxygen (EGO) sensor and conditioned by the EEC (or MCU) System, the actuator shaft moves in and out. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Feedback Control Solenoid > Component Information > Description and Operation > Carburetor Feedback Motor - 7200 > Page 2687 Feedback Control Solenoid: Description and Operation Carburetor Feedback Solenoid - YFA This solenoid assembly is an integral part of the YFA feedback carburetors In a feedback system, it operates as a pulse width modulated (dithering) solenoid, varying the air bled into the idle and main fuel metering circuits, in response to commands from the MCU or EEC, thereby varying the fuel/air ratio delivered to the engine. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Feedback Control Solenoid > Component Information > Description and Operation > Carburetor Feedback Motor - 7200 > Page 2688 Feedback Control Solenoid: Description and Operation Carburetor Feedback Solenoid - 2150A Feedback Fuel Control utilizes a pulsing solenoid to introduce fresh air from the air cleaner into the idle and main system vacuum passages to lean the fuel and air mixture from the maximum rich condition (0% duty cycle - solenoid closed) to the maximum lean condition (100% duty cycle solenoid fully open). The solenoid operates under the control of the EEC-IV system. Also new to the 2150 carburetor is a throttle position sensor required by the EEC system. This new sensor was designed for the 2150 carburetor and was made non-adjustable to reduce production and warranty costs. To package the throttle position sensor and the feedback system changes were made to the booster assembly, main body, airhorn, throttle shaft and to certain choke linkage parts (fast idle cam, cam hub, cam rod, fast idle level & choke shield). Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Feedback Control Solenoid > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures Feedback Control Solenoid: Symptom Related Diagnostic Procedures After completing the MCU or EEC diagnostic procedure, and tracing the probable cause of the problem to the feedback solenoid, perform one or more of the following procedures: Feedback Carburetors - Rough Idle, Lean Drive 1. With the engine running at idle, retighten the solenoid mounting screws to 30 lb-in. If idle does not change, proceed to Step 2. 2. With the engine running at idle, apply a stethoscope or metal rod to the solenoid body and listen (or feel) for a 10 Hz constant pulse. If the pulse is not evident, or is erratic, replace the solenoid assembly and gasket. 3. With the engine running at idle, disconnect the solenoid lead. If the idle quality improves significantly with the solenoid disconnected, replace the solenoid assembly and gasket. NOTE: Since disconnecting the lead will appreciably richen the idle mixture, similar to the propane-gain technique, some degree of idle quality improvement and idle speed gain is to be expected, even with a properly operating solenoid. Feedback Carburetors - Running Rich, Poor Economy Use Step 2, above for diagnosis. NOTE: The 2.3L or 4.9L YFA 1-V Feedback Solenoid for the 1985 model year is not interchangeable with the 1981/82 4.9L solenoid. The former being designed for 38 ohm resistance, while the 1981/82 (4.9L) is 22 ohm. The Electronic Control Assembly (ECA) will be damaged if these units are interchanged. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Feedback Control Solenoid > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2691 Feedback Control Solenoid: Component Tests and General Diagnostics Carburetor Feedback Motor - 7200 1. Remove the FBCA motor from carburetor. Connect wiring harness to FBCA motor; turn ignition switch to Run to extend shaft. Turn ignition switch to Off. If FBCA shaft does not extend, replace FBCA motor and retest. 2. Push FBCA motor shaft back in by hand. If shaft will not push in, replace FBCA motor and retest. 3. Remove and clean pintle valve, spring and carburetor passage with choke cleaner and a small brush. 4. Reinstall pintle, spring and FBCA motor. Tighten FBCA motor to 8-10 lb-ft. 5. Retest per appropriate quick test. 6. Check/reset curb idle, if necessary. NOTE: FBCA motor is partly diagnosed as a part of the 5.8L MCU electronic system. Carburetor Feedback Solenoid - 2150A Duty Cycle Solenoid (FBCA) Diagnostic Routine NOTE: This procedure should be conducted only after completion of EEC IV diagnostic procedure when the resultant error codes included 41 or 42, and the appropriate Pinpoint Tests have been performed. To verify that the FBCA is functioning properly warm-up engine until the radiator hose is pressurized and hot. Turn ignition key to the Off position. Remove FBCA from carburetor, plug idle system feedback passage (top hole) in carburetor mainbody with a rubber plug, and restart engine. Observe FBCA for proper function. The rubber plunger in the actuator should be dithering open and closed If no dithering is observed immediately after start-up, replace FBCA. NOTE: Duty cycle dithering will be experienced only for a short period after engine start-up. Computer Related Diagnostic Information Ford provides trouble code/symptom driven diagnostics for this component. For complete diagnosis and pinpoint testing, refer to Computers and Control Systems, Testing and Inspection. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Technical Service Bulletins > Customer Interest for Idle Speed/Throttle Actuator Electronic: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up Technical Service Bulletin # 91257 Date: 911213 Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up Article No. 91-25-7 12/13/91 ^ HARD COLD START - DURING INITIAL START-UP, IDLE OR DECEL - EFI ENGINES SLUDGE IN THROTTLE BODY AND/OR IDLE AIR BY-PASS VALVE ^ HESITATION/STALLS - DURING INITIAL START-UP, IDLE OR DECEL - EFI ENGINES SLUDGE IN THROTTLE BODY AND/OR IDLE AIR BY-PASS VALVE FORD: 1983-87 EXP 1983-91 ESCORT 1984-90 MUSTANG, THUNDERBIRD 1986-90 TAURUS 1986-91 CROWN VICTORIA 1988-90 TEMPO LINCOLN-MERCURY: 1983-85 LN7 1983-87 LYNX 1984-88 CAPRI 1984-90 COUGAR 1986-90 CONTINENTAL, MARK VII, SABLE 1986-91 GRAND MARQUIS, TOWN CAR 1988-90 TOPAZ 1991 TRACER LIGHT TRUCK: 1985-90 BRONCO II, BRONCO 1985-91 ECONOLINE, F-150-350 SERIES 1985-92 RANGER 1986-91 AEROSTAR 1991 EXPLORER ISSUE: Hard cold starts, hesitation and stalls on initial start-up or during idle or decel may be caused by sludge in the throttle body and/or idle by-pass valve. Sludge deposits or oil film on the throttle body bore and plate or the idle air by-pass valve may cause one or more of the following conditions. ^ Hard Cold Start ^ Stall On Initial Start-Up ^ Stall During Idle ^ Stall During Decel ^ Rough Idle ^ Rolling Idle ^ Hesitation During Acceleration ACTION: A new idle air by-pass service kit (F2PZ-9F939-A) is now available for service use to correct sludge contamination concerns of the throttle bore and plate only. It eliminates the need to clean the majority of past model throttle body applications. Cleaning is not required on sludge tolerant throttle body designs released for 1991 and newer model years. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Technical Service Bulletins > Customer Interest for Idle Speed/Throttle Actuator Electronic: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 2700 Figure 1 Install an idle air by-pass service kit (F2PZ-9F939-A) as applicable to provide a permanent correction for symptoms caused by throttle body sludge deposits. Refer to the instruction sheet included in the kit for installation details. Refer to Figure 1 for a specific application list of EFI (port fuel Injection) engines involved in this TSB article. The idle air by-pass service kit (F2PZ-9F939-A) includes the following items. ^ One (1) Idle Adjust Spacer ^ Two (2) Gaskets Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Technical Service Bulletins > Customer Interest for Idle Speed/Throttle Actuator Electronic: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 2701 ^ Two (2) Attaching Bolts ^ One (1) "Attention" Sticker ^ One (1) Instruction Sheet Figure 2 Refer to Figure 2 for a pictorial of the kits components. NOTE: EFFECTIVE WITH THIS TSB, THROTTLE BODY CLEANING IS NO LONGER COVERED UNDER 5/50 EMISSIONS WARRANTY, UNLESS AS SPECIFIED IN THE FOLLOWING APPLICATION CHARTS. FAILURE TO FOLLOW THE CORRECT PROCEDURE MAY RESULT IN THE CLAIM BEING DISALLOWED. The idle air adjust spacer incorporates sludge tolerant design features that eliminate throttle body sludge related conditions. Once installed, throttle body cleaning is not allowed and periodic adjustment of the throttle body is not required. Procedures, Warranty and Labor CHECKS TO MAKE PRIOR TO SERVICE KIT INSTALLATION Confirm that the following items are not causing the idle quality concern before proceeding with the service kit installation. ^ Contamination within the idle air by-pass solenoid ^ Lack of fuel system control (excessively rich or lean) ^ Ignition timing change ^ Incorrect or malfunctioning EGR system ^ Incorrect or malfunctioning cooling system ^ Vacuum leaks (air intake manifold, vacuum hoses, vacuum reservoirs, power brake booster where applicable) ^ EEC diagnostics have been performed and vehicle malfunction indicated service output codes have been resolved and cleared. If any of the areas listed above are found to be at fault, correct them before proceeding with the service kit installation. Idle Speed Adjustment Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Technical Service Bulletins > Customer Interest for Idle Speed/Throttle Actuator Electronic: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 2702 WARNING: BEFORE PROCEEDING WITH THE IDLE SPEED ADJUSTMENT, VERIFY THAT THE FOLLOWING ITEMS ARE TAKEN CARE OF PROPERLY. ^ The transmission is in PARK or Neutral. ^ The parking brake is applied. ^ The wheels are properly blocked. ^ The engine is at operating temperature. ^ The heater, A/C, cooling fan and other accessories are OFF. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Technical Service Bulletins > Customer Interest for Idle Speed/Throttle Actuator Electronic: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 2703 Figure 3 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Technical Service Bulletins > Customer Interest for Idle Speed/Throttle Actuator Electronic: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 2704 Figure 4 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Technical Service Bulletins > Customer Interest for Idle Speed/Throttle Actuator Electronic: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 2705 Figure 5 The EFI throttle body idle speed adjustment procedures for the various model year passenger cars and light trucks are outlined in step-by-step procedures featured in Figures 3, 4 and 5. Select the appropriate procedure for the vehicle involved and adjust the throttle body idle RPM accordingly, after service kit installation. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Technical Service Bulletins > Customer Interest for Idle Speed/Throttle Actuator Electronic: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 2706 Figure 6 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Technical Service Bulletins > Customer Interest for Idle Speed/Throttle Actuator Electronic: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 2707 Figure 7 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Technical Service Bulletins > Customer Interest for Idle Speed/Throttle Actuator Electronic: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 2708 Figure 8 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Technical Service Bulletins > Customer Interest for Idle Speed/Throttle Actuator Electronic: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 2709 Figure 9 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Technical Service Bulletins > Customer Interest for Idle Speed/Throttle Actuator Electronic: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 2710 Figure 10 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Technical Service Bulletins > Customer Interest for Idle Speed/Throttle Actuator Electronic: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 2711 Figure 11 THROTTLE BODY AND IDLE AIR BY-PASS SOLENOID SERVICE PROCEDURE Detailed application charts for throttle body and idle air by-pass solenoid service procedures by engine VIN # /engine displacement/vehicle application and model year are shown in Figures 6 through 11. Refer to these charts to see if the service kit is to be installed and which service cleaning procedure, if any, is to be used. SERVICE CLEANING PROCEDURES The following items should be noted prior to beginning the service cleaning procedure. ^ Confirm that the correct service cleaning procedure is identified in the Application Charts, Figures 6-11, for the vehicle/engine combination being Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Technical Service Bulletins > Customer Interest for Idle Speed/Throttle Actuator Electronic: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 2712 serviced. ^ Do not clean throttle bodies identified to accept service kit (F2PZ-9F939-A), IDLE AIR ADJUST SPACER. ^ Use a 1" (25.4 mm) to 1-1/2" (38.1 mm) wire stemmed horse hair or nylon bottle cleaner type brush. ^ Use rubber gloves and eye protection. ^ Do not clean throttle bodies identified with a yellow/black "ATTENTION" label. ^ Do not clean "Black" plastic air by-pass valves. Refer to TSB 89-13-8 for service details. ^ Do not run vehicles with air flow meters when the air duct is removed. ^ Do not use carburetor cleaner as a cleaning solvent. Use Carburetor Tune-up Cleaner (D9AZ-19579-AA). Procedure # 1 THROTTLE BODY AND IDLE AIR BY-PASS VALVE CLEANING CAUTION: DO NOT RUN VEHICLES EQUIPPED WITH AIR FLOW METERS DURING THE CLEANING PROCEDURE. IF THERE IS A YELLOW/BLACK "ATTENTION" LABEL ON THE THROTTLE BODY ADVISING NOT TO CLEAN, OR IF THE VEHICLE IS IDENTIFIED AS ACCEPTING SERVICE KIT (F2PZ-9F939-A), USE PROCEDURE # 2 FOR IDLE AIR BY-PASS VALVE CLEANING ONLY. 1. Plug the actuator into the connector in the Rotunda Cleaner/Tester, Tool 113-00009. 2. Remove the air duct to the throttle body inlet. 3. Disoonnect the idle air by-pass valve signal lead. 4. Attach the actuator harness plug to the idle air by-pass valve. 5. Start the actuator and then start the engine. Do not start engines that have air flow meters. 6. Spray just enough Carburetor Tune-up Cleaner (D9AZ-19579-AA) into the throttle bore to wet the bore and throttle plate. 7. Spray the Carburetor Tune-up Cleaner for about five (5) seconds into the idle air by-pass valve inlet passage while the actuator is operating. 8. Stop the engine and actuator. Let everything soak for fifteen (15) minutes. 9. After a fifteen (15) minute soak, saturate the cleaning brush with solvent and scrub between the throttle body bore and plate while holding the throttle wide open. NOTE: IT IS NECESSARY TO APPLY SOME PRESSURE ON THE BRUSH WHILE SCRUBBING. 10. Repeat saturating the brush and scrubbing for one (1) to two (2) minutes, making sure to reach into the corners where the throttle shaft meets the bore wall. 11. Start the actuator and the start the engine. Do not start engines that have air flow meters. 12. Spray Carburetor Tune-up Cleaner into the throttle bore for up to one (1) minute to wash away residue. Do not spray for longer than six (6) continuous seconds on engines that have air flow meters and are not running. 13. Spray Carburetor Tune-up Cleaner into the idle by-pass valve passage leading to the inlet of the valve for up to one (1) minute. Do not spray for longer than six (6) continuous seconds on engines that have air flow meters and are not running. 14. Stop actuator and stop engine, if running. NOTE: MAKE SURE THE THROTTLE PLATES OPERATE FREELY AND CLOSE PROPERLY. 15. Reinstall the air duct. 16. Start and run the engine for about one (1) minute to dry out the solvent residue. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Technical Service Bulletins > Customer Interest for Idle Speed/Throttle Actuator Electronic: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 2713 17. Operate the actuator to make sure the solvent is purged from the idle by-pass valve. 18. Disconnect the actuator from the idle air by-pass valve. 19. Reattach the control signal lead to the air by-pass valve. 20. Check engine for normal operation. It may be necessary to reset the idle speed due to a previous adjustment for an idle concern. (Refer to the respective Powertrain/Emissions Diagnosis Service Manual, Throttle Body Section, for idle speed adjust procedure.) Procedure # 2 Idle Air By-Pass Valve Cleaning Only CAUTION: THIS CLEANING PROCEDURE MAY BE USED WITH SLUDGE TOLERANT THROTTLE BODIES WHICH ARE IDENTIFIED WITH A YELLOW/BLACK "ATTENTION" LABEL AND THOSE USING SERVICE KIT (F2PZ-9F939-A). NO ATTEMPT SHOULD BE MADE TO CLEAN THROTTLE BODY BORE/PLATE AREA BY DIRECT SPRAYING OR SCRUBBING. DO NOT RUN VEHICLES WITH AIR FLOW METERS DURING CLEANING PROCEDURE. 1. Plug the actuator into the connector in the Rotunda Air By-Pass Valve Adapter 113-00009, or equivalent. 2. Remove the air duct to the throttle body inlet. 3. Disconnect the idle air by-pass valve signal lead. 4. Attach the actuator harness plug to the idle air by-pass valve. 5. Start the actuator and then start the engine. NOTE: DO NOT START ENGINES THAT HAVE AIR FLOW METERS. 6. Spray the Carburetor Tune-up Cleaner for about five (5) seconds into the idle air by-pass valve inlet passage while the actuator is operating. CAUTION: AVOID DIRECT SPRAYING ON THROTTLE PLATE/BORE AREA. 7. Stop the engine and actuator. Let everything soak for fifteen (15) minutes. 8. Start the actuator and the start the engine. CAUTION: DO NOT START ENGINES THAT HAVE AIR FLOW METERS. 9. Spray Carburetor Tune-up Cleaner into the throttle bore for up to one (1) minute. CAUTION: DO NOT SPRAY FOR LONGER THAN SIX (6) CONTINUOUS SECONDS ON ENGINES THAT HAVE AIR FLOW METERS AND ARE NOT RUNNING. 10. Stop actuator and stop engine if running. 11. Reinstall the air duct. 12. Start and run the engine for about one (1) minute to dry out the solvent residue. 13. Operate the actuator to make sure the solvent is purged from the idle by-pass valve. 14. Disconnect the actuator from the idle air by-pass valve. 15. Reattach the control signal lead to the air by-pass valve. 16. Check engine for normal operation. NOTE: IT SHOULD NOT BE NECESSARY TO RESET THE IDLE SPEED SINCE ONLY THE IDLE AIR BY-PASS VALVE WAS SERVICED IN THIS PROCEDURE Warranty Coverage Throttle bodies and idle air by-pass valves on all EFI (Port Fuel Injection) engines through the 1992 model year that can be cleaned (as identified in the application charts) are covered under 5/50 Emissions Warranty Coverage. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Technical Service Bulletins > Customer Interest for Idle Speed/Throttle Actuator Electronic: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 2714 For those throttle bodies identified as having sludge tolerant designs or using service kit (F2PZ-9F939-A) where cleaning is not allowed per the application charts, the warranty claims for cleaning will not be reimbursed even within the 12/12 warranty coverage period. Cleaning is not allowed. Service kit installation (single time) is covered under 5/50 emission warranty. Labor Standards Operations The labor operations shown in the following Operation/Description/Time columns are identified by procedure number and vehicle line. Specific engines for various vehicles are identified in the sludge cleaning procedure application charts. The throttle body cleaning operations with combinations and the air by-pass valve cleaning combinations will appear in future Labor Manuals under the following operation numbers. ^ 9926 B - Throttle body and idle air by-pass valve cleaning ^ 9926 B2 - Adjust idle speed ^ 9715 A - Air by-pass valve cleaning only ^ 9715 A1 - Adjust idle speed PART NUMBER PART NAME CLASS F2PZ-9F939-A Idle Air By-pass Service Kit B D9AZ-19579-AA Carburstor Tune-Up Cleaner BG OTHER APPLICABLE ARTICLES: 89-13-8 SUPERSEDES: 88-24-5, 88-24-6, 89-16-5, 91-10-9, 91-7-4 Operation Description WARRANTY STATUS: Eligible Under Warranty Coverage As Stated In The Text Of This Article OPERATION DESCRIPTION TIME 912507A Idle Air By-Pass Valve 0.5 Hr. Cleaning - 1983-85 Escort, EXP, LN7, LYNX 1.6L EFI. 912507B Idle Air By-Pass Valve 0.5 Hr. Cleaning - 1986-91 Escort 1.9L EFI, 1986/87 EXP, Lynx 1.9L EFI, 1991 Tracer 1.9L EFI. 912507C Idle Air By Pass Valve 0.5 Hr. Cleaning - 1984-87 Mustang 2.3L T/C, 1986/87 Capri, Cougar 2.3L T/C, 1984-88 T-Bird 2.3L T/C, 1987/92 Mustang 2.3L EFI. 912507D Idle By-Pass Valve Cleaning 0.6 Hr. - 1988-91 Tempo, Topaz 2.3L HSC, 1985-92 Ranger 2.3L EFI. 912507E Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1986/87 Aerostar 2.3L EFI, 1985 Bronco II 2.3L EFI. 912507F Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1986-90 Bronco II 2.9L EFI, 1986-92 Ranger 2.9L EFI. 912507G Idle Air By-Pass Valve 0.6 Hr. Cleaning - 1991/92 Probe 3.0L EFI, 1986-91 Taurus 3.0L EFI, 1987-91 Sable 3.0L EFI. 912507H Idle Air By-Pass Valve 0.7 Hr. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Technical Service Bulletins > Customer Interest for Idle Speed/Throttle Actuator Electronic: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 2715 Cleaning - 1986-91 Aerostar 3.0L EFI, 1991 Ranger 3.0L EFI. 912507I Idle Air By-Pass Valve 0.6 Hr. Cleaning - 1988 Continental, Cougar, Taurus, T-Bird, Sable 3.8L EFI. 1988 Cougar, T-Bird 3.8L S/C. 912507J Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1990-92 Aerostar 4.0L EFI, 1990 Bronco II 4.0L EFI, 1991/92 Explorer 4.0L EFI, 1990-92 Ranger 4.0L EFI. 912507K Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1987-92 Bronco 4.9L EFI, 1987-92 F-Series 4.9L EFI, 1987/90 Econoline (Without Rear Heater) 4.9L EFI, 1991/92 Econoline (All) 4.9L EFI. 912507L Idle Air By-Pass Valve 0.6 Hr. Cleaning - 1986-88 Cougar, T-Bird 5.0L EFI, 1986-87 Continental, Mark VII 5.OL EFI, 1986/91 Crn - Victoria, Grn - Marquis 5.0L EFI, 1986-92 Mark VII 5.0L HO, 1982-92 Mustang 5.0L HO. 912507M Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1985-92 Bronco, E-Series, F-Series 5.0L EFI. 912507N Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1988-90 Bronco, F-Series 5.8L. 1991 Econo, F-Series, Bronco 5.8L (Do not Clean Solenoid, Calib; 1-64E-R10, 1-64H-R10, 1-64J-R10, 1-64K-R10, 1-64M-R10, 1-64P-R10, 1-64R-R10, 1-75A-R00, 1-76A-R00, 1-76B-R00, 1-76C-R00. 912507O Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1991/92 F And B Series, 7.0L EFI. 912507P Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1987-92 E-Series, F-Series 7.5L EFI. 912507Q Throttle Body And Idle Air 0.9 Hr. By-Pass Valve Cleaning - 1989/90 Probe 3.0L EFI. 912507R Throttle Body And Idle Air 0.8 Hr. By-Pass Valve Cleaning - 1987-90 Econoline (With Rear Heat) 4.9L EFI. 912507S Throttle Body And Idle Air 0.9 Hr. By-Pass Valve Cleaning - 1988-90 Econoline 5.8L EFI. 912507T Service Kit Install - All Cars 1.0 Hr. And Light Trucks (Except Aerostar And Econoline) - Refer To The Service Procedure Application Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Technical Service Bulletins > Customer Interest for Idle Speed/Throttle Actuator Electronic: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 2716 Charts, For Vehicle Application. 912507U Service Kit Install - 1.2 Hr. Aerostar, Econoline - Refer To Service Procedure Application Charts - For Vehicle Application. DEALER CODING BASIC PART NO. CONDITION CODE 9E926 49 OASIS CODES: 602300, 607000, 607400, 607700, 608400, 611500, 618400 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Technical Service Bulletins > Customer Interest for Idle Speed/Throttle Actuator Electronic: > 89244 > Dec > 89 > Engine - Rough Idling Condition Idle Speed/Throttle Actuator - Electronic: Customer Interest Engine - Rough Idling Condition ^ FUEL SYSTEM-EFI ENGINES - AIR BY-PASS VALVE REPLACEMENT PART INOPERATIVE ^ IDLE - ROUGH-REPLACEMENT AIR BY-PASS VALVE INOPERATIVE Article No. 89-24-4 FORD: 1983-88 ESCORT, EXP, THUNDERBIRD 1984-88 MUSTANG 1986-88 CROWN VICTORIA, TAURUS 1988 TEMPO LINCOLN-MERCURY: 1983 LN7 1983-86 LYNX 1983-88 COUGAR 1984-86 CAPRI 1986-88 CONTINENTAL, GRAND MARQUIS, MARK VII, SABLE, TOWN CAR 1988 TOPAZ MERKUR: 1985-88 XR4TI 1988 SCORPIO LIGHT TRUCK: 1985-88 BRONCO, F-150, F-250, RANGER 1986-88 AEROSTAR, BRONCO II, ECONOLINE 1987-88 F-350 1988 F SUPER DUTY Figure 1 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Technical Service Bulletins > Customer Interest for Idle Speed/Throttle Actuator Electronic: > 89244 > Dec > 89 > Engine - Rough Idling Condition > Page 2721 ISSUE: A rough idle created when the air by-pass valve is replaced may be caused by a revision made to the valve's wiring harness. Vehicles built before the 1989 model year had a diode in the air by-pass valve wiring harness. The new replacement valves have a 3D marking on the plastic portion of the solenoid, above the connector cap, Figure 1. They have a diode in the air by-pass valve. On the air by-pass valves used on vehicles built before the 1989 model year, the positive and negative leads are not important to the operation of the valve. However, the polarity on the new replacement air by-pass valve is important because if the wiring harness is reversed the air by-pass valve will not work. ACTION: Reverse the wires in the air by-pass valve connector and retest the valve. Refer to the following EFI Engine Application Chart for engines using these air by-pass valves. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 620800 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed/Throttle Actuator - Electronic: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up Technical Service Bulletin # 91257 Date: 911213 Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up Article No. 91-25-7 12/13/91 ^ HARD COLD START - DURING INITIAL START-UP, IDLE OR DECEL - EFI ENGINES SLUDGE IN THROTTLE BODY AND/OR IDLE AIR BY-PASS VALVE ^ HESITATION/STALLS - DURING INITIAL START-UP, IDLE OR DECEL - EFI ENGINES SLUDGE IN THROTTLE BODY AND/OR IDLE AIR BY-PASS VALVE FORD: 1983-87 EXP 1983-91 ESCORT 1984-90 MUSTANG, THUNDERBIRD 1986-90 TAURUS 1986-91 CROWN VICTORIA 1988-90 TEMPO LINCOLN-MERCURY: 1983-85 LN7 1983-87 LYNX 1984-88 CAPRI 1984-90 COUGAR 1986-90 CONTINENTAL, MARK VII, SABLE 1986-91 GRAND MARQUIS, TOWN CAR 1988-90 TOPAZ 1991 TRACER LIGHT TRUCK: 1985-90 BRONCO II, BRONCO 1985-91 ECONOLINE, F-150-350 SERIES 1985-92 RANGER 1986-91 AEROSTAR 1991 EXPLORER ISSUE: Hard cold starts, hesitation and stalls on initial start-up or during idle or decel may be caused by sludge in the throttle body and/or idle by-pass valve. Sludge deposits or oil film on the throttle body bore and plate or the idle air by-pass valve may cause one or more of the following conditions. ^ Hard Cold Start ^ Stall On Initial Start-Up ^ Stall During Idle ^ Stall During Decel ^ Rough Idle ^ Rolling Idle ^ Hesitation During Acceleration ACTION: A new idle air by-pass service kit (F2PZ-9F939-A) is now available for service use to correct sludge contamination concerns of the throttle bore and plate only. It eliminates the need to clean the majority of past model throttle body applications. Cleaning is not required on sludge tolerant throttle body designs released for 1991 and newer model years. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed/Throttle Actuator - Electronic: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 2727 Figure 1 Install an idle air by-pass service kit (F2PZ-9F939-A) as applicable to provide a permanent correction for symptoms caused by throttle body sludge deposits. Refer to the instruction sheet included in the kit for installation details. Refer to Figure 1 for a specific application list of EFI (port fuel Injection) engines involved in this TSB article. The idle air by-pass service kit (F2PZ-9F939-A) includes the following items. ^ One (1) Idle Adjust Spacer ^ Two (2) Gaskets Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed/Throttle Actuator - Electronic: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 2728 ^ Two (2) Attaching Bolts ^ One (1) "Attention" Sticker ^ One (1) Instruction Sheet Figure 2 Refer to Figure 2 for a pictorial of the kits components. NOTE: EFFECTIVE WITH THIS TSB, THROTTLE BODY CLEANING IS NO LONGER COVERED UNDER 5/50 EMISSIONS WARRANTY, UNLESS AS SPECIFIED IN THE FOLLOWING APPLICATION CHARTS. FAILURE TO FOLLOW THE CORRECT PROCEDURE MAY RESULT IN THE CLAIM BEING DISALLOWED. The idle air adjust spacer incorporates sludge tolerant design features that eliminate throttle body sludge related conditions. Once installed, throttle body cleaning is not allowed and periodic adjustment of the throttle body is not required. Procedures, Warranty and Labor CHECKS TO MAKE PRIOR TO SERVICE KIT INSTALLATION Confirm that the following items are not causing the idle quality concern before proceeding with the service kit installation. ^ Contamination within the idle air by-pass solenoid ^ Lack of fuel system control (excessively rich or lean) ^ Ignition timing change ^ Incorrect or malfunctioning EGR system ^ Incorrect or malfunctioning cooling system ^ Vacuum leaks (air intake manifold, vacuum hoses, vacuum reservoirs, power brake booster where applicable) ^ EEC diagnostics have been performed and vehicle malfunction indicated service output codes have been resolved and cleared. If any of the areas listed above are found to be at fault, correct them before proceeding with the service kit installation. Idle Speed Adjustment Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed/Throttle Actuator - Electronic: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 2729 WARNING: BEFORE PROCEEDING WITH THE IDLE SPEED ADJUSTMENT, VERIFY THAT THE FOLLOWING ITEMS ARE TAKEN CARE OF PROPERLY. ^ The transmission is in PARK or Neutral. ^ The parking brake is applied. ^ The wheels are properly blocked. ^ The engine is at operating temperature. ^ The heater, A/C, cooling fan and other accessories are OFF. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed/Throttle Actuator - Electronic: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 2730 Figure 3 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed/Throttle Actuator - Electronic: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 2731 Figure 4 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed/Throttle Actuator - Electronic: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 2732 Figure 5 The EFI throttle body idle speed adjustment procedures for the various model year passenger cars and light trucks are outlined in step-by-step procedures featured in Figures 3, 4 and 5. Select the appropriate procedure for the vehicle involved and adjust the throttle body idle RPM accordingly, after service kit installation. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed/Throttle Actuator - Electronic: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 2733 Figure 6 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed/Throttle Actuator - Electronic: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 2734 Figure 7 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed/Throttle Actuator - Electronic: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 2735 Figure 8 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed/Throttle Actuator - Electronic: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 2736 Figure 9 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed/Throttle Actuator - Electronic: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 2737 Figure 10 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed/Throttle Actuator - Electronic: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 2738 Figure 11 THROTTLE BODY AND IDLE AIR BY-PASS SOLENOID SERVICE PROCEDURE Detailed application charts for throttle body and idle air by-pass solenoid service procedures by engine VIN # /engine displacement/vehicle application and model year are shown in Figures 6 through 11. Refer to these charts to see if the service kit is to be installed and which service cleaning procedure, if any, is to be used. SERVICE CLEANING PROCEDURES The following items should be noted prior to beginning the service cleaning procedure. ^ Confirm that the correct service cleaning procedure is identified in the Application Charts, Figures 6-11, for the vehicle/engine combination being Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed/Throttle Actuator - Electronic: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 2739 serviced. ^ Do not clean throttle bodies identified to accept service kit (F2PZ-9F939-A), IDLE AIR ADJUST SPACER. ^ Use a 1" (25.4 mm) to 1-1/2" (38.1 mm) wire stemmed horse hair or nylon bottle cleaner type brush. ^ Use rubber gloves and eye protection. ^ Do not clean throttle bodies identified with a yellow/black "ATTENTION" label. ^ Do not clean "Black" plastic air by-pass valves. Refer to TSB 89-13-8 for service details. ^ Do not run vehicles with air flow meters when the air duct is removed. ^ Do not use carburetor cleaner as a cleaning solvent. Use Carburetor Tune-up Cleaner (D9AZ-19579-AA). Procedure # 1 THROTTLE BODY AND IDLE AIR BY-PASS VALVE CLEANING CAUTION: DO NOT RUN VEHICLES EQUIPPED WITH AIR FLOW METERS DURING THE CLEANING PROCEDURE. IF THERE IS A YELLOW/BLACK "ATTENTION" LABEL ON THE THROTTLE BODY ADVISING NOT TO CLEAN, OR IF THE VEHICLE IS IDENTIFIED AS ACCEPTING SERVICE KIT (F2PZ-9F939-A), USE PROCEDURE # 2 FOR IDLE AIR BY-PASS VALVE CLEANING ONLY. 1. Plug the actuator into the connector in the Rotunda Cleaner/Tester, Tool 113-00009. 2. Remove the air duct to the throttle body inlet. 3. Disoonnect the idle air by-pass valve signal lead. 4. Attach the actuator harness plug to the idle air by-pass valve. 5. Start the actuator and then start the engine. Do not start engines that have air flow meters. 6. Spray just enough Carburetor Tune-up Cleaner (D9AZ-19579-AA) into the throttle bore to wet the bore and throttle plate. 7. Spray the Carburetor Tune-up Cleaner for about five (5) seconds into the idle air by-pass valve inlet passage while the actuator is operating. 8. Stop the engine and actuator. Let everything soak for fifteen (15) minutes. 9. After a fifteen (15) minute soak, saturate the cleaning brush with solvent and scrub between the throttle body bore and plate while holding the throttle wide open. NOTE: IT IS NECESSARY TO APPLY SOME PRESSURE ON THE BRUSH WHILE SCRUBBING. 10. Repeat saturating the brush and scrubbing for one (1) to two (2) minutes, making sure to reach into the corners where the throttle shaft meets the bore wall. 11. Start the actuator and the start the engine. Do not start engines that have air flow meters. 12. Spray Carburetor Tune-up Cleaner into the throttle bore for up to one (1) minute to wash away residue. Do not spray for longer than six (6) continuous seconds on engines that have air flow meters and are not running. 13. Spray Carburetor Tune-up Cleaner into the idle by-pass valve passage leading to the inlet of the valve for up to one (1) minute. Do not spray for longer than six (6) continuous seconds on engines that have air flow meters and are not running. 14. Stop actuator and stop engine, if running. NOTE: MAKE SURE THE THROTTLE PLATES OPERATE FREELY AND CLOSE PROPERLY. 15. Reinstall the air duct. 16. Start and run the engine for about one (1) minute to dry out the solvent residue. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed/Throttle Actuator - Electronic: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 2740 17. Operate the actuator to make sure the solvent is purged from the idle by-pass valve. 18. Disconnect the actuator from the idle air by-pass valve. 19. Reattach the control signal lead to the air by-pass valve. 20. Check engine for normal operation. It may be necessary to reset the idle speed due to a previous adjustment for an idle concern. (Refer to the respective Powertrain/Emissions Diagnosis Service Manual, Throttle Body Section, for idle speed adjust procedure.) Procedure # 2 Idle Air By-Pass Valve Cleaning Only CAUTION: THIS CLEANING PROCEDURE MAY BE USED WITH SLUDGE TOLERANT THROTTLE BODIES WHICH ARE IDENTIFIED WITH A YELLOW/BLACK "ATTENTION" LABEL AND THOSE USING SERVICE KIT (F2PZ-9F939-A). NO ATTEMPT SHOULD BE MADE TO CLEAN THROTTLE BODY BORE/PLATE AREA BY DIRECT SPRAYING OR SCRUBBING. DO NOT RUN VEHICLES WITH AIR FLOW METERS DURING CLEANING PROCEDURE. 1. Plug the actuator into the connector in the Rotunda Air By-Pass Valve Adapter 113-00009, or equivalent. 2. Remove the air duct to the throttle body inlet. 3. Disconnect the idle air by-pass valve signal lead. 4. Attach the actuator harness plug to the idle air by-pass valve. 5. Start the actuator and then start the engine. NOTE: DO NOT START ENGINES THAT HAVE AIR FLOW METERS. 6. Spray the Carburetor Tune-up Cleaner for about five (5) seconds into the idle air by-pass valve inlet passage while the actuator is operating. CAUTION: AVOID DIRECT SPRAYING ON THROTTLE PLATE/BORE AREA. 7. Stop the engine and actuator. Let everything soak for fifteen (15) minutes. 8. Start the actuator and the start the engine. CAUTION: DO NOT START ENGINES THAT HAVE AIR FLOW METERS. 9. Spray Carburetor Tune-up Cleaner into the throttle bore for up to one (1) minute. CAUTION: DO NOT SPRAY FOR LONGER THAN SIX (6) CONTINUOUS SECONDS ON ENGINES THAT HAVE AIR FLOW METERS AND ARE NOT RUNNING. 10. Stop actuator and stop engine if running. 11. Reinstall the air duct. 12. Start and run the engine for about one (1) minute to dry out the solvent residue. 13. Operate the actuator to make sure the solvent is purged from the idle by-pass valve. 14. Disconnect the actuator from the idle air by-pass valve. 15. Reattach the control signal lead to the air by-pass valve. 16. Check engine for normal operation. NOTE: IT SHOULD NOT BE NECESSARY TO RESET THE IDLE SPEED SINCE ONLY THE IDLE AIR BY-PASS VALVE WAS SERVICED IN THIS PROCEDURE Warranty Coverage Throttle bodies and idle air by-pass valves on all EFI (Port Fuel Injection) engines through the 1992 model year that can be cleaned (as identified in the application charts) are covered under 5/50 Emissions Warranty Coverage. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed/Throttle Actuator - Electronic: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 2741 For those throttle bodies identified as having sludge tolerant designs or using service kit (F2PZ-9F939-A) where cleaning is not allowed per the application charts, the warranty claims for cleaning will not be reimbursed even within the 12/12 warranty coverage period. Cleaning is not allowed. Service kit installation (single time) is covered under 5/50 emission warranty. Labor Standards Operations The labor operations shown in the following Operation/Description/Time columns are identified by procedure number and vehicle line. Specific engines for various vehicles are identified in the sludge cleaning procedure application charts. The throttle body cleaning operations with combinations and the air by-pass valve cleaning combinations will appear in future Labor Manuals under the following operation numbers. ^ 9926 B - Throttle body and idle air by-pass valve cleaning ^ 9926 B2 - Adjust idle speed ^ 9715 A - Air by-pass valve cleaning only ^ 9715 A1 - Adjust idle speed PART NUMBER PART NAME CLASS F2PZ-9F939-A Idle Air By-pass Service Kit B D9AZ-19579-AA Carburstor Tune-Up Cleaner BG OTHER APPLICABLE ARTICLES: 89-13-8 SUPERSEDES: 88-24-5, 88-24-6, 89-16-5, 91-10-9, 91-7-4 Operation Description WARRANTY STATUS: Eligible Under Warranty Coverage As Stated In The Text Of This Article OPERATION DESCRIPTION TIME 912507A Idle Air By-Pass Valve 0.5 Hr. Cleaning - 1983-85 Escort, EXP, LN7, LYNX 1.6L EFI. 912507B Idle Air By-Pass Valve 0.5 Hr. Cleaning - 1986-91 Escort 1.9L EFI, 1986/87 EXP, Lynx 1.9L EFI, 1991 Tracer 1.9L EFI. 912507C Idle Air By Pass Valve 0.5 Hr. Cleaning - 1984-87 Mustang 2.3L T/C, 1986/87 Capri, Cougar 2.3L T/C, 1984-88 T-Bird 2.3L T/C, 1987/92 Mustang 2.3L EFI. 912507D Idle By-Pass Valve Cleaning 0.6 Hr. - 1988-91 Tempo, Topaz 2.3L HSC, 1985-92 Ranger 2.3L EFI. 912507E Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1986/87 Aerostar 2.3L EFI, 1985 Bronco II 2.3L EFI. 912507F Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1986-90 Bronco II 2.9L EFI, 1986-92 Ranger 2.9L EFI. 912507G Idle Air By-Pass Valve 0.6 Hr. Cleaning - 1991/92 Probe 3.0L EFI, 1986-91 Taurus 3.0L EFI, 1987-91 Sable 3.0L EFI. 912507H Idle Air By-Pass Valve 0.7 Hr. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed/Throttle Actuator - Electronic: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 2742 Cleaning - 1986-91 Aerostar 3.0L EFI, 1991 Ranger 3.0L EFI. 912507I Idle Air By-Pass Valve 0.6 Hr. Cleaning - 1988 Continental, Cougar, Taurus, T-Bird, Sable 3.8L EFI. 1988 Cougar, T-Bird 3.8L S/C. 912507J Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1990-92 Aerostar 4.0L EFI, 1990 Bronco II 4.0L EFI, 1991/92 Explorer 4.0L EFI, 1990-92 Ranger 4.0L EFI. 912507K Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1987-92 Bronco 4.9L EFI, 1987-92 F-Series 4.9L EFI, 1987/90 Econoline (Without Rear Heater) 4.9L EFI, 1991/92 Econoline (All) 4.9L EFI. 912507L Idle Air By-Pass Valve 0.6 Hr. Cleaning - 1986-88 Cougar, T-Bird 5.0L EFI, 1986-87 Continental, Mark VII 5.OL EFI, 1986/91 Crn - Victoria, Grn - Marquis 5.0L EFI, 1986-92 Mark VII 5.0L HO, 1982-92 Mustang 5.0L HO. 912507M Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1985-92 Bronco, E-Series, F-Series 5.0L EFI. 912507N Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1988-90 Bronco, F-Series 5.8L. 1991 Econo, F-Series, Bronco 5.8L (Do not Clean Solenoid, Calib; 1-64E-R10, 1-64H-R10, 1-64J-R10, 1-64K-R10, 1-64M-R10, 1-64P-R10, 1-64R-R10, 1-75A-R00, 1-76A-R00, 1-76B-R00, 1-76C-R00. 912507O Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1991/92 F And B Series, 7.0L EFI. 912507P Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1987-92 E-Series, F-Series 7.5L EFI. 912507Q Throttle Body And Idle Air 0.9 Hr. By-Pass Valve Cleaning - 1989/90 Probe 3.0L EFI. 912507R Throttle Body And Idle Air 0.8 Hr. By-Pass Valve Cleaning - 1987-90 Econoline (With Rear Heat) 4.9L EFI. 912507S Throttle Body And Idle Air 0.9 Hr. By-Pass Valve Cleaning - 1988-90 Econoline 5.8L EFI. 912507T Service Kit Install - All Cars 1.0 Hr. And Light Trucks (Except Aerostar And Econoline) - Refer To The Service Procedure Application Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed/Throttle Actuator - Electronic: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 2743 Charts, For Vehicle Application. 912507U Service Kit Install - 1.2 Hr. Aerostar, Econoline - Refer To Service Procedure Application Charts - For Vehicle Application. DEALER CODING BASIC PART NO. CONDITION CODE 9E926 49 OASIS CODES: 602300, 607000, 607400, 607700, 608400, 611500, 618400 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed/Throttle Actuator - Electronic: > 89244 > Dec > 89 > Engine - Rough Idling Condition Idle Speed/Throttle Actuator - Electronic: All Technical Service Bulletins Engine - Rough Idling Condition ^ FUEL SYSTEM-EFI ENGINES - AIR BY-PASS VALVE REPLACEMENT PART INOPERATIVE ^ IDLE - ROUGH-REPLACEMENT AIR BY-PASS VALVE INOPERATIVE Article No. 89-24-4 FORD: 1983-88 ESCORT, EXP, THUNDERBIRD 1984-88 MUSTANG 1986-88 CROWN VICTORIA, TAURUS 1988 TEMPO LINCOLN-MERCURY: 1983 LN7 1983-86 LYNX 1983-88 COUGAR 1984-86 CAPRI 1986-88 CONTINENTAL, GRAND MARQUIS, MARK VII, SABLE, TOWN CAR 1988 TOPAZ MERKUR: 1985-88 XR4TI 1988 SCORPIO LIGHT TRUCK: 1985-88 BRONCO, F-150, F-250, RANGER 1986-88 AEROSTAR, BRONCO II, ECONOLINE 1987-88 F-350 1988 F SUPER DUTY Figure 1 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed/Throttle Actuator - Electronic: > 89244 > Dec > 89 > Engine - Rough Idling Condition > Page 2748 ISSUE: A rough idle created when the air by-pass valve is replaced may be caused by a revision made to the valve's wiring harness. Vehicles built before the 1989 model year had a diode in the air by-pass valve wiring harness. The new replacement valves have a 3D marking on the plastic portion of the solenoid, above the connector cap, Figure 1. They have a diode in the air by-pass valve. On the air by-pass valves used on vehicles built before the 1989 model year, the positive and negative leads are not important to the operation of the valve. However, the polarity on the new replacement air by-pass valve is important because if the wiring harness is reversed the air by-pass valve will not work. ACTION: Reverse the wires in the air by-pass valve connector and retest the valve. Refer to the following EFI Engine Application Chart for engines using these air by-pass valves. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 620800 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Technical Service Bulletins > Page 2749 IDLE SPEED CONTROL - FI ENGINES W/ISC. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Mechanical > Idle Speed Vacuum Solenoid Valve > Component Information > Locations Idle Speed Vacuum Solenoid Valve: Locations RH Side Of V8-351/5. Rear Of LH Rocker Cover Applicable to: 8L Engine With EEC-IV Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Description and Operation Knock Sensor: Description and Operation The Knock Sensor, is a piezoelectric accelerometer with the sensor designed to resonate at approximately the same frequency as the engine knock frequency. The sensor uses the resonant frequency to mechanically amplify the vibrations. This method allows relatively large signals to be achieved without electrical amplification and with small package size. The sensor has a thin circular piezoelectric ceramic disk which is bonded to a metal diaphragm. Electrical connections are made through a two pin integral connector. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Description and Operation > Page 2757 Knock Sensor: Testing and Inspection Ford provides trouble code/symptom driven diagnostics for this component. For complete diagnosis and pinpoint testing, refer to Computers and Control Systems, Testing and Inspection. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Component Locations Main Relay (Computer/Fuel System): Component Locations Fuel Pump Relay Engine Compartment Components. LH Side Of Engine Compartment, On Relay Bracket. Fuel pump relay is next to the EEC Relay. Applicable to: 4.9L/6-300 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Component Locations > Page 2762 Engine Compartment Components. LH Side Of Engine Compartment, On Relay Bracket. Fuel pump relay is next to the EEC Relay. Applicable to: 5.0L/V8-302 & 5.8L/V8-350 Engine Compartment Components. LH Side Of Engine Compartment, On Relay Bracket. Fuel pump relay is next to the EEC Relay. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Component Locations > Page 2763 Applicable to: 7.5L/V8-460 EEC Power Relay Under Dash Panel Next To, Or On ECA Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Component Locations > Page 2764 Right Hand Instrument Panel Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 2765 Main Relay (Computer/Fuel System): Description and Operation There are two types of relays: the power relay and the time delay power relay. The time delay relay has a delay of 5 to 10 seconds and is used with an actuator assembly throttle control. Both relay types consist of a movable contact in the normally open position. All power relays (except time delay) have the same design with a different bracket attachment. Function EEC power relays are in parallel with the ignition switch and provide power to the EEC module. Power relays also provide reverse battery protection and increased load handling to improve ignition switch reliability. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 2766 Main Relay (Computer/Fuel System): Testing and Inspection Ford provides trouble code/symptom driven diagnostics for this component. For complete diagnosis and pinpoint testing, refer to Computers and Control Systems, Testing and Inspection. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications MANIFOLD ABSOLUTE AND BAROMETRIC PRESSURE SENSORS Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 2770 Right Hand Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 2771 Manifold Pressure/Vacuum Sensor: Testing and Inspection Ford provides trouble code/symptom driven diagnostics for this component. For complete diagnosis and pinpoint testing, refer to Computers and Control Systems, Testing and Inspection. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Engine - Lack of Power/No Start Diagnosis Oxygen Sensor: Technical Service Bulletins Engine - Lack of Power/No Start Diagnosis Article No. 91-12-11 06/12/91 LACK OF POWER 7.5L, 5.8L, 5.0L, 4.9L - CATALYTIC CONVERTER DIAGNOSTIC TIPS LIGHT TRUCK: 1986-91 BRONCO, ECONOLINE, F-150-350 SERIES 1988-91 F SUPER DUTY, F47 ISSUE: Lack of power or a no start condition may be diagnosed as an exhaust restriction caused by a plugged catalytic converter. A plugged catalytic converter (internal deterioration) is usually caused by abnormal engine operation. ACTION: Diagnose the catalytic converter to confirm internal failure. Refer to the Catalyst and Exhaust System Diagnostic Section, in the Engine/Emissions Diagnostic Shop Manual and the following procedures for service details. 1. Lack of proper HEGO operation may cause, or be the result of a rich or lean fuel condition, which could cause additional heat in the catalyst. Perform self test KOEO and KOER, service any codes. NOTE: IF TWO DIGIT CODES 41, 42, 85 OR THREE DIGIT CODES 171, 172, 173, 179, 181, 182, 183 AND 565 ARE RECEIVED, CHECK FOR PROPER HEGO GROUND. If the HEGO ground is good, the following areas may be at fault: ^ Ignition Coil ^ Distributor Cap ^ Distributor Rotor ^ Fouled Spark Plug ^ Spark Plug Wires ^ Air Filter ^ Stuck Open Injector ^ Fuel Contamination Engine OIL ^ Manifold Leaks Intake/ Exhaust ^ Fuel Pressure ^ Poor Power Ground ^ Engine Not At Normal Operating Temperature ^ HEGO Sensor 2. Spark timing that is retarded from specification may increase exhaust gas temperature and shorten catalyst life. Refer to the following procedure for service details. a. Check spark timing. Check base timing with spout disconnected. Set base timing to the specification on the vehicle emission decal. b. Check computed timing with spout connected. NOTE: COMPUTED TIMING IS EQUAL TO BASE TIMING PLUS 20~ BTDC +/- 3~. 3. Misfiring spark plugs may cause an unburned fuel air mixture to pass through the catalyst, which could cause higher than normal catalyst temperatures. Refer to the following procedure for service details. a. Check secondary ignition, hook the vehicle up to an engine analyzer and check for a secondary ignition misfire. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Engine - Lack of Power/No Start Diagnosis > Page 2776 NOTE: SERVICE ANY ITEM THAT IS NOT PERFORMING AT PROPER SPECIFICATIONS BEFORE CONTINUING. 4. Fuel pressure that is too high may cause rich air fuel mixtures to pass through the catalyst which could cause higher than normal catalyst temperatures. Refer to the following procedure for service details. a. Check fuel pressure, install fuel pressure gauge, start and run the engine at idle. Fuel pressures between 28 and 34 PSI are typical (4.9L typically is 15 PSI higher). b. Disconnect the vacuum line going to the fuel pressure regulator. Fuel pressure typically jumps to 40 PSI +/- 3 PSI (4.9L typically is 15 PSI higher). Visually inspect vacuum line for raw fuel. NOTE: FUEL PRESSURES ABOVE THESE VALUES SHOULD BE CORRECTED. HOWEVER, THIS MAY NOT BE THE CAUSE OF THE CONCERN. SERVICE AS NECESSARY. 5. Throttle plates in the throttle body not returning to the proper closed position may cause excessive catalyst temperatures during downhill grades. Refer to the following procedure for service details. a. Visually inspect the throttle body and linkage for: ^ Binding or sticking throttle linkage. ^ Tight speed control linkage or cable. ^ Vacuum line interference. ^ Electrical harness interference. NOTE: AFTERMARKET GOVERNORS, THROTTLE LINKAGE AND CABLES ASSOCIATED WITH POWER TAKE-OFF UNITS, MAY ALSO INTERFERE WITH PROPER THROTTLE RETURN. SERVICE AS NECESSARY. 6. It is extremely important that all systems related to the engine and emission systems operate properly. a. Visually inspect the engine compartment to make sure all vacuum hoses and spark plug wires are properly routed and securely connected. b. Inspect all wiring harnesses and connectors for insulation damage, burned, overheated, loose or broken conditions. c. Verify proper operation of the thermactor system. Thermactor systems that fail to dump thermactor air to the atmosphere properly or at the correct time can cause high catalyst temperatures. d. Visually inspect thermactor system for damaged or kinked hoses and perform a function test on following components: air control valve, check valve, silencer, filter and the air bypass solenoid. e. Verify proper operation of the engine cooling system thermostat. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under Basic Warranty Coverage, Emissions Warranty Coverage OPERATION DESCRIPTION TIME 911211A Diagnostics - Perform 0.5 Hrs. KOEO And KOER Self Tests 911211B Timing - Check Or Adjust 0.5 Hrs. Spark Timing, Check Computed Timing And Check Secondary Ignition System With Engine Analyzer. 911211C Check - Fuel Pressure And 0.2 Hrs. Inspect Vacuum Line For Raw Fuel. 911211D Inspect - Throttle Body And 0.1 Hrs. Linkage. 911211E Inspect - Vacuum Hoses, 0.1 Hrs. Electrical Harnesses, Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Engine - Lack of Power/No Start Diagnosis > Page 2777 Connectors And Spark Plug Wires For Routing Damage. 911211F Thermactor System - 0.3 Hrs. Inspect For Proper Operation And Damaged Component. Includes Function Check Of Air Control Valve, Thermactor Air Bypass Solenoid, Check Valves, Silencer And Filter. 911211G Thermostat - Check For 0.2 Hrs. Proper Operation. DEALER CODING BASIC PART NO. CONDITION CODE 5E212 25 OASIS CODES: 403000, 603300, 614000 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Engine - Lack of Power/No Start Diagnosis > Page 2778 Oxygen Sensor: Technical Service Bulletins EGO Sensors - Silicone Contamination Article No. 93-23-6 11/10/93 ^ EGO SENSORS - SILICONE CONTAMINATION ^ ENGINE - SEALANTS, LOW VOLATILITY SILICONE REQUIRED ^ EXHAUST SYSTEM - SILICONE CONTAMINATION OF EXHAUST GAS OXYGEN (EGO) SENSORS FORD: 1984-86 LTD 1984-88 EXP 1984-94 CROWN VICTORIA, ESCORT, MUSTANG, TEMPO, THUNDERBIRD 1986-94 TAURUS 1988-93 FESTIVA 1989-94 PROBE 1994 ASPIRE LINCOLN-MERCURY: 1984-86 CAPRI, MARQUIS 1984-87 LYNX 1984-92 MARK VII 1984-94 CONTINENTAL, COUGAR, GRAND MARQUIS, TOPAZ, TOWN CAR 1986-94 SABLE 1988-89 TRACER 1991-94 CAPRI, TRACER 1993-94 MARK VIII MERKUR: 1985-89 XR4TI 1988-89 SCORPIO LIGHT TRUCK: 1983-94 RANGER 1984-90 BRONCO II 1984-94 BRONCO, ECONOLINE, F-150-350 SERIES 1986-94 AEROSTAR 1988-94 F-47, F-53 1991-94 EXPLORER 1993-94 VILLAGER This TSB article is being republished in its entirety to update model applicability and to revise the part number of the Low Volatility Sealant. ISSUE: EGO sensors can be contaminated if volatile types of silicone are used when servicing the engine. Volatile silicones can migrate throughout the system during the first one hundred hours of service. They are commonly found in liquid "silicone rubber" sealants and gasket material. These products are commonly sold in tubes and caulking-type cartridges. ACTION: When service is performed on the engine, only use new low volatility silicone sealant (F1AZ-19662-A) where specified. Also replace the contaminated EGO sensor if required. CAUTION: DO NOT SUBSTITUTE CONVENTIONAL SILICONE RUBBER SEALANTS WHEN LOW VOLATILITY SILICONE SEALANT IS SPECIFIED. PART NUMBER PART NAME CLASS F1AZ-19662-A Low Volatility RTV Sealant B OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 89-14-5 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Engine - Lack of Power/No Start Diagnosis > Page 2779 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 403000, 490000, 499000 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Page 2780 Engine View Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Description and Operation > Exhaust Gas Oxygen Sensor Oxygen Sensor: Description and Operation Exhaust Gas Oxygen Sensor The EGO Sensor supplies ECA with a signal which indicates either a rich or lean condition during engine operation. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Description and Operation > Exhaust Gas Oxygen Sensor > Page 2783 Oxygen Sensor: Description and Operation Heated Exhaust Gas Oxygen Sensor The Heated Exhaust Gas Oxygen Sensor (HEGO), supplies the ECA with a signal which indicates a rich or lean condition during engine operation. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Description and Operation > Page 2784 Oxygen Sensor: Testing and Inspection Ford provides trouble code/symptom driven diagnostics for this component. For complete diagnosis and pinpoint testing, refer to Computers and Control Systems, Testing and Inspection. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Power Steering Pressure Switch > Component Information > Locations Power Steering Pressure Switch: Locations In Power Steering Hose, Near Steering Gear Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Power Steering Pressure Switch > Component Information > Locations > Page 2788 Power Steering Pressure Switch: Testing and Inspection Ford provides trouble code/symptom driven diagnostics for this component. For complete diagnosis and pinpoint testing, refer to Computers and Control Systems, Testing and Inspection. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Description and Operation Pressure Feedback Exhaust Sensor: Description and Operation The Pressure Feedback Electronic (PFE) EGR transducer converts a varying exhaust pressure signal into a proportional analog voltage which is digitized by the EEC IV processor. The EEC IV processor uses the signal received from the PFE transducer to complete the optimum EGR flow. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Electronic Throttle Control Module > Component Information > Locations Electronic Throttle Control Module: Locations Under LH Side Of I/P Under LH Side Of I/P Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Electronic Throttle Control Module > Component Information > Locations > Page 2796 Electronic Throttle Control Module: Testing and Inspection Ford provides trouble code/symptom driven diagnostics for this component. For complete diagnosis and pinpoint testing, refer to Computers and Control Systems, Testing and Inspection. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Body/Frame - Arc Welding Precautions Engine Control Module: Technical Service Bulletins Body/Frame - Arc Welding Precautions Article No. 90-11-6 EEC IV-ELECTRONIC CONTROL MODULES AND PROCESSORS-POSSIBLE DAMAGE FROM ARC WELDING FORD: 1985-90 CROWN VICTORIA, ESCORT, MUSTANG, TEMPO, THUNDERBIRD 1986-90 TAURUS LINCOLN-MERCURY: 1985-86 CAPRI 1985-90 CONTINENTAL, COUGAR, GRAND MARQUIS, MARK VII, TOPAZ, TOWN CAR 1986-90 SABLE MERKUR: 1985-89 XR4Ti 1988-90 SCORPIO LIGHT TRUCK: 1985-90 BRONCO II, BRONCO, ECONOLINE, F-150, F-250, F-350, RANGER 1986-90 AEROSTAR 1989-90 F SUPER DUTY 1991 EXPLORER ISSUE: Electronic control modules, including EEC processors, may be damaged if the negative battery ground cable is not disconnected before arc welding is done to the vehicle, This occurs because the arc welding process can produce high electrical currents in the body of a vehicle when the negative battery ground cable is left connected. ACTION: If arc welding procedures are to be performed, be sure to disconnect the battery ground cable, CAUTION: DISCONNECT THE NEGATIVE BATTERY GROUND CABLE BEFORE USING ANY ELECTRIC WELDING EQUIPMENT OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 2800, 680000 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 2801 Right Hand Instrument Panel Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions Engine Control Module: Diagram Information and Instructions Symbol Identification Wire Color Code Identification Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2804 NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Page 2805 Engine Control Module: Description and Operation The center of the EEC IV system is a microprocessor called the Electronic Control Assembly (ECA). The ECA, receives data from a number of sensors and other electronic components (switches, relays, etc.). The ECA contains a specific calibration for optimizing emissions, fuel economy, and driveability. Based on information received and programmed into its memory, the ECA generates output signals to control various relays, solenoids, and other actuators. The ECA in the EEC IV system is a microprocessor like the one in the other EEC systems. One significant difference is that this ECA has the calibration module located inside the ECA assembly, unlike the EEC III system. The ECA is found in different locations, depending on the model. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Page 2806 Engine Control Module: Testing and Inspection Ford provides trouble code/symptom driven diagnostics for this component. For complete diagnosis and pinpoint testing, refer to Computers and Control Systems, Testing and Inspection. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Component Locations Main Relay (Computer/Fuel System): Component Locations Fuel Pump Relay Engine Compartment Components. LH Side Of Engine Compartment, On Relay Bracket. Fuel pump relay is next to the EEC Relay. Applicable to: 4.9L/6-300 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Component Locations > Page 2811 Engine Compartment Components. LH Side Of Engine Compartment, On Relay Bracket. Fuel pump relay is next to the EEC Relay. Applicable to: 5.0L/V8-302 & 5.8L/V8-350 Engine Compartment Components. LH Side Of Engine Compartment, On Relay Bracket. Fuel pump relay is next to the EEC Relay. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Component Locations > Page 2812 Applicable to: 7.5L/V8-460 EEC Power Relay Under Dash Panel Next To, Or On ECA Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Component Locations > Page 2813 Right Hand Instrument Panel Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 2814 Main Relay (Computer/Fuel System): Description and Operation There are two types of relays: the power relay and the time delay power relay. The time delay relay has a delay of 5 to 10 seconds and is used with an actuator assembly throttle control. Both relay types consist of a movable contact in the normally open position. All power relays (except time delay) have the same design with a different bracket attachment. Function EEC power relays are in parallel with the ignition switch and provide power to the EEC module. Power relays also provide reverse battery protection and increased load handling to improve ignition switch reliability. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 2815 Main Relay (Computer/Fuel System): Testing and Inspection Ford provides trouble code/symptom driven diagnostics for this component. For complete diagnosis and pinpoint testing, refer to Computers and Control Systems, Testing and Inspection. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Barometric Pressure Switch > Component Information > Description and Operation Barometric Pressure Switch: Description and Operation The Ignition Barometric Pressure Switch, is used to control spark timing and/or other electrical devices in response to changes in barometric pressure (i.e., altitude). When controlling spark timing, the ignition module (12A244) is made to vary the spark timing by an amount determined by calibration resistors in the switch assembly. In normal operation, spark timing is increased for vehicle operation above the switching point (increasing altitude) and retarded for vehicle operation below the switching point (decreasing altitude). When controlling other electrical devices, only On/Off control is provided; with On (switch closed) above the switching point and Off (switch open) below the switching point. Some switch assemblies control both spark timing and another device (dual switch assembly) and other switch assemblies control only one or the other (single switch assembly). Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Barometric Pressure Switch > Component Information > Testing and Inspection > Component Testing Barometric Pressure Switch: Testing and Inspection Component Testing ^ Dual switch assembly shown. ^ Attaching brackets vary according to installation requirements. ^ Connectors may vary. Either resistance value is correct if altitude is between 3,000 and 4,600 feet. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Barometric Pressure Switch > Component Information > Testing and Inspection > Component Testing > Page 2822 Barometric Pressure Switch: Testing and Inspection Computer Related Diagnostic Information Ford provides trouble code/symptom driven diagnostics for this component. For complete diagnosis and pinpoint testing, refer to Computers and Control Systems, Testing and Inspection. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Camshaft Position Sensor: Diagram Information and Instructions Symbol Identification Wire Color Code Identification Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2827 NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications TEMPERATURE SENSORS Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 2831 Coolant Temperature Sensor/Switch (For Computer): Locations RH Side Of V8-351/5. Front Of Engine, Near Distributor Applicable to: 8L Engine With EEC-IV Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 2832 Coolant Temperature Sensor/Switch (For Computer): Description and Operation The Engine Coolant Temperature (ECT) Sensor, detects the temperature of engine coolant and supplies the Information to Electronic Control Assembly (ECA). The ECT sensor is threaded into the heater outlet fitting or cooling passage on the engine. For engine control applications, the ECT signal is used to modify ignition timing, EGR flow, and air to fuel ratio as a function of engine coolant temperature. On electronic instrument cluster applications, the ECT output is used to control a coolant temperature indicator. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 2833 Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection Ford provides trouble code/symptom driven diagnostics for this component. For complete diagnosis and pinpoint testing, refer to Computers and Control Systems, Testing and Inspection. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Crankshaft Position Sensor: Diagram Information and Instructions Symbol Identification Wire Color Code Identification Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2838 NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision Technical Service Bulletin # 8918A9 Date: 890915 EVP Sensor - Manual Revision ENGINE EMISSIONS DIAGNOSTIC MANUALS, VOLUME H - 1985 THROUGH 1989 - EGR VALVE POSITION SENSOR (EVP) DIAGNOSTIC PROCEDURES REVISED Article No. 89-18A-9 FORD: 1985-89 CROWN VICTORIA, ESCORT 1985-88 EXP 1985-86 LTD 1985-89 MUSTANG, TEMPO, THUNDERBIRD 1986-89 TAURUS 1988-89 FESTIVA 1989 PROBE LINCOLN-MERCURY: 1985-86 CAPRI 1985-89 CONTINENTAL, COUGAR, GRAND MARQUIS 1985-87 LYNX 1985-89 MARK VII 1985-86 MARQUIS 1985-89 TOPAZ, TOWN CAR 1986-89 SABLE 1987-89 TRACER MERKUR: 1986-89 XR4TI 1988-89 SCORPIO LIGHT TRUCK: 1985-89 BRONCO, BRONCO II, ECONOLINE, F-150, F-250, F-350, RANGER 1986-89 AEROSTAR ISSUE: The EGR Valve Position Sensor (EVP) diagnostic procedures in 1985 through 1989 Engine Emissions Diagnosis Shop Manuals, Volume H, have been revised. EVP Sensors may exhibit internal wear problems that can cause driveability symptoms and display a Continuous Self-Test Code 32. This is not associated to correcting the problem using the existing diagnostic procedures. ACTION: Refer to the pages following this TSB article for the revised diagnostic procedures. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 680000 1985 Pinpoint Tests - DM - EGR, EVP and EVR Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2843 1985 EEC IV - Pinpoint Tests - All Vehicles 22-77 EGR Valve Position Sensor (EVP) EGR Valve Regulator (EVR) Pinpoint DM Test 1985 Pinpoint Tests - Fa - Neutral Drive Switch -A/C Input Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2844 1985 22-78 EEC IV - Pinpoint Tests - All Vehicles Neutral Drive Switch FA A/C Input PinpointTest 1986 (EGR) Systems Functional Diagnosis 1986 Exhaust Gas Recirculation (EGR) Systems 6-11 Functional Diagnosis Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2845 PORTED EGR VALVE 1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked, crimped or broken hoses. 2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating temperature. 3. Install a tachometer. 4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (EFI engines only). 5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose. 6. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If necessary, adjust idle speed to the emission decal specification. 7. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand vacuum pump. 8. When vacuum is applied to the EGR valve and any of the following occur, replace the valve: ^ Engine does not stall. ^ Idle speed does not drop more than 100 rpm. ^ Idle speed does not return to normal (+/- 25 rpm) after the vacuum is removed. 9. Reconnect the idle air bypass valve electrical connector. 10. Unplug and reconnect the EGR vacuum supply hose. 11. The EGR system is OK, refer to the Diagnostic Routines in Section 2. 1986 6-12 Exhaust Gas Recirculation (EGR) Systems Functional Diagnosis ELECTRONIC VALVE 1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked, crimped or broken hoses. 2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating temperature. 3. Install a tachometer. 4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (EFI engines only). Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2846 5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose. 6. Disconnect the 9G428 EVP sensor electrical connector mounted on top of the 9H473 valve. 7. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If necessary, adjust idle speed to the emission decal specification. 8. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand vacuum pump. 9. When vacuum is applied to the EGR valve and any of the following occur, replace the valve: ^ Engine does not stall. ^ Idle speed does not drop more than 100 rpm. ^ Idle speed does not return to normal (+/- 25 rpm) after the vacuum is removed. 10. Reconnect the idle air bypass valve electrical connector. 11. Unplug and reconnect the EGR vacuum supply hose. 12. Reconnect the EVP sensor electrical connector. 13. The EGR valve is OK, REPLACE EVP sensor if the Continuous Code 32 was present. If the Continuous Code 32 was not present, refer to the Diagnostic Routines in Section 2. 1986 Quick Test: Continuous Self-Test 6.0 EEC IV - Quick Test - All Engines 18-13 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2847 QUICK TEST: Continuous Self-Test 6.0 1986 18-14 EEC IV-Quick Test-All Engines QUICK TEST: Continuous Self-Test 6.0 Pinpoint Test - DN - EGR - EVP & EVR Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2848 1986 EEC IV-Pinpoint Tests - All Vehicles 21-95 EGR Valve Position Sensor (EVP) PinpointTest DN EGR Valve Regulator (EVR) Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2849 21-96 1986 EEC IV-Pinpoint Tests-All Vehicles EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Valve Regulator (EVR) Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2850 EEC IV-Pinpoint Tests-All Vehicles 1986 21-97A EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Valve Regulator (EVR) Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2851 1986 21-97B EEC IV-Pinpoint Tests-All Vehicles EGR Valve Position Sensor (EVP) EGR Valve Regulator (EVR) Pinpoint Test DN Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2852 1986 EEC IV-Pinpoint Tests-All Vehicles 21-98 EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Valve Regulator (EVR) 1987 (EGR) Systems - Functional Diagnosis 1987 6-11 Exhaust Gas Recirculation (EGR) Systems Functional Diagnosis PORTED EGR VALVE 1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked, crimped or broken hoses. 2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating temperature. 3. Install a tachometer, Rotunda 059-00010 or equivalent. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2853 4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (EFI engines only). 5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose. 6. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If necessary, adjust idle speed according to Section 4. 7. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand vacuum pump, Rotunda 021-00014 or equivalent. 8. When vacuum is applied to the EGR valve and any of the following occur, replace the valve: ^ Engine does not stall. ^ Idle speed does not drop more than 100 rpm. ^ Idle speed does not return to normal (+/- 25 rpm) after the vacuum is removed. 9. Reconnect the idle air bypass valve electrical connector. 10. Unplug and reconnect the EGR vacuum supply hose. 11. The EGR system is OK, refer to the Diagnostic Routines in Section 2. 1987 6-12 Exhaust Gas Recirculation (EGR) Systems Functional Diagnosis ELECTRONIC EGR (EEGR) VALVE 1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked, crimped or broken hoses. 2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating temperature. 3. Install a tachometer, Rotunda 059-00010 or equivalent. 4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (EFI engines only). 5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose. 6. Disconnect the 9G428 EVP sensor electrical connector mounted on top of the 9H473 valve. 7. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If necessary, adjust idle speed according to Section 4. 8. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand vacuum pump, Rotunda 021-00014 or equivalent. 9. When vacuum is applied to the EGR valve and any of the following occur, replace the valve: ^ Engine does not stall. ^ Idle speed does not drop more than 100 rpm. ^ Idle speed does not return to normal (+/- 25 rpm) after the vacuum is removed. 10. Reconnect the idle air bypass valve electrical connector. 11. Unplug and reconnect the EGR vacuum supply hose. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2854 12. Reconnect the EVP sensor electrical connector. 13. The EGR valve is OK, REPLACE EVP sensor if the Continuous Code 32 was present. If the Continous Code 32 was not present, refer to the Diagnostic Routines in Section 2. 1987 Quick Test: Continuous Self-Test - 6.0 1987 EEC-IV Quick Test-All Engines 16-15 QUICK TEST: Continuous 6.0 Self-Test Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2855 16-16 1987 EEC-IV Quick Test-All Engines QUICK TEST: Continuous 6.0 Self-Test Pinpoint Test - DN - EGR - EVP & EVR 1987 EEC IV - Pinpoint Tests - All Vehicles 19-91 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2856 EGR VALVE Position Sensor (EVP) EGR Valve Regulator (EVR) - 2.3L HSC, 2.5L, 5.0L SEFI Passenger Car and 4.9L and 5.0L Truck Pinpoint Test DN 19-92A 1987 EEC IV Pinpoint Tests-All Vehicles EGR Valve Position Sensor (EVP) EGR Valve Regulator (EVR) - 2.3L HSC, 2.5L, Pinpoint Test DN 5.0L SEFI Passenger Car and 4.9L and 5.0L Truck Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2857 1987 EEC IV-Pinpoint Tests-All Vehicles 19-92B EGR Valve Position Sensor (EVP) EGR Valve Regulator (EVR) - 2.3L HSC, 2.5L, 5.0L SEFI Passenger Car and 4.9L and 5.0L Truck Pinpoint Test DN Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2858 1987 19-93-A EEC IV-Pinpoint Tests-All Vehicles EGR Valve Position Sensor (EVP) EGR Valve Regulator (EVR) - 2.3L HSC, 2.5L, 5.0L SEFI Passenger Car 4.9L and 5.0L Truck Pinpoint Test DN Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2859 EEC IV-Pinpoint Tests-All Vehicles 1987 19-94 EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Valve Regulator (EVR) (EGR) Systems - Functional Diagnosis 1988 Exhaust Gas Recirculation (EGR) Systems 6-11 Functional Diagnosis Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2860 PORTED EGR VALVE 1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked, crimped or broken hoses. 2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating temperature. 3. Install a tachometer, Rotunda 059-00010 or equivalent. 4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (EFI engines only). 5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose. 6. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If necessary, adjust idle speed according to Section 4. 7. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand vacuum pump, Rotunda 021-00014 or equivalent. 8. When vacuum is fully applied to the EGR valve: ^ If idle speed drops more than 100 rpm or if engine stalls, perform the next step. Otherwise, replace the EGR valve. ^ Remove the vacuum from the EGR valve. If idle speed does not return to normal (+/- 25 rpm), replace the EGR valve. 9. Reconnect the idle air bypass valve electrical connector. 10. Unplug and reconnect the EGR vacuum supply hose. 11. The EGR system is OK, refer to the Diagnostic Routines in Section 2. 6-12 1988 Exhaust Gas Recirculation (EGR) Systems Functional Diagnosis ELECTRONIC EGR (EEGR) VALVE 1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked, crimped or broken hoses. 2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating temperature. NOTE: The EVR solenoid has a constant internal leak. You will notice a small vacuum signal. This signal should be less than 2-1/2 in-Hg at idle. 3. Install a tachometer, Rotunda 059-00010 or equivalent. 4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (1.9L EFI engines only). 5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose. 6. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If necessary, adjust idle speed according to Section 4. 7. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand vacuum pump, Rotunda 021-00014 or equivalent. 8. When vacuum is applied to the EGR valve and any of the following occur, replace the valve: ^ Engine does not stall. ^ Idle speed does not drop more than 100 rpm. ^ Idle speed does not return to normal (+/- 25 rpm) after the vacuum is removed. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2861 9. Reconnect the idle air bypass valve electrical connector. 10. Unplug and reconnect the EGR vacuum supply hose. 11. The EGR is OK, REPLACE EVP sensor if the Continuous Code 32 was present. If the Continuous Code 32 was not present, refer to the Diagnostic Routines in Section 2. Quick Test:Continuous Self-Test - 6.0 1988 EEC-IV - Quick Test - All Engines 16-15 QUICK TEST: Continuous Self-Test 6.0 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2862 1988 16-16 EEC-IV - Quick Test - All Engines QUICK TEST: Continuous 6.0 Self-Test Pinpoint Test - DN - EGR - EVP & EVR Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2863 EEC-IV - Pinpoint Tests - All Vehicles 1988 19-101 EGR Valve Position Sensor (EVP) EGR Valve Regulator (EVR) Pinpoint Test DN Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2864 19-102 1988 EEC-IV - Pinpoint Tests - All Vehicles EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Valve Regulator (EVR) Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2865 1988 EEC-IV - Pinpoint Tests - All Vehicles 19-102A EGR Valve Position Sensor (EVP) EGR Valve Regulator (EVR) Pinpoint Test DN Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2866 1988 19-103 EEC-IV - Pinpoint Tests - All Vehicles EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Valve Regulator (EVR) Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2867 1988 EEC-IV - Pinpoint Tests - All Vehicles 19-104 EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Valve Regulator (EVR) (EGR) Systems - Functional Diagnosis 1989 6-11 Exhaust Gas Recirculation (EGR) Systems Functional Diagnosis Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2868 PORTED EGR VALVE 1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked, crimped or broken hoses. 2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating temperature. 3. Install a tachometer, Rotunda 059-00010 or equivalent. 4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (EFI engines only). 5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose. 6. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If necessary, adjust idle speed according to Section 4. 7. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand vacuum pump, Rotunda 021-00014 or equivalent. 8. When vacuum is fully applied to the EGR valve: ^ If idle speed drops more than 100 rpm or if engine stalls, perform the next step. Otherwise, for vacuum leak at EGR valve, replace the valve. ^ If EGR passages are blocked, clean the valve using Rotunda 021-80056 EGR valve cleaner. ^ Remove the vacuum from the EGR valve. If idle speed does not return to normal (+/- 25 rpm), check for contamination, clean the valve. ^ Make sure there is no sand left in the valve or pick-up tube. Replace the valve if necessary. 9. Reconnect the idle air bypass valve electrical connector. 10. Unplug and reconnect the EGR vacuum supply hose. 11. The EGR system is OK, refer to the Diagnostic Routines in Section 2. 1989 6-12 Exhaust Gas Recirculation (EGR) Systems Functional Diagnosis ELECTRONIC EGR (EEGR) VALVE 1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked, crimped or broken hoses. 2. Make certain there is less than 2.5 in-Hg vacuum to the EGR valve at idle with the engine at normal operating temperature. NOTE: The EVR solenoid has a constant internal leak. You will notice a small vacuum signal. This signal should be less than 1.0 in-Hg at idle. 3. Install a tachometer, Rotunda 059-00010 or equivalent. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2869 4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (1.9L EFI engines only). 5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose. 6. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If necessary, adjust idle speed according to Section 4. 7. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand vacuum pump, Rotunda 021-00014 or equivalent. 8. When vacuum is applied to the EGR valve and any of the following occur: ^ Engine does not stall ^ Idle speed does not drop more than 100 rpm ^ Idle speed does not return to normal (+/- 25 rpm) after the vacuum is removed Then: ^ For vacuum leak at EGR valve, replace the valve. ^ Check for contamination, clean the EGR valve, using Rotunda 021-80056 EGR valve cleaner or equivalent. ^ Make sure there is no sand left in the valve. ^ Replace the EGR valve if necessary. 9. Reconnect the idle air bypass valve electrical connector. Unplug and reconnect the EGR vacuum supply hose. 10. If EGR valve is OK, REPLACE EVP sensor if Continuous Code 32 was present. If the Continuous Code 32 was not present, refer to the Diagnostic Routines in Section 2. Quick Test:Continuous Self-Test - 6.0 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2870 1989 EEC-IV - Quick Test - All Engines 14-17 QUICK TEST: Continuous 6.0 Self-Test Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2871 1989 14-18 EEC-IV - Quick Test - All Engines QUICK TEST: Continuous 6.0 Self-Test 1989 EEC-IV - Quick Test - All Engines 14-19 QUICK TEST: Continuous 6.0 Self-Test Quick Test:Diagnostic By Symptom - 7.0 1989 14-20 EEC-IV - Quick Test - All Engines QUICK TEST: Diagnostic By Symptom 7.0 A DIAGNOSTIC BY SYMPTOM SPECIAL NOTES: ^ Verify that a Pass Code 11 was received in Key On Engine Off, Engine Running and Continuous Self-Tests before continuing with this test. ^ If a symptom is present and the EEC system is suspected, Go to part B of Diagnostic By Symptom. If the EEC system is not suspected, GO to Section 2, Diagnostic Routines. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2872 Pinpoint Test - DN - EGR - EVP & EVR 1989 EEC-IV - Pinpoint Tests-All Vehicles 17-133 EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Vacuum Regulator Solenoid (EVR) Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2873 1989 17-134 EEC-IV - Pinpoint Tests - All Vehicles EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Vacuum Regulator Solenoid (EVR) Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2874 1989 EEC-IV-Pinpoint Tests - All Vehicles 17-134A Pinpoint Test DN EGR Valve Position Sensor (EVP) EGR Vacuum Regulator Solenoid (EVR) Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2875 1989 17-135 EEC-IV - Pinpoint Tests - All Vehicles EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Vacuum Regulator Solenoid (EVR) Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2876 1989 EEC-IV - Pinpoint Tests - All Vehicles 17-136A EGR Valve Position Sensor (EVP) 04GPinpoint Test DN EGR Vacuum Regulator Solenoid (EVR) Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > Page 2877 EGR Valve Position Sensor: Locations Attached To EGR Valve Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > Page 2878 EGR Valve Position Sensor: Description and Operation The EVP Sensor provides EEC System with a signal indicating position of the EGR valve. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Description and Operation Knock Sensor: Description and Operation The Knock Sensor, is a piezoelectric accelerometer with the sensor designed to resonate at approximately the same frequency as the engine knock frequency. The sensor uses the resonant frequency to mechanically amplify the vibrations. This method allows relatively large signals to be achieved without electrical amplification and with small package size. The sensor has a thin circular piezoelectric ceramic disk which is bonded to a metal diaphragm. Electrical connections are made through a two pin integral connector. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Description and Operation > Page 2882 Knock Sensor: Testing and Inspection Ford provides trouble code/symptom driven diagnostics for this component. For complete diagnosis and pinpoint testing, refer to Computers and Control Systems, Testing and Inspection. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications MANIFOLD ABSOLUTE AND BAROMETRIC PRESSURE SENSORS Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 2886 Right Hand Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 2887 Manifold Pressure/Vacuum Sensor: Testing and Inspection Ford provides trouble code/symptom driven diagnostics for this component. For complete diagnosis and pinpoint testing, refer to Computers and Control Systems, Testing and Inspection. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Engine - Lack of Power/No Start Diagnosis Oxygen Sensor: Technical Service Bulletins Engine - Lack of Power/No Start Diagnosis Article No. 91-12-11 06/12/91 LACK OF POWER 7.5L, 5.8L, 5.0L, 4.9L - CATALYTIC CONVERTER DIAGNOSTIC TIPS LIGHT TRUCK: 1986-91 BRONCO, ECONOLINE, F-150-350 SERIES 1988-91 F SUPER DUTY, F47 ISSUE: Lack of power or a no start condition may be diagnosed as an exhaust restriction caused by a plugged catalytic converter. A plugged catalytic converter (internal deterioration) is usually caused by abnormal engine operation. ACTION: Diagnose the catalytic converter to confirm internal failure. Refer to the Catalyst and Exhaust System Diagnostic Section, in the Engine/Emissions Diagnostic Shop Manual and the following procedures for service details. 1. Lack of proper HEGO operation may cause, or be the result of a rich or lean fuel condition, which could cause additional heat in the catalyst. Perform self test KOEO and KOER, service any codes. NOTE: IF TWO DIGIT CODES 41, 42, 85 OR THREE DIGIT CODES 171, 172, 173, 179, 181, 182, 183 AND 565 ARE RECEIVED, CHECK FOR PROPER HEGO GROUND. If the HEGO ground is good, the following areas may be at fault: ^ Ignition Coil ^ Distributor Cap ^ Distributor Rotor ^ Fouled Spark Plug ^ Spark Plug Wires ^ Air Filter ^ Stuck Open Injector ^ Fuel Contamination Engine OIL ^ Manifold Leaks Intake/ Exhaust ^ Fuel Pressure ^ Poor Power Ground ^ Engine Not At Normal Operating Temperature ^ HEGO Sensor 2. Spark timing that is retarded from specification may increase exhaust gas temperature and shorten catalyst life. Refer to the following procedure for service details. a. Check spark timing. Check base timing with spout disconnected. Set base timing to the specification on the vehicle emission decal. b. Check computed timing with spout connected. NOTE: COMPUTED TIMING IS EQUAL TO BASE TIMING PLUS 20~ BTDC +/- 3~. 3. Misfiring spark plugs may cause an unburned fuel air mixture to pass through the catalyst, which could cause higher than normal catalyst temperatures. Refer to the following procedure for service details. a. Check secondary ignition, hook the vehicle up to an engine analyzer and check for a secondary ignition misfire. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Engine - Lack of Power/No Start Diagnosis > Page 2892 NOTE: SERVICE ANY ITEM THAT IS NOT PERFORMING AT PROPER SPECIFICATIONS BEFORE CONTINUING. 4. Fuel pressure that is too high may cause rich air fuel mixtures to pass through the catalyst which could cause higher than normal catalyst temperatures. Refer to the following procedure for service details. a. Check fuel pressure, install fuel pressure gauge, start and run the engine at idle. Fuel pressures between 28 and 34 PSI are typical (4.9L typically is 15 PSI higher). b. Disconnect the vacuum line going to the fuel pressure regulator. Fuel pressure typically jumps to 40 PSI +/- 3 PSI (4.9L typically is 15 PSI higher). Visually inspect vacuum line for raw fuel. NOTE: FUEL PRESSURES ABOVE THESE VALUES SHOULD BE CORRECTED. HOWEVER, THIS MAY NOT BE THE CAUSE OF THE CONCERN. SERVICE AS NECESSARY. 5. Throttle plates in the throttle body not returning to the proper closed position may cause excessive catalyst temperatures during downhill grades. Refer to the following procedure for service details. a. Visually inspect the throttle body and linkage for: ^ Binding or sticking throttle linkage. ^ Tight speed control linkage or cable. ^ Vacuum line interference. ^ Electrical harness interference. NOTE: AFTERMARKET GOVERNORS, THROTTLE LINKAGE AND CABLES ASSOCIATED WITH POWER TAKE-OFF UNITS, MAY ALSO INTERFERE WITH PROPER THROTTLE RETURN. SERVICE AS NECESSARY. 6. It is extremely important that all systems related to the engine and emission systems operate properly. a. Visually inspect the engine compartment to make sure all vacuum hoses and spark plug wires are properly routed and securely connected. b. Inspect all wiring harnesses and connectors for insulation damage, burned, overheated, loose or broken conditions. c. Verify proper operation of the thermactor system. Thermactor systems that fail to dump thermactor air to the atmosphere properly or at the correct time can cause high catalyst temperatures. d. Visually inspect thermactor system for damaged or kinked hoses and perform a function test on following components: air control valve, check valve, silencer, filter and the air bypass solenoid. e. Verify proper operation of the engine cooling system thermostat. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under Basic Warranty Coverage, Emissions Warranty Coverage OPERATION DESCRIPTION TIME 911211A Diagnostics - Perform 0.5 Hrs. KOEO And KOER Self Tests 911211B Timing - Check Or Adjust 0.5 Hrs. Spark Timing, Check Computed Timing And Check Secondary Ignition System With Engine Analyzer. 911211C Check - Fuel Pressure And 0.2 Hrs. Inspect Vacuum Line For Raw Fuel. 911211D Inspect - Throttle Body And 0.1 Hrs. Linkage. 911211E Inspect - Vacuum Hoses, 0.1 Hrs. Electrical Harnesses, Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Engine - Lack of Power/No Start Diagnosis > Page 2893 Connectors And Spark Plug Wires For Routing Damage. 911211F Thermactor System - 0.3 Hrs. Inspect For Proper Operation And Damaged Component. Includes Function Check Of Air Control Valve, Thermactor Air Bypass Solenoid, Check Valves, Silencer And Filter. 911211G Thermostat - Check For 0.2 Hrs. Proper Operation. DEALER CODING BASIC PART NO. CONDITION CODE 5E212 25 OASIS CODES: 403000, 603300, 614000 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Engine - Lack of Power/No Start Diagnosis > Page 2894 Oxygen Sensor: Technical Service Bulletins EGO Sensors - Silicone Contamination Article No. 93-23-6 11/10/93 ^ EGO SENSORS - SILICONE CONTAMINATION ^ ENGINE - SEALANTS, LOW VOLATILITY SILICONE REQUIRED ^ EXHAUST SYSTEM - SILICONE CONTAMINATION OF EXHAUST GAS OXYGEN (EGO) SENSORS FORD: 1984-86 LTD 1984-88 EXP 1984-94 CROWN VICTORIA, ESCORT, MUSTANG, TEMPO, THUNDERBIRD 1986-94 TAURUS 1988-93 FESTIVA 1989-94 PROBE 1994 ASPIRE LINCOLN-MERCURY: 1984-86 CAPRI, MARQUIS 1984-87 LYNX 1984-92 MARK VII 1984-94 CONTINENTAL, COUGAR, GRAND MARQUIS, TOPAZ, TOWN CAR 1986-94 SABLE 1988-89 TRACER 1991-94 CAPRI, TRACER 1993-94 MARK VIII MERKUR: 1985-89 XR4TI 1988-89 SCORPIO LIGHT TRUCK: 1983-94 RANGER 1984-90 BRONCO II 1984-94 BRONCO, ECONOLINE, F-150-350 SERIES 1986-94 AEROSTAR 1988-94 F-47, F-53 1991-94 EXPLORER 1993-94 VILLAGER This TSB article is being republished in its entirety to update model applicability and to revise the part number of the Low Volatility Sealant. ISSUE: EGO sensors can be contaminated if volatile types of silicone are used when servicing the engine. Volatile silicones can migrate throughout the system during the first one hundred hours of service. They are commonly found in liquid "silicone rubber" sealants and gasket material. These products are commonly sold in tubes and caulking-type cartridges. ACTION: When service is performed on the engine, only use new low volatility silicone sealant (F1AZ-19662-A) where specified. Also replace the contaminated EGO sensor if required. CAUTION: DO NOT SUBSTITUTE CONVENTIONAL SILICONE RUBBER SEALANTS WHEN LOW VOLATILITY SILICONE SEALANT IS SPECIFIED. PART NUMBER PART NAME CLASS F1AZ-19662-A Low Volatility RTV Sealant B OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 89-14-5 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Engine - Lack of Power/No Start Diagnosis > Page 2895 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 403000, 490000, 499000 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Page 2896 Engine View Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Description and Operation > Exhaust Gas Oxygen Sensor Oxygen Sensor: Description and Operation Exhaust Gas Oxygen Sensor The EGO Sensor supplies ECA with a signal which indicates either a rich or lean condition during engine operation. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Description and Operation > Exhaust Gas Oxygen Sensor > Page 2899 Oxygen Sensor: Description and Operation Heated Exhaust Gas Oxygen Sensor The Heated Exhaust Gas Oxygen Sensor (HEGO), supplies the ECA with a signal which indicates a rich or lean condition during engine operation. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Description and Operation > Page 2900 Oxygen Sensor: Testing and Inspection Ford provides trouble code/symptom driven diagnostics for this component. For complete diagnosis and pinpoint testing, refer to Computers and Control Systems, Testing and Inspection. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Power Steering Pressure Switch > Component Information > Locations Power Steering Pressure Switch: Locations In Power Steering Hose, Near Steering Gear Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Power Steering Pressure Switch > Component Information > Locations > Page 2904 Power Steering Pressure Switch: Testing and Inspection Ford provides trouble code/symptom driven diagnostics for this component. For complete diagnosis and pinpoint testing, refer to Computers and Control Systems, Testing and Inspection. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Description and Operation Pressure Feedback Exhaust Sensor: Description and Operation The Pressure Feedback Electronic (PFE) EGR transducer converts a varying exhaust pressure signal into a proportional analog voltage which is digitized by the EEC IV processor. The EEC IV processor uses the signal received from the PFE transducer to complete the optimum EGR flow. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Throttle Position Sensor - Request For Return Throttle Position Sensor: Technical Service Bulletins Throttle Position Sensor - Request For Return Number: 92686 To: All Ford and Lincoln-Mercury Dealers Subject: Request for Return of Throttle Position Sensor E5ZZ-9B989-B (CX-1022) and E6ZZ-9B989-B (CX-1130) Because the subject parts may not meet Ford's high quality requirements, they should be withdrawn from all inventories. All used E5ZZ-9B989-B (CX-1022) and E6ZZ-9B989-B (CX-1130) should be returned to your facing PDC within 30 days from the date of this letter. Use the least expensive mode of transportation for your return. The subject parts are obsolete and replaced by E7SZ-9B989-B (CX-1200), which is available for ordering immediately. You are requested to complete a separate FPS-340 form in accordance with the instructions on the front of the form. Annotate "Return Per FPSD Instructions Purge No. PN 1026" in the Customer's Detail Explanation Section and use Reason Code J (Unsatisfactory Service Stock). You will receive full credit in your parts statement for the price of each unused part returned, plus the prepaid transportation cost. In order to receive credit, all parts must be received at the Parts Distribution Center within 30 days from the date of this letter. Material other than subject parts received on this return will be sent back to you freight collect. Any questions should be referred to your Zone Manager or facing PDC Manager. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Throttle Position Sensor - Request For Return > Page 2912 Throttle Position Sensor: Technical Service Bulletins Throttle Position Sensor - Diagnostic Tips Article No. 85-20-11 SELF-TEST CODE 53 - EEC IV - THROTTLE POSITION SENSOR DIAGNOSTIC TIP FORD 1985-86 ESCORT, EXP, TEMPO, MUSTANG, LTD, THUNDERBIRD LINCOLN-MERCURY 1985-86 LYNX, TOPAZ, CAPRI, MARQUIS, COUGAR LIGHT TRUCK 1985-86 RANGER, BRONCO II, ECONOLINE, F-SERIES CALIBRATION: All with EEC IV WARNING: This modification is authorized only for the listed engines. Performing this modification on other engine calibrations is unauthorized and could create liability under applicable federal or local laws. A new design Throttle Position Sensor (TPS) has been released for all 1986 EEC IV applications. The new TPS is designed to eliminate a false Self-Test Code 53. A Code 53 indicates the TPS system has failed at the wide open throttle position (approximately 5.0 volts), The new TPS eliminates false Code 53 by limiting the wide open throttle voltage to 4.75 volts. With the new TPS, Code 53 will only result from a circuit or TPS malfunction. The new Throttle Position Sensors can be used to replace faulty sensors on 1985 vehicles. If the old design service part is used, a false Code 53 may result. PART NUMBER PART NAME CLASS E6DZ-9B989-A Throttle Position Sensor C E6TZ-9B989-C Throttle Position Sensor WC E6DZ-9B989-C Throttle Position Sensor WC E6FZ-9B989-A Throttle Position Sensor B E6ZZ-9B989-A Throttle Position Sensor B E6ZZ-9B989-B Throttle Position Sensor WC E6TZ-9B989-A Throttle Position Sensor C OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Throttle Position Sensor - Request For Return > Page 2913 Throttle Position Sensor: Technical Service Bulletins Throttle Position Sensor - Application Chart EEC-IV THROTTLE POSITION SENSOR-APPLICATION CHART-SERVICE TIP Article No. 89-16-4 FORD: 1984-88 CROWN VICTORIA, ESCORT, EXP, MUSTANG, TAURUS, TEMPO, THUNDERBIRD LINCOLN-MERCURY: 1984-88 COUGAR, GRAND MARQUIS, LYNX, MARK VI, MARK VII, SABLE, TOPAZ, TOWN CAR LIGHT TRUCK: 1984-88 ALL LIGHT TRUCK LINES ISSUE: A quick reference throttle position sensor (TPS) application chart has been put together to assist technicians in correct part useage. If the wrong TPS is installed, it could fail prematurely. ACTION: Refer to one of the following TPS service replacement charts to make sure that the correct service part is installed. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Throttle Position Sensor - Request For Return > Page 2914 OASIS CODES: 680000 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Throttle Position Sensor - Request For Return > Page 2915 Throttle Position Sensor: Technical Service Bulletins TPS Mounting Screws - Hard to Remove THROTTLE POSITION SENSOR-MOUNTING SCREWS HARD TO REMOVE-SERVICE TIP Article No. 89-14-7 FORD: 1983-89 CROWN VICTORIA, MUSTANG, TEMPO, THUNDERBIRD 1984-89 ESCORT 1986-89 TAURUS LINCOLN-MERCURY: 1983-89 CONTINENTAL, COUGAR, GRAND MARQUIS, MARK VII, TOPAZ, TOWN CAR 1984-87 LYNX MERKUR: 1985-89 ALL MERKUR LINES LIGHT TRUCK: 1983-89 ALL LIGHT TRUCK LINES ISSUE: All Throttle Position Sensor (TPS) mounting screws have a "Pozidrive" head. The "Pozidrive" head looks a lot like a Phillips screw head. Use of a Phillips head screwdriver to remove a "Pozidrive" screw will normally result in a rounded or damaged screw head. Many technicians think it is an overtorqued or "frozen" screw. An adhesive was also used as a thread sealant starting with the 1988 model year. This adhesive requires still more effort to loosen and remove the screw. ACTION: To prevent rounded or damages screw heads when servicing the TPS mounting screws, technicians should always use a # 2 "Pozidrive" screwdriver. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 4800, 680000 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 2916 THROTTLE POSITION SENSOR SPECIFICATIONS Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 2917 Engine View Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 2918 Throttle Position Sensor: Description and Operation The Throttle Position (TP) Sensor (Rotary), Figure 1 supplies the ECA with a signal proportional to opening angle of carburetor throttle plates. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 2919 Throttle Position Sensor: Testing and Inspection Ford provides trouble code/symptom driven diagnostics for this component. For complete diagnosis and pinpoint testing, refer to Computers and Control Systems, Testing and Inspection. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 2920 Throttle Position Sensor: Adjustments ADJUSTMENT This procedure can be used to check and/or adjust level C sensors only: 1. Install an EEC-IV Breakout Box, Rotunda T83L-50 EEC-IV, or equivalent. 2. Attach a DVOM, Rotunda 014-00407 or equivalent, on 20V scale. Connect the positive lead (+) to test Pin 47 and the negative lead (-) to test Pin 46. 3. Turn ignition key to Run position (do not start engine). 4. Adjust TP Sensor (rotate) until the DVOM reads 1.0V (0.9-1.1). 5. Tighten TP Sensor screws to 1.2-1.8 N-m (11-16 lb-in). 6. While watching the DVOM, move the throttle to wide open and back to idle position. For proper operation, the DVOM should move from 1.0 to at least 4.0 and back to 1.0V. 7, Perform EEC-IV Quick Test. Refer to Powertrain Management/Computers and Control Systems/System Diagnosis Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Specifications VEHICLE SPEED SENSOR Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Specifications > Page 2924 Vehicle Speed Sensor: Locations At Transmission Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Testing and Inspection > Speed Control/Speedometer Vehicle Speed Sensor: Testing and Inspection Speed Control/Speedometer 1980-87 Models Exc. 1983-87 Ranger, 1984-87 Bronco II & 1986-87 Aerostar 1. Disconnect 6 way connector from amplifier assembly, then connect an ohmmeter between dark green wire w/white stripe and black wire on 1980 E-100-350, 1981-83 F-100-350 models and Bronco, and 1984-87 F-150-350 and Bronco, or green and black wire on 1980 F-100-350 and 1981-83 E-100-350 models and 1984-87 E-150-350 at the speed sensor end. A reading of 40 ohms should be obtained. A reading of 0 ohms indicates a shorted coil and an infinity reading indicates an open coil. 2. Replace sensor if a correct reading has not been obtained. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Testing and Inspection > Speed Control/Speedometer > Page 2927 Vehicle Speed Sensor: Testing and Inspection Computer Related Diagnostic Information Ford provides trouble code/symptom driven diagnostics for this component. For complete diagnosis and pinpoint testing, refer to Computers and Control Systems, Testing and Inspection. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Testing and Inspection > Page 2928 Vehicle Speed Sensor: Service and Repair 1. Separate electrical connector leading to the amplifier assembly. 2. Disconnect upper and lower speedometer cables at the speed sensor. Remove speed sensor. 3. Reverse procedure to install. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Throttle Position Sensor - Request For Return Throttle Position Sensor: Technical Service Bulletins Throttle Position Sensor - Request For Return Number: 92686 To: All Ford and Lincoln-Mercury Dealers Subject: Request for Return of Throttle Position Sensor E5ZZ-9B989-B (CX-1022) and E6ZZ-9B989-B (CX-1130) Because the subject parts may not meet Ford's high quality requirements, they should be withdrawn from all inventories. All used E5ZZ-9B989-B (CX-1022) and E6ZZ-9B989-B (CX-1130) should be returned to your facing PDC within 30 days from the date of this letter. Use the least expensive mode of transportation for your return. The subject parts are obsolete and replaced by E7SZ-9B989-B (CX-1200), which is available for ordering immediately. You are requested to complete a separate FPS-340 form in accordance with the instructions on the front of the form. Annotate "Return Per FPSD Instructions Purge No. PN 1026" in the Customer's Detail Explanation Section and use Reason Code J (Unsatisfactory Service Stock). You will receive full credit in your parts statement for the price of each unused part returned, plus the prepaid transportation cost. In order to receive credit, all parts must be received at the Parts Distribution Center within 30 days from the date of this letter. Material other than subject parts received on this return will be sent back to you freight collect. Any questions should be referred to your Zone Manager or facing PDC Manager. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Throttle Position Sensor - Request For Return > Page 2933 Throttle Position Sensor: Technical Service Bulletins Throttle Position Sensor - Diagnostic Tips Article No. 85-20-11 SELF-TEST CODE 53 - EEC IV - THROTTLE POSITION SENSOR DIAGNOSTIC TIP FORD 1985-86 ESCORT, EXP, TEMPO, MUSTANG, LTD, THUNDERBIRD LINCOLN-MERCURY 1985-86 LYNX, TOPAZ, CAPRI, MARQUIS, COUGAR LIGHT TRUCK 1985-86 RANGER, BRONCO II, ECONOLINE, F-SERIES CALIBRATION: All with EEC IV WARNING: This modification is authorized only for the listed engines. Performing this modification on other engine calibrations is unauthorized and could create liability under applicable federal or local laws. A new design Throttle Position Sensor (TPS) has been released for all 1986 EEC IV applications. The new TPS is designed to eliminate a false Self-Test Code 53. A Code 53 indicates the TPS system has failed at the wide open throttle position (approximately 5.0 volts), The new TPS eliminates false Code 53 by limiting the wide open throttle voltage to 4.75 volts. With the new TPS, Code 53 will only result from a circuit or TPS malfunction. The new Throttle Position Sensors can be used to replace faulty sensors on 1985 vehicles. If the old design service part is used, a false Code 53 may result. PART NUMBER PART NAME CLASS E6DZ-9B989-A Throttle Position Sensor C E6TZ-9B989-C Throttle Position Sensor WC E6DZ-9B989-C Throttle Position Sensor WC E6FZ-9B989-A Throttle Position Sensor B E6ZZ-9B989-A Throttle Position Sensor B E6ZZ-9B989-B Throttle Position Sensor WC E6TZ-9B989-A Throttle Position Sensor C OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Throttle Position Sensor - Request For Return > Page 2934 Throttle Position Sensor: Technical Service Bulletins Throttle Position Sensor - Application Chart EEC-IV THROTTLE POSITION SENSOR-APPLICATION CHART-SERVICE TIP Article No. 89-16-4 FORD: 1984-88 CROWN VICTORIA, ESCORT, EXP, MUSTANG, TAURUS, TEMPO, THUNDERBIRD LINCOLN-MERCURY: 1984-88 COUGAR, GRAND MARQUIS, LYNX, MARK VI, MARK VII, SABLE, TOPAZ, TOWN CAR LIGHT TRUCK: 1984-88 ALL LIGHT TRUCK LINES ISSUE: A quick reference throttle position sensor (TPS) application chart has been put together to assist technicians in correct part useage. If the wrong TPS is installed, it could fail prematurely. ACTION: Refer to one of the following TPS service replacement charts to make sure that the correct service part is installed. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Throttle Position Sensor - Request For Return > Page 2935 OASIS CODES: 680000 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Throttle Position Sensor - Request For Return > Page 2936 Throttle Position Sensor: Technical Service Bulletins TPS Mounting Screws - Hard to Remove THROTTLE POSITION SENSOR-MOUNTING SCREWS HARD TO REMOVE-SERVICE TIP Article No. 89-14-7 FORD: 1983-89 CROWN VICTORIA, MUSTANG, TEMPO, THUNDERBIRD 1984-89 ESCORT 1986-89 TAURUS LINCOLN-MERCURY: 1983-89 CONTINENTAL, COUGAR, GRAND MARQUIS, MARK VII, TOPAZ, TOWN CAR 1984-87 LYNX MERKUR: 1985-89 ALL MERKUR LINES LIGHT TRUCK: 1983-89 ALL LIGHT TRUCK LINES ISSUE: All Throttle Position Sensor (TPS) mounting screws have a "Pozidrive" head. The "Pozidrive" head looks a lot like a Phillips screw head. Use of a Phillips head screwdriver to remove a "Pozidrive" screw will normally result in a rounded or damaged screw head. Many technicians think it is an overtorqued or "frozen" screw. An adhesive was also used as a thread sealant starting with the 1988 model year. This adhesive requires still more effort to loosen and remove the screw. ACTION: To prevent rounded or damages screw heads when servicing the TPS mounting screws, technicians should always use a # 2 "Pozidrive" screwdriver. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 4800, 680000 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 2937 THROTTLE POSITION SENSOR SPECIFICATIONS Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 2938 Engine View Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 2939 Throttle Position Sensor: Description and Operation The Throttle Position (TP) Sensor (Rotary), Figure 1 supplies the ECA with a signal proportional to opening angle of carburetor throttle plates. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 2940 Throttle Position Sensor: Testing and Inspection Ford provides trouble code/symptom driven diagnostics for this component. For complete diagnosis and pinpoint testing, refer to Computers and Control Systems, Testing and Inspection. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 2941 Throttle Position Sensor: Adjustments ADJUSTMENT This procedure can be used to check and/or adjust level C sensors only: 1. Install an EEC-IV Breakout Box, Rotunda T83L-50 EEC-IV, or equivalent. 2. Attach a DVOM, Rotunda 014-00407 or equivalent, on 20V scale. Connect the positive lead (+) to test Pin 47 and the negative lead (-) to test Pin 46. 3. Turn ignition key to Run position (do not start engine). 4. Adjust TP Sensor (rotate) until the DVOM reads 1.0V (0.9-1.1). 5. Tighten TP Sensor screws to 1.2-1.8 N-m (11-16 lb-in). 6. While watching the DVOM, move the throttle to wide open and back to idle position. For proper operation, the DVOM should move from 1.0 to at least 4.0 and back to 1.0V. 7, Perform EEC-IV Quick Test. Refer to Powertrain Management/Computers and Control Systems/System Diagnosis Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Specifications VEHICLE SPEED SENSOR Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Specifications > Page 2945 Vehicle Speed Sensor: Locations At Transmission Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Testing and Inspection > Speed Control/Speedometer Vehicle Speed Sensor: Testing and Inspection Speed Control/Speedometer 1980-87 Models Exc. 1983-87 Ranger, 1984-87 Bronco II & 1986-87 Aerostar 1. Disconnect 6 way connector from amplifier assembly, then connect an ohmmeter between dark green wire w/white stripe and black wire on 1980 E-100-350, 1981-83 F-100-350 models and Bronco, and 1984-87 F-150-350 and Bronco, or green and black wire on 1980 F-100-350 and 1981-83 E-100-350 models and 1984-87 E-150-350 at the speed sensor end. A reading of 40 ohms should be obtained. A reading of 0 ohms indicates a shorted coil and an infinity reading indicates an open coil. 2. Replace sensor if a correct reading has not been obtained. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Testing and Inspection > Speed Control/Speedometer > Page 2948 Vehicle Speed Sensor: Testing and Inspection Computer Related Diagnostic Information Ford provides trouble code/symptom driven diagnostics for this component. For complete diagnosis and pinpoint testing, refer to Computers and Control Systems, Testing and Inspection. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Testing and Inspection > Page 2949 Vehicle Speed Sensor: Service and Repair 1. Separate electrical connector leading to the amplifier assembly. 2. Disconnect upper and lower speedometer cables at the speed sensor. Remove speed sensor. 3. Reverse procedure to install. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Injection Vacuum Control Solenoid Valve > Component Information > Locations Engine View Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Injection Vacuum Control Solenoid Valve > Component Information > Locations > Page 2955 Air Injection Vacuum Control Solenoid Valve: Description and Operation The dual thermactor air control solenoid valve assembly consists of two normally closed solenoid vacuum valves (TAB & TAD), one controlling the thermactor air bypass valve and the other the thermactor diverter valve. Both are vented when de-energized, sourced by the intake manifold vacuum reservoir and controlled by an EEC system (they are also discussed in the EEC and MCU Systems diagnostic procedures). Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Injection Vacuum Control Solenoid Valve > Component Information > Locations > Page 2956 Air Injection Vacuum Control Solenoid Valve: Testing and Inspection For additional information, refer to Powertrain Management / Computers and Control Systems / System Diagnosis. The function of each valve can be determined by externally energizing with vacuum sourced and output gauged. (Refer to solenoid vacuum valve, NC). The resistance of each solenoid should be between 51 and 108 ohms when checked at the coil terminals. If the resistance is not within these values, the solenoid should be replaced. NOTE: The valves can be expected to have a very small leakage rate when energized or deenergized. This leakage is not measurable in the field and is not detrimental to valve function. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Injection Bypass Valve > Component Information > Description and Operation > Air Bypass Valves Air Injection Bypass Valve: Description and Operation Air Bypass Valves There are two general groups of Air Bypass Valves, normally closed and normally open. Each group is available in remote (in-line) versions or pump-mounted (mounted directly on the air pump) versions (Figures 1, 2, and 3). The bypass valves are part of the Thermactor System. Normally closed valves supply air to the exhaust system with medium and high applied vacuum signals during normal (engine at normal operating temperature) modes, short idles and some accelerations. With low or no vacuum applied the pump air is dumped through the silencer ports of the valve. Normally open air bypass valves are available with or without vacuum vents. Test procedures differ for each. Normally open valves with a vacuum vent provide a timed air dump during decelerations and also dump when a vacuum pressure difference is maintained between the signal port and the vent port. The signal port must have 10 kPa (3 in Hg) more vacuum than the vent port to hold the dump. This mode is used to protect the catalyst from overheating. Normally open valves without a vacuum vent provide a timed dump of air for 1.1 or 2.8 seconds when a sudden high vacuum of about 68 kPa (20 in.-Hg.) is applied to the signal port. This prevents backfire during deceleration. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Injection Bypass Valve > Component Information > Description and Operation > Air Bypass Valves > Page 2961 Normally Open Air Bypass Valves without Vacuum Vent -Heavy Truck Applications Normally open valves without a vacuum vent provide a timed dump of air for 2 seconds nominal when a sudden high vacuum of about 68 kPa (20 in.-Hg) is applied to the signal port. This prevents backfire during deceleration. Normally Open Air Bypass Valves (9B289)-Heavy Truck Application Normally open valves with a vacuum vent provide a timed air dump decelerations and also dump when a vacuum pressure difference is maintained between the signal port and the vent port. The signal port must have 10 kPa (3 in-Hg) more vacuum than the vent port to hold the dump. This mode is used to protect the catalyst from overheating. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Injection Bypass Valve > Component Information > Description and Operation > Air Bypass Valves > Page 2962 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Injection Bypass Valve > Component Information > Description and Operation > Air Bypass Valves > Page 2963 Air Injection Bypass Valve: Description and Operation Combination Air Bypass/Air Control Valve The Combination Air Bypass/Air Control Valve (9F491) combines the functions of the air bypass valve (9B289) and the air control valve (9F491) into a single unit. There are two normally closed valves; the non-bleed type Figure 1 and the bleed type Figure 2 all of which look alike. One distinguishing feature will be that the bleed type will have a the percent of bleed molded into the plastic case. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Injection Bypass Valve > Component Information > Description and Operation > Air Bypass Valves > Page 2964 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Injection Bypass Valve > Component Information > Testing and Inspection > Air Bypass Valves Air Injection Bypass Valve: Testing and Inspection Air Bypass Valves Normally Closed Bypass Valves 1. Disconnect the air supply hose at the valve outlet. 2. Remove vacuum line to check to see that a vacuum signal is present at the vacuum nipple. Remove or bypass any restrictors or delay valves in the vacuum line. There must be a vacuum present at the nipple before proceeding. 3. With the engine at 1500 rpm and the vacuum line connected to the vacuum nipple, air pump supply air should be heard and felt at the air bypass valve outlet (Fig. 1). 4. With the engine at 1500 rpm, disconnect the vacuum line. Air at the outlet should be significantly decreased or shut off. Air pump supply air should be heard or felt at the silencer ports. 5. If the normally closed air bypass valve does not successfully complete the above tests, check the air pump. If the air pump is operating satisfactorily, replace the air bypass valve. Normally Open Air Bypass Valves With Vacuum Vents 1. Disconnect the air pump supply line at the outlet. 2. Disconnect all vacuum lines from the vacuum nipple and the vacuum vent (Fig. 2). 3. With the engine at 1500 rpm, air pump supply air should be heard and felt at the outlet (Fig. 2) 4. Using a length of vacuum hose with no restrictors or devices, connect the vacuum nipple to one of the manifold vacuum fittings on the intake manifold. With the vacuum vent open to atmosphere and the engine at 1500 rpm, virtually no air should be felt at the valve outlet and virtually all air should be bypassed through the silencer ports. 5. Using the same direct vacuum line to an intake manifold vacuum source, cap the vacuum vent. Accelerate the engine to 2000 rpm, and suddenly release the throttle. A momentary interruption of air pump supply air should be felt at the valve outlet (Fig. 2) 6. Reconnect all vacuum and thermactor lines. If any of the above tests are not satisfactorily completed, check the air pump. If the air pump is operating satisfactorily, replace the air bypass valve. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Injection Bypass Valve > Component Information > Testing and Inspection > Air Bypass Valves > Page 2967 Normally Open Air Bypass Valves Without Vacuum Vent 1. Disconnect the air supply line at the valve outlet (Fig. 3). 2. Disconnect the vacuum line at the vacuum nipple. 3. With the engine at 1500 rpm, air should be heard and felt at the valve outlet. 4. Connect a direct vacuum line that is free from restrictions from any manifold vacuum source to the vacuum nipple on the air bypass valve. Air at the outlet should be momentarily decreased or shut off. 5. Air pump supply air should be heard or felt at silencer ports (Fig. 3) during the momentary dump. Restore all original connections. If any of the above tests are not satisfactorily completed, check the air pump. If the air pump is operating satisfactorily, replace the air bypass valve. Normally Open Air Bypass Valves Without Vacuum Vent-Heavy Truck Applications 1. Disconnect the air supply line at the valve outlet (Figure 4). 2. Disconnect the vacuum line at the vacuum nipple. 3. With the engine at 1500 rpm air 3 should be heard and felt at the valve outlet. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Injection Bypass Valve > Component Information > Testing and Inspection > Air Bypass Valves > Page 2968 4. Connect a direct vacuum line that is free from restrictions from any manifold vacuum source to the vacuum nipple on the air bypass valve. Air at the outlet should be momentarily decreased or shut off. 5. Air pump supply air should be heard or felt at silencer ports (Figure 4) during the momentary dump. Restore all original connections. If any of the above tests are not satisfactorily completed. check the air pump. If the air pump is operating satisfactorily, replace the air bypass valve. Normally Open Air Bypass Valves With Vacuum Vents-Heavy Truck Application 1 Disconnect the air supply line at the valve outlet (Figure 5) and relief port if applicable. 2. Disconnect the vacuum line at the vacuum nipple. 3. With the engine at 1500 rpm, air should be heard and felt at the valve outlet. 4. Connect a direct vacuum line that is free from restrictions from any manifold vacuum source to the vacuum nipple on the air bypass valve. Air at the outlet should be momentarily decreased or shut off. 5. Air pump supply air should be heard or felt at silencer ports (Figure 5) during the momentary dump. Restore all original connections. If any of the above tests are not satisfactorily completed, check the air pump. If the air pump is operating satisfactorily, replace the air bypass valve. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Injection Bypass Valve > Component Information > Testing and Inspection > Air Bypass Valves > Page 2969 Air Injection Bypass Valve: Testing and Inspection Combination Air Bypass/Air Control Valve Normally Closed, Figures 1 and 2. 1. Disconnect hoses from outlets A and B. 2. Disconnect and plug vacuum line to port D. 3. With engine operating at 1500 rpm air flow should be noted coming out of the bypass vents. 4. Reconnect vacuum line to port D and disconnect and plug vacuum line to port S. Insure vacuum is present in the line to vacuum port D. 5. With engine operating at 1500 rpm air flow should be noted coming out of outlet B (no air flow should be detected at outlet A). 6. Apply 27-34 kPa (8.10 in-Hg) vacuum to port S With engine operating at 1500 rpm, air flow should be noted coming out of outlet A. 7 If the valve is the bleed type, some lesser amount of air will flow from outlet A or B, and the main discharge will change when vacuum is applied to port S. NOTE: If there is a small air tap attached to the inlet tube from the air pump, air flow should be present during engine operation. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Injection Bypass Valve > Component Information > Testing and Inspection > Air Bypass Valves > Page 2970 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Injection Check Valve > Component Information > Description and Operation > Air Check Valve/Pulse Air Valve Air Injection Check Valve: Description and Operation Air Check Valve/Pulse Air Valve The Air Check Valve (Fig. 1) is a one-way valve that allows thermactor air to pass into the exhaust system while preventing exhaust gases from passing in the opposite direction. The Pulse Air Valve (Fig. 2) replaces the air pump application in some thermactor Systems. It permits air to be drawn into the exhaust system on vacuum exhaust pulses and blocks the backflow of high pressure exhaust pulses. The fresh air completes the oxidation of exhaust gas components. NOTE: Although the two valves share the same basic part number and have the same appearance, they are NOT INTERCHANGEABLE. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Injection Check Valve > Component Information > Description and Operation > Air Check Valve/Pulse Air Valve > Page 2975 Air Injection Check Valve: Description and Operation Anti-Backfire Gulp Valve The anti-backfire valve is located downstream from the air bypass valve, and its purpose Is to divert a portion of the thermactor air to the intake manifold when it is triggered by intake manifold vacuum signal on decel, that is, only during periods of sudden decrease in intake manifold pressure. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Injection Check Valve > Component Information > Testing and Inspection > Air Check Valve/Pulse Air Valve Air Injection Check Valve: Testing and Inspection Air Check Valve/Pulse Air Valve 1. Inspect all hoses, tubes and the air valve for leaks. 2. Disconnect the hose on the inlet side of the air valve, and connect the check valve tester T75L-9487-A or equivalent as shown in Fig. 2. Note that a 6 inch length of tube, securely clamped, should be used between the valve and the tester. 3. Squeeze the rubber bulb on the tester as flat as possible, then release it. The bulb should remain creased for 8 seconds and should not return to a normal shape until after 15 seconds. If the above tester is not available, blow through the check valve, toward manifold, then attempt to suck back through the valve; the valve should free flow in the direction of the exhaust manifold only. 4. For the pulse air valve only: after starting the engine and at curb idle, a suction should be felt at the valve inlet. If not, replace the valve. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Injection Check Valve > Component Information > Testing and Inspection > Air Check Valve/Pulse Air Valve > Page 2978 Air Injection Check Valve: Testing and Inspection Anti-Backfire Gulp Valve 1. Disconnect the air supply hose from the air pump side of the valve (Fig. 1). 2. Observe the valve pintle by looking inside the valve through the disconnected port. Accelerate the engine to approximately 3000 rpm, suddenly release the throttle, the pintle should be open and then close. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Injection Control Valve > Component Information > Description and Operation > Air Control Valve Air Injection Control Valve: Description and Operation Air Control Valve The Air Supply Control Valve is used In the Thermactor (secondary air) System. The air control valve directs air pump output to the exhaust manifold or downstream to the catalyst system depending upon the engine control strategy. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Injection Control Valve > Component Information > Description and Operation > Air Control Valve > Page 2983 Air Injection Control Valve: Description and Operation Combination Air Bypass/Air Control Valve The Combination Air Bypass/Air Control Valve (9F491) combines the functions of the air bypass valve (9B289) and the air control valve (9F491) into a single unit. There are two normally closed valves; the non-bleed type Figure 1 and the bleed type Figure 2 all of which look alike. One distinguishing feature will be that the bleed type will have a the percent of bleed molded into the plastic case. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Injection Control Valve > Component Information > Description and Operation > Air Control Valve > Page 2984 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Injection Control Valve > Component Information > Testing and Inspection > Air Control Valve Air Injection Control Valve: Testing and Inspection Air Control Valve 1. Verify that airflow is being supplied to the valve inlet by disconnecting the air supply hose at the inlet and verifying the presence of air flow with the engine at 1500 rpm. Reconnect the air supply hose to the valve inlet. 2. Disconnect the air supply hoses at outlets A and B. 3. Remove the vacuum line at the vacuum nipple. 4. Accelerate the engine to 1500 rpm. Air flow should be heard and felt at outlet B with little or no air flow at outlet A. 5. With the engine at 1500 rpm, connect a direct vacuum line from any manifold vacuum fitting to the air control valve vacuum nipple. Air flow should be heard and felt at outlet A with little or no air flow at outlet B. 6. If the valve is the bleed type less air will flow from outlet A or B, and the main discharge will change when vacuum is applied to the vacuum nipple. 7. (a.) If the above conditions are met and a Ford Authorized Decal states that the emissions control system has been modified and timing has been set to seven (7) degrees BTDC, then testing is complete. Restore all connections. A vacuum retard delay valve that was installed as part of the modification can produce an engine Running Code 45 under normal operating conditions. (b.) If the above conditions are not met, replace the air control valve and restore all connections. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Injection Control Valve > Component Information > Testing and Inspection > Air Control Valve > Page 2987 Air Injection Control Valve: Testing and Inspection Combination Air Bypass/Air Control Valve Normally Closed, Figures 1 and 2. 1. Disconnect hoses from outlets A and B. 2. Disconnect and plug vacuum line to port D. 3. With engine operating at 1500 rpm air flow should be noted coming out of the bypass vents. 4. Reconnect vacuum line to port D and disconnect and plug vacuum line to port S. Insure vacuum is present in the line to vacuum port D. 5. With engine operating at 1500 rpm air flow should be noted coming out of outlet B (no air flow should be detected at outlet A). 6. Apply 27-34 kPa (8.10 in-Hg) vacuum to port S With engine operating at 1500 rpm, air flow should be noted coming out of outlet A. 7 If the valve is the bleed type, some lesser amount of air will flow from outlet A or B, and the main discharge will change when vacuum is applied to port S. NOTE: If there is a small air tap attached to the inlet tube from the air pump, air flow should be present during engine operation. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Injection Control Valve > Component Information > Testing and Inspection > Air Control Valve > Page 2988 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Injection Hose/Tube > Component Information > Testing and Inspection Air Injection Hose/Tube: Testing and Inspection 1. Inspect all hoses and tubes for deterioration or cracks. 2. Check hose and tube routing as interference may cause wear. 3. Check all hose and tube connections. 4. Check the pressure side of the system for leaks with a soapy water solution. With the pump running, bubbles will form if a leak exists. 5. When replacing any hose or tube, note routing before removal. The hoses used with this system are made of special material to withstand high temperature. No other type should be used. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Injection Muffler > Component Information > Description and Operation Air Injection Muffler: Description and Operation The Air Silencer is a combination silencer and filter for air supply pumps that are not equipped with an impeller type centrifugal air filter fan or for pulse air (thermactor II) Systems. The air silencer is mounted in a convenient position in the engine compartment and is connected to the air supply pump or pulse air valve inlet by means of a flexible hose. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Injection Muffler > Component Information > Description and Operation > Page 2995 Air Injection Muffler: Testing and Inspection 1. Inspect hoses and air silencer for leaks. 2. Disconnect hose from air silencer outlet, remove silencer and visually inspect for plugging. 3. The air silencer is operating satisfactorily if no plugging or leaks are encountered. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Pump <--> [Air Injection Pump] > Component Information > Technical Service Bulletins > Exhaust Air Pump Assembly - Obsolete Part Return Air Pump: Technical Service Bulletins Exhaust Air Pump Assembly - Obsolete Part Return Article No. 93-3-11 February 3, 1993 SERVICE PARTS RETURN OF OBSOLETE EXHAUST AIR PUMP ASSEMBLY FORD: 1981 FAIRMONT, THUNDERBIRD LINCOLN-MERCURY: 1981 COUGAR, MONARCH LIGHT TRUCK: 1981-83 ECONOLINE 1981-86 F-150-350 SERIES 1986 BRONCO ISSUE: Exhaust Air Pump Assembly (E1TZ-9A486-D) (CX-631) may not meet Ford's high quality requirements and should be withdrawn from your inventory. This Sort and Purge of part numbers (E1TZ-9A486-D) (CX-631) which lack the threaded mounting hole should be withdrawn from your inventory and returned to your facing PDC within 30 days of this TSB. ACTION: Return the obsolete parts from your dealership's inventory. 1. Sort stock (E1TZ-9A486-D) (CX-631) which lacks the threaded mounting hole. 2. Return part numbers (E1TZ-9A486-D) (CX-631) which lack this threaded hole and return to your facing PDC using the least expensive transportation. 3. If claim is processed electronically via DOES II, use return code "GB"; otherwise, complete a separate FPS-340 claim for these parts. 4. Indicate Reason "J" on claims. 5. In the Remarks Section write "Returned per TSB 93-3-11". LIMITS ^ The returns must be received within 30 days from the date of this TSB. ^ Returns are restricted to the subject parts. ^ The parts returned must have been purchased from FPSD in accordance with Policy and Procedure Bulletin 4000. CREDIT Credit for parts and prepaid freight costs will be issued. NOTE: REPLACEMENT STOCK IS AVAILABLE FOR ORDERING IMMEDIATELY. PART NUMBER PART NAME CLASS E1TZ-9A486-D Exhaust Air Pump Assembly AM OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 403000, 623000 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Pump <--> [Air Injection Pump] > Component Information > Technical Service Bulletins > Page 3000 Air Pump: Description and Operation Passenger Cars and Light Trucks The Air Supply Pump is a belt driven, positive displacement, vane type pump that provides air for the thermactor system. it is available in 11-cubic inch and 19-cubic inch sizes, either of which may be driven with different pulley ratios for different applications. The 11-cubic inch pump (Figure 1) receives its air through a remote filter attached to the air inlet nipple or through an impeller type centrifugal air filter fan. The 19-cubic inch pump (Figure 2) uses an impeller type centrifugal air filter fan which separate dirt, dust, and other contaminants from the Intake air by centrifugal force. The air supply pump does not have a pressure relief valve, a function performed by the bypass valve. Heavy Duty Trucks The Air Supply Pump is a belt driven, positive displacement, vane type pump that provides air for the thermactor system It is available in 19-cubic inch and 23-cubic inch sizes, either of which may be driven with different pulley ratios for different applications. Both pumps (Figure 3), receive air from a remote silencer filter attached to the pumps' air inlet nipple. The pressure relief function is performed by the bypass valve. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Pump <--> [Air Injection Pump] > Component Information > Technical Service Bulletins > Page 3001 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Pump <--> [Air Injection Pump] > Component Information > Technical Service Bulletins > Page 3002 Air Pump: Testing and Inspection 1. Check belt tension, and adjust to specifications. 2. Disconnect air supply hose from bypass control valve. 3. The pump is operating satisfactorily if air flow is felt at the pump outlet and the flow increases as the engine speed is increased. Do not pry on the pump to adjust belt. The aluminum housing is likely to collapse. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Pulsed Secondary Air Injection > Component Information > Description and Operation Pulsed Secondary Air Injection: Description and Operation Fig. 79 Thermactor II system (typical) Fig. 80 Thermactor II pulse air valve operation Some engines are equipped with this type of exhaust air injection system, Fig. 79, which does not have an air pump. The system uses the natural pulses of the exhaust system to draw air into the exhaust manifold. The system is regulated by a pulse air valve. The valve, Fig. 80, is connected to the air cleaner with a hose and to the exhaust manifold with a metal tube. Some pulse air valves closely resemble the standard Thermactor check valves, but are not interchangeable with them. When pressure inside the exhaust manifold is more than the pressure in the air cleaner, the reed in the pulse air valve is closed. When pressure in the exhaust manifold is lower than in the air cleaner, the reed opens and allows air to be drawn into the exhaust manifold. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Thermal Vacuum Valve, Air Injection > Component Information > Description and Operation Thermal Vacuum Valve: Description and Operation The TIV valve vents the vacuum signal to the atmosphere when the preset manifold vacuum or pressure is exceeded. It is used to divert thermactor air flow during extended idle conditions to limit exhaust temperature and to cut EGR in a heavy boost mode for turbocharged applications. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Thermal Vacuum Valve, Air Injection > Component Information > Description and Operation > Page 3009 Thermal Vacuum Valve: Testing and Inspection Conditions ^ Disconnect both nipples of the thermactor idle vacuum (TIV) valve. ^ Install a vacuum hose from the manifold vacuum source to the small nipple of the TIV valve. Checks TIV valves with code words ASH or RED on decal: 1. With the engine at idle, in Neutral, place fingers over the TIV valve atmospheric vent holes. If no vacuum is sensed, the TIV is defective and must be replaced. 2. While the engine is still idling in neutral, apply vacuum, shown below, to the TIV valve large nipple from a test source. If vacuum is still sensed when placing fingers over vent holes, The TIV is defective and must be replaced. 3. Disconnect the TIV large nipple from manifold vacuum and the TIV small nipple from the test vacuum. Reconnect the TIV valve to original hoses or connectors. TIV valves with code mode TUR on decal: 1. With the engine at idle, transmission in Neutral, place fingers over TIV valve atmospheric vent holes. If vacuum is sensed, the TIV is defective and must be replaced. 2. While the engine is still idling in Neutral, apply pressure, shown below, to the TIV valve's large nipple from a test source If vacuum is not sensed when placing a finger over the vent holes, the TIV is defective and must be replaced. 3. Disconnect the TIV valve's large nipple from manifold vacuum and the small nipple from the test pressure. Reconnect the TIV to its original hoses or connectors. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Vacuum Check Valve, AIR > Component Information > Description and Operation Vacuum Check Valve: Description and Operation A vacuum check valve blocks air flow in one direction. It allows free air flow in the other direction. The check side of this valve will hold the highest vacuum seen on the vacuum side. If not, replace it. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Vacuum Check Valve, AIR > Component Information > Description and Operation > Page 3013 Vacuum Check Valve: Testing and Inspection Apply 54 kPa (16 in. Hg.) vacuum to "check" side of valve and trap. If vacuum remains above 50.6 kPa (15 in. Hg.) for 10 seconds, the valve is acceptable. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Engine - Lack of Power/No Start Diagnosis Catalytic Converter: Technical Service Bulletins Engine - Lack of Power/No Start Diagnosis Article No. 91-12-11 06/12/91 LACK OF POWER 7.5L, 5.8L, 5.0L, 4.9L - CATALYTIC CONVERTER DIAGNOSTIC TIPS LIGHT TRUCK: 1986-91 BRONCO, ECONOLINE, F-150-350 SERIES 1988-91 F SUPER DUTY, F47 ISSUE: Lack of power or a no start condition may be diagnosed as an exhaust restriction caused by a plugged catalytic converter. A plugged catalytic converter (internal deterioration) is usually caused by abnormal engine operation. ACTION: Diagnose the catalytic converter to confirm internal failure. Refer to the Catalyst and Exhaust System Diagnostic Section, in the Engine/Emissions Diagnostic Shop Manual and the following procedures for service details. 1. Lack of proper HEGO operation may cause, or be the result of a rich or lean fuel condition, which could cause additional heat in the catalyst. Perform self test KOEO and KOER, service any codes. NOTE: IF TWO DIGIT CODES 41, 42, 85 OR THREE DIGIT CODES 171, 172, 173, 179, 181, 182, 183 AND 565 ARE RECEIVED, CHECK FOR PROPER HEGO GROUND. If the HEGO ground is good, the following areas may be at fault: ^ Ignition Coil ^ Distributor Cap ^ Distributor Rotor ^ Fouled Spark Plug ^ Spark Plug Wires ^ Air Filter ^ Stuck Open Injector ^ Fuel Contamination Engine OIL ^ Manifold Leaks Intake/ Exhaust ^ Fuel Pressure ^ Poor Power Ground ^ Engine Not At Normal Operating Temperature ^ HEGO Sensor 2. Spark timing that is retarded from specification may increase exhaust gas temperature and shorten catalyst life. Refer to the following procedure for service details. a. Check spark timing. Check base timing with spout disconnected. Set base timing to the specification on the vehicle emission decal. b. Check computed timing with spout connected. NOTE: COMPUTED TIMING IS EQUAL TO BASE TIMING PLUS 20~ BTDC +/- 3~. 3. Misfiring spark plugs may cause an unburned fuel air mixture to pass through the catalyst, which could cause higher than normal catalyst temperatures. Refer to the following procedure for service details. a. Check secondary ignition, hook the vehicle up to an engine analyzer and check for a secondary ignition misfire. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Engine - Lack of Power/No Start Diagnosis > Page 3018 NOTE: SERVICE ANY ITEM THAT IS NOT PERFORMING AT PROPER SPECIFICATIONS BEFORE CONTINUING. 4. Fuel pressure that is too high may cause rich air fuel mixtures to pass through the catalyst which could cause higher than normal catalyst temperatures. Refer to the following procedure for service details. a. Check fuel pressure, install fuel pressure gauge, start and run the engine at idle. Fuel pressures between 28 and 34 PSI are typical (4.9L typically is 15 PSI higher). b. Disconnect the vacuum line going to the fuel pressure regulator. Fuel pressure typically jumps to 40 PSI +/- 3 PSI (4.9L typically is 15 PSI higher). Visually inspect vacuum line for raw fuel. NOTE: FUEL PRESSURES ABOVE THESE VALUES SHOULD BE CORRECTED. HOWEVER, THIS MAY NOT BE THE CAUSE OF THE CONCERN. SERVICE AS NECESSARY. 5. Throttle plates in the throttle body not returning to the proper closed position may cause excessive catalyst temperatures during downhill grades. Refer to the following procedure for service details. a. Visually inspect the throttle body and linkage for: ^ Binding or sticking throttle linkage. ^ Tight speed control linkage or cable. ^ Vacuum line interference. ^ Electrical harness interference. NOTE: AFTERMARKET GOVERNORS, THROTTLE LINKAGE AND CABLES ASSOCIATED WITH POWER TAKE-OFF UNITS, MAY ALSO INTERFERE WITH PROPER THROTTLE RETURN. SERVICE AS NECESSARY. 6. It is extremely important that all systems related to the engine and emission systems operate properly. a. Visually inspect the engine compartment to make sure all vacuum hoses and spark plug wires are properly routed and securely connected. b. Inspect all wiring harnesses and connectors for insulation damage, burned, overheated, loose or broken conditions. c. Verify proper operation of the thermactor system. Thermactor systems that fail to dump thermactor air to the atmosphere properly or at the correct time can cause high catalyst temperatures. d. Visually inspect thermactor system for damaged or kinked hoses and perform a function test on following components: air control valve, check valve, silencer, filter and the air bypass solenoid. e. Verify proper operation of the engine cooling system thermostat. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under Basic Warranty Coverage, Emissions Warranty Coverage OPERATION DESCRIPTION TIME 911211A Diagnostics - Perform 0.5 Hrs. KOEO And KOER Self Tests 911211B Timing - Check Or Adjust 0.5 Hrs. Spark Timing, Check Computed Timing And Check Secondary Ignition System With Engine Analyzer. 911211C Check - Fuel Pressure And 0.2 Hrs. Inspect Vacuum Line For Raw Fuel. 911211D Inspect - Throttle Body And 0.1 Hrs. Linkage. 911211E Inspect - Vacuum Hoses, 0.1 Hrs. Electrical Harnesses, Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Engine - Lack of Power/No Start Diagnosis > Page 3019 Connectors And Spark Plug Wires For Routing Damage. 911211F Thermactor System - 0.3 Hrs. Inspect For Proper Operation And Damaged Component. Includes Function Check Of Air Control Valve, Thermactor Air Bypass Solenoid, Check Valves, Silencer And Filter. 911211G Thermostat - Check For 0.2 Hrs. Proper Operation. DEALER CODING BASIC PART NO. CONDITION CODE 5E212 25 OASIS CODES: 403000, 603300, 614000 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Description and Operation > Dual Catalytic Converter Catalytic Converter: Description and Operation Dual Catalytic Converter Fig. 17 Dual catalytic converter This converter consists of two catalytic converters in one shell, with a mixing chamber in between the two, Fig. 17. Each converter is composed of a ceramic ``honey comb'' coated with a rhodium/platinum catalyst designed to control oxides of nitrogen (NOx), unburned hydrocarbons (HC) and carbon monoxide (CO), and is therefore called a ``three way catalyst'' (TWC). The rear converter is coated with platinum catalyst and is called a ``conventional'' oxidation catalyst'' (COC) converter. The platinum catalyst is also called a ``two way catalyst'' since it only acts on two of the major pollutants, HC and CO. The TWC converter acts on the exhaust gases from the engine. As the gases flow from the TWC to the COC converter, they mix with air from the thermactor pump injected into the mixing chamber or ``mid-bed''. This air is required for proper oxidation of HC and CO in the COC converter. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Description and Operation > Dual Catalytic Converter > Page 3022 Catalytic Converter: Description and Operation General Description Fig. 4 Single type catalytic converter with single substrate catalyst Fig. 5 Single type catalytic converter with dual substrate catalyst Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Description and Operation > Dual Catalytic Converter > Page 3023 Fig. 6 Dual type catalytic converter The catalytic converter used on some vehicles, serves two purposes: it permits a faster chemical reaction to take place and although it enters into the chemical reaction, it remains unchanged, ready to repeat the process. The catalytic converter combines hydrocarbons (HC) and carbon monoxide (CO) with oxygen to form water (H2O) and carbon dioxide (CO2). The catalyst is structured in the form of a honeycomb monolithic composition, Figs. 4,5 and 6 . The catalyst consists of a porous substrate of an inert material, coated with platinum and other noble metals (the catalytically active materials.) This device, located in the exhaust system between the exhaust manifold and muffler, requires the use of heat shields, in some cases, due to its high operating temperatures. The heat shields are necessary to protect chassis components, passenger compartment and other areas from heat related damage. A small diameter fuel tank filler tube neck is incorporated to prevent the larger service station pump nozzle, used for leaded fuels, being inserted into the filler tube, thereby preventing system contamination. Since the use of leaded fuels contaminates the catalysts, deteriorating its effectiveness, the use of unleaded fuels is mandatory in vehicles equipped with catalytic converters. The catalytic converter can tolerate small amounts of leaded fuels without permanently reducing the catalyst effectiveness. There are basically three types of catalysts, the conventional oxidation catalyst (COC) containing Platinum (Pt) and Palladium (Pd) which are effective for catalyzing the oxidation reactions of hydrocarbons (HC) and carbon monoxide (CO) emissions. A three-way catalyst (TWC) containing Platinum (Pt) and Rhodium (RH), is not only effective for catalyzing the oxidation reactions of HC and CO emissions, but it also catalyzes the reduction of nitrogen oxides (NOx). A light off catalyst (LOC) is a single bed converter. It is arranged in series with the main catalytic converter assembly of COC and/or TWC as the aft member(s). This converter is designed to perform the very specialized function of exhaust emission control during engine warm-up when the main converter(s) is not yet at the temperature required for maximum efficiency. The LOC is designed to operate effectively in the high environmental conditions that exist near the manifold flange. The LOC is designed with a minimum heat sink effect and, provides minimum delay in warm-up of the main catalytic converter(s). The oxidation catalyst requires the use of a secondary air source which is provided by the pulse air or thermactor air injection systems. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Description and Operation > Page 3024 Catalytic Converter: Testing and Inspection Blocked or restricted exhaust system usually results in lack of power or popping through the intake system. Verify that this condition is not caused by ignition timing problems, then proceed with diagnosis. Catalyst and Exhaust Systems Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Description and Operation > Page 3025 Catalyst and Exhaust Systems Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Early Fuel Evaporation ( EFE ) > Exhaust Heat Control Valve <--> [EFE Valve] > Component Information > Specifications > Mechanical Specifications Exhaust Heat Control Valve: Mechanical Specifications PVS Body Color Opening Temperature Black 92-98 F Blue 125-131 F Purple 157-163 F Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Early Fuel Evaporation ( EFE ) > Exhaust Heat Control Valve <--> [EFE Valve] > Component Information > Specifications > Mechanical Specifications > Page 3031 Exhaust Heat Control Valve: Pressure, Vacuum and Temperature Specifications PVS Body Color Opening Temperature Black 92-98 F Blue 125-131 F Purple 157-163 F Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Early Fuel Evaporation ( EFE ) > Exhaust Heat Control Valve <--> [EFE Valve] > Component Information > Description and Operation > Exhaust Heat Control Valve Exhaust Heat Control Valve: Description and Operation Exhaust Heat Control Valve The purpose of the exhaust heat control valve, is to divert hot gases from the exhaust manifold to the intake manifold riser pad. Heat is transferred from the exhaust gas to the riser pad, which in turn heats the incoming fuel/air charge. There are two types currently available; the bimetal spring type and the vacuum actuated type. Bimetal Type The valve is normally in the closed position engine cold and not running to divert exhaust gases to the intake manifold riser pad. When the engine is started, the heat from the exhaust gases actuates the bimetal spring which opens the valve. As operating temperatures are reached, the valve will remain open. The valve, when cold, will also open at high engine speeds, due to the action of the exhaust gas on the unbalanced valve plate. Vacuum Operated The vacuum operated heat valve functions as follows: ^ When the engine is started, the valve is closed by intake manifold vacuum acting on the vacuum motor. ^ The valve will stay closed until one of two conditions occurs: 1. When the engine coolant temperature reaches a predetermined value, the vacuum supply to the heat valve is shut-off by a temperature sensing vacuum switch and the heat valve opens. 2. When the engine speed/load condition causes a drop in intake manifold vacuum below a specific value, the heat valve opens. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Early Fuel Evaporation ( EFE ) > Exhaust Heat Control Valve <--> [EFE Valve] > Component Information > Description and Operation > Exhaust Heat Control Valve > Page 3034 Exhaust Heat Control Valve: Description and Operation Fuel Evaporation Heater (EFE) Switch The Fuel Evaporation Heater (EFE) switch, is mounted upside down at the rear of the engine on the bottom of the intake manifold. The purpose of the switch is to control a relay and heater element in the early fuel evaporation system (EFE) based on engine temperature The normally closed switch will activate the relay and heater at low engine temperature and will open at the specified calibration temperature of the switch. This will open the control relay shutting off the EFE heater after engine warm-up. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Early Fuel Evaporation ( EFE ) > Exhaust Heat Control Valve <--> [EFE Valve] > Component Information > Description and Operation > Page 3035 Exhaust Heat Control Valve: Testing and Inspection Bimetal Type A. Inspect valve assembly for any abnormal condition. Service or replace as necessary. B. Lubricate the valve with COAZ-19A501-A or C4AZ-19A5O1-A graphite lube or equivalent. C. Check valve and thermostatic spring operation by manually rotating the valve shaft. Valve must be free and return to the closed position when cold (Rotunda Choke Tester Model 090-00001 or equivalent may be used if necessary to cool bimetal). Vacuum Operated Apply 33.77-67.54 kPa (10-15 in-Hg.) vacuum to the vacuum motor using a hand vacuum pump and trap for 60 seconds. The valve must close and not leak more than 6.75 kPa (2 in-Hg.) and open when the vacuum is released. it it does not operate in this manner replace the valve. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Early Fuel Evaporation ( EFE ) > Vacuum Check Valve, EFE > Component Information > Technical Service Bulletins > Customer Interest for Vacuum Check Valve: > 86817 > Apr > 86 > Engine - Rough Idle/Stalls On Cold Start Vacuum Check Valve: Customer Interest Engine - Rough Idle/Stalls On Cold Start Article No. 86-8-17 IDLE - ROUGH/STALL (5.8L(W)) DURING COLD START OR A/C OPERATION - 8500 LBS. GVW LIGHT TRUCK 1986 F SERIES, BRONCO CALIBRATIONS: 4-64G-R15 and 4-64Z-R14 WARNING: This modification is authorized only for the listed engines. Performing this modification on other engine calibrations is unauthorized and could create liability under applicable federal or local laws. Rough engine idle and/or stalls, during cold start or air conditioning operation may be caused by an improperly installed vacuum check valve to throttle kicker. To correct the above conditions, the following procedure is recommended. 1. Locate vacuum check valve (part number D9AE- 12A197-AA) connected to throttle kicker vacuum hose. Valve should be installed with blue side connected to hose attached to throttle kicker and black side should be connected to hose attached to vacuum source (remove and re-install, if necessary). 2. If check valve was properly installed, continue engine performance diagnostics as outlined in the 1986 Car/Truck Engine/Emissions Diagnosis Manual, Volume H, to determine the cause of the concern. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION: SP12197A86 TIME: 0.3 Hr. DLR. CODING: Basic Part No. 12A197 - Code: J4, J8 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Early Fuel Evaporation ( EFE ) > Vacuum Check Valve, EFE > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Vacuum Check Valve: > 86817 > Apr > 86 > Engine - Rough Idle/Stalls On Cold Start Vacuum Check Valve: All Technical Service Bulletins Engine - Rough Idle/Stalls On Cold Start Article No. 86-8-17 IDLE - ROUGH/STALL (5.8L(W)) DURING COLD START OR A/C OPERATION - 8500 LBS. GVW LIGHT TRUCK 1986 F SERIES, BRONCO CALIBRATIONS: 4-64G-R15 and 4-64Z-R14 WARNING: This modification is authorized only for the listed engines. Performing this modification on other engine calibrations is unauthorized and could create liability under applicable federal or local laws. Rough engine idle and/or stalls, during cold start or air conditioning operation may be caused by an improperly installed vacuum check valve to throttle kicker. To correct the above conditions, the following procedure is recommended. 1. Locate vacuum check valve (part number D9AE- 12A197-AA) connected to throttle kicker vacuum hose. Valve should be installed with blue side connected to hose attached to throttle kicker and black side should be connected to hose attached to vacuum source (remove and re-install, if necessary). 2. If check valve was properly installed, continue engine performance diagnostics as outlined in the 1986 Car/Truck Engine/Emissions Diagnosis Manual, Volume H, to determine the cause of the concern. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION: SP12197A86 TIME: 0.3 Hr. DLR. CODING: Basic Part No. 12A197 - Code: J4, J8 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Emissions Maintenance Light > Component Information > Technical Service Bulletins > Emission Maintenance Warning Module - Service Emissions Maintenance Light: Technical Service Bulletins Emission Maintenance Warning Module - Service Article No. 89-22-8 ^ EMISSION MAINTENANCE WARNING MODULE SERVICE INFORMATION ^ LAMP - "EMISSIONS/CHECK ENGINE" - EMISSION MAINTENANCE WARNING MODULE SERVICE INFORMATION LIGHT TRUCK: 1985-89 BRONCO 1985-87 BRONCO II 1985-89 ECONOLINE, F-150, F-250, F-350 1985-88 RANGER 1986-87 AEROSTAR MEDIUM/HEAVY TRUCK: 1988-90 F & B SERIES ISSUE: The Emission Maintenance Warning "EMW" module operates a light that is located on the instrument panel. For 1985-87 model year vehicles, the light will display the word "EMISSIONS". For 1988-89 model year vehicles, the light will display the words "CHECK ENGINE". When the light is lit, it is indicating that the 60,000 mile emission maintenance should be performed. After the maintenance is performed the EMW module must be reset to zero time. Another type of module is the "IMS" module. This module is not part of the light circuit and does not require maintenance. At a predetermined time, the IMS module directs the EEC IV processor to make a strategy change. A third type of module is the "COMBO" module. This module combines the functions of the IMS and the EMW modules. ACTION: Refer to the following module application charts for the specific vehicle application and location of the different types of modules. NOTE: FOR APPLICATIONS NOT LOSTED IN THE FOLLOWING MODULE APPLICATION CHARTS, THE "CHECK ENGINE" LIGHT IS CONTROLLED BY THE EEC IV PROCESSOR. THESE VEHICLES DO NOT USE THE "EMW" MODULE. 1985 & 1986 MODULE APPLICATION CHART 1987 MODULE APPLICATION CHART Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Emissions Maintenance Light > Component Information > Technical Service Bulletins > Emission Maintenance Warning Module - Service > Page 3053 1988 MODULE APPLICATION CHART 1989 MODULE APPLICATION CHART 1990 MODULE APPLICATION CHART PART NUMBER PART NAME CLASS E5TZ-12B514-C EMW Module - 1000 Hr BM E5TZ-12B514-A EMW Module - 2000 Hr AM E7TZ-12B514-A COMBO Module BM OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 2300, 2500 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Bowl Vent Solenoid > Component Information > Locations Engine View Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Bowl Vent Solenoid > Component Information > Locations > Page 3058 Bowl Vent Solenoid: Description and Operation The Fuel Bowl Vent Solenoid Valve, Figure 1 is part of the Evaporative Emission Control System, and is a normally open valve located in the fuel bowl vent line. The vent solenoid valve closes off the fuel bowl vent line when the engine is running, and it returns to the normally open condition when the ignition switch is turned off. NOTE: if lean fuel mixture Is suspected as the cause of a problem, Inspect the bowl vent solenoid valve for proper closing during engine operation. If the valve leaks or does not close, the carburetor will give a leaner air/fuel mixture. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Bowl Vent Solenoid > Component Information > Locations > Page 3059 Bowl Vent Solenoid: Testing and Inspection Apply 9-14 volts DC to valve, and the valve should close, not allowing air to pass. If valve does not close, replace valve. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Bowl Vent Valve > Component Information > Description and Operation > Carburetor Fuel Bowl Thermal Vent Valve Bowl Vent Valve: Description and Operation Carburetor Fuel Bowl Thermal Vent Valve The Thermal Vent Valve, Figure 1 is a temperature actuated Off/On valve. It is inserted in the carburetor-to-canister vent line and is closed when the engine compartment is cold. This prevents fuel tank vapors (generated when the fuel tank heats up before the engine compartment does) from being vented through the carburetor fuel bowl-forcing them instead into the carbon canister. This effect can occur, for instance, when sunlight strikes a vehicle which has been sitting out all night, and begins to warm the fuel tank. With the thermal vent valve closed, the vapors cannot enter the carburetor fuel bowl vent valve (now closed) but must be routed to the carbon canister. As the engine compartment warms up, during normal engine operation, the thermal vent valve opens. When the engine is again turned off, the thermal vent valve (now open because underhood temperature is above 120°F) allows fuel vapors generated from the carburetor float bowl to pass through the valve and store themselves in the carbon canister. As the thermal vent valve cools, it again closed and the cycle begins again. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Bowl Vent Valve > Component Information > Description and Operation > Carburetor Fuel Bowl Thermal Vent Valve > Page 3064 Bowl Vent Valve: Description and Operation Solenoid Vent Valve The Fuel Bowl Vent Solenoid Valve, Figure 1 is part of the Evaporative Emission Control System, and is a normally open valve located in the fuel bowl vent line. The vent solenoid valve closes off the fuel bowl vent line when the engine is running, and it returns to the normally open condition when the ignition switch is turned off. NOTE: if lean fuel mixture Is suspected as the cause of a problem, Inspect the bowl vent solenoid valve for proper closing during engine operation. If the valve leaks or does not close, the carburetor will give a leaner air/fuel mixture. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Bowl Vent Valve > Component Information > Description and Operation > Carburetor Fuel Bowl Thermal Vent Valve > Page 3065 Bowl Vent Valve: Description and Operation Vacuum Bowl Vent Valve and Vacuum/Thermostatic Bowl Vent Valve The Vacuum Bowl Vent Valve and the Vacuum/Thermostatic Bowl Vent Valve are vacuum and vacuum/temperature actuated On/Off valves. The Vacuum Bowl Vent Valve (E3TE-9G332-AA), Figure 2 and the Vacuum Thermostatic Bowl Vent Valve (E3EE-9G332-AA), Figure 1, are similar in appearance. The valves are used in the Evaporative Emission System to control vapor flow from the carburetor bowl to the carbon canister. With either valve, the flow path from the bowl to the canister is closed by manifold vacuum when the engine is running. The thermostatic valve also closes the bowl-to-canister flow path when the temperature of the valve is 90°F or less (even without manifold vacuum). When the temperature of the valve is 120° F or more the valve is open (unless closed by manifold vacuum) Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Bowl Vent Valve > Component Information > Testing and Inspection > Carburetor Fuel Bowl Thermal Vent Valve Bowl Vent Valve: Testing and Inspection Carburetor Fuel Bowl Thermal Vent Valve At 90°F and below, the vent valve is fully closed and at 120°F and above, the vent valve is fully open. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Bowl Vent Valve > Component Information > Testing and Inspection > Carburetor Fuel Bowl Thermal Vent Valve > Page 3068 Bowl Vent Valve: Testing and Inspection Solenoid Vent Valve Apply 9-14 volts DC to valve, and the valve should close, not allowing air to pass. If valve does not close, replace valve. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Bowl Vent Valve > Component Information > Testing and Inspection > Carburetor Fuel Bowl Thermal Vent Valve > Page 3069 Bowl Vent Valve: Testing and Inspection Vacuum Bowl Vent Valve and Vacuum/Thermostatic Bowl Vent Valve The Vacuum Vent Valve (E3TE-9G332-AA), Figure 2 should flow air between carburetor port and canister port when no vacuum is applied to vacuum signal nipple and should not flow air with a vacuum applied at the vacuum signal nipple The above test also applies to the Vacuum/Thermostatic Vent Valve (E3EE-9G332-AA), Figure 1 when it is at a temperature of 120°F or more. At a temperature of 90°F or less the valve should not flow air, or be very restrictive to air flow. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Control Valve > Component Information > Description and Operation Canister Purge Control Valve: Description and Operation The Canister Purge Valve is part of the Evaporative Emission Control System. The valve, is in-line with the carbon canister and controls the flow of vapors from the canister to the engine. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Control Valve > Component Information > Description and Operation > Page 3073 Canister Purge Control Valve: Testing and Inspection Application of vacuum to Port B (only) should indicate no flow, valve should be closed; if not, replace valve. After applying and maintaining 54 kPa (16 in.-Hg.) vacuum to Port A, apply vacuum to Port B. Air should pass; if not, replace valve. Important: Never apply vacuum to Port(s) C. Doing so may dislodge internal diaphragm and valve will be permanently damaged. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Locations Engine View Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Locations > Page 3077 Canister Purge Solenoid: Description and Operation The canister purge solenoid is part of the Evaporative Emission Control System and is used with the Electronic Engine Control (EEC). This valve controls the flow of vapors from the carbon canister to the intake manifold during various engine operating modes. This valve controls carbon canister purging. This is a normally closed valve that is opened by a signal from the electronic control assembly (ECA). Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Locations > Page 3078 Canister Purge Solenoid: Testing and Inspection With valve de-energized, apply 5 in.-Hg. to "vacuum source" port, valve should not pass air; if it does, replace valve. While applying 9-14 volts DC to valve, the valve will open and pass air. If it does not, replace valve. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Charcoal Canister <--> [Evaporative Emission Control Canister] > Component Information > Locations Charcoal Canister: Locations Fig. 23 Evaporative emission control system. V8-351 Light Duty Fig. 24 Evaporative emission control system. V8-351 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Charcoal Canister <--> [Evaporative Emission Control Canister] > Component Information > Locations > Page 3082 Charcoal Canister: Description and Operation The fuel vapors from the fuel tank and carburetor bowl are stored in the carbon canister until the vehicle is operated, at which time, the vapors will purge from the canister into the engine for consumption. There are two canister sizes, that is, 925 ml and 1400 ml carbon. Canisters are sometimes used in pairs when the vehicle has a large fuel tank or dual tanks or dual bowls. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Charcoal Canister <--> [Evaporative Emission Control Canister] > Component Information > Locations > Page 3083 Charcoal Canister: Testing and Inspection There are no moving parts and nothing to wear in the canister. Check for loose, missing, cracked, or broken connections and parts. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Fuel Overflow Reservoir > Component Information > Description and Operation Fuel Overflow Reservoir: Description and Operation This system provides a vapor space above the gasoline surface in the fuel tank. This area is enough to permit breathing space for the tank vapor valve assembly under all static and most dynamic conditions. Horizontally mounted tanks accomplish this by a raised mounting section for the valve assembly which is centrally located on the upper surface of the tank. Vertically mounted tanks use a centrally mounted vapor valve assembly on the uppermost surface of the fuel tank. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Liquid Vapor Separator, Evaporative System > Component Information > Description and Operation Liquid Vapor Separator: Description and Operation Fig. 47 Fuel tank vapor valve All fuel tank vapor valves, Fig. 55, use a small orifice which allows only vapor and not fuel to pass into the line going to the vapor storage canister. This assembly is mounted on the fuel tank. Fuel vapors trapped in the sealed fuel tank are vented through the vapor valve assembly. The vapors leave the valve assembly through a single vapor line and continue to the charcoal canister for storage, until they are purged into the engine. On vehicles equipped with fuel/vapor return lines, vapors created in the fuel line is continuously vented back to the fuel tank. This prevents engine surging from fuel enrichment. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Thermal Vacuum Valve - EVAP > Component Information > Description and Operation Thermal Vacuum Valve - EVAP: Description and Operation Fig. 22 Ported vacuum switches & vacuum control valves Fig. 23 Electrical vacuum switch These switches, Figs. 22 and 23, used on some vehicles, control vacuum to emission components during engine warm-up.The 2-port and 4-port types open when coolant temperature reaches a predetermined value. The 3-port type switches vacuum from the center to the top or bottom ports. Electrical switches can be opened or closed until the PVS is fully cycled. All PVS units are temperature-activated and have a specific opening and closing temperature. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Thermal Vacuum Valve - EVAP > Component Information > Description and Operation > Page 3093 Thermal Vacuum Valve - EVAP: Testing and Inspection Fig. 22 Ported vacuum switches & vacuum control valves Fig. 23 Electrical vacuum switch VACUUM SWITCH TEST 1. With engine cold, turn ignition key to ``ON,'' connect vacuum gauge to port A, Figs. 22 and 23, and a vacuum source to port B and then C. There should be no vacuum flow from A to B but there should be vacuum from A to C. 2. Start engine and run until it reaches normal operating temperature, then apply vacuum to port B and then port C. There should be vacuum from A to B but no vacuum from A to C. On 4-port valve, check A1 to B1 and A2 to B2 separately. 3. If vacuum flow is not as described, replace valve. ELECTRICAL SWITCH TEST 1. Using a suitable ohmmeter, measure resistance across switch terminals with engine cold and note reading. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Thermal Vacuum Valve - EVAP > Component Information > Description and Operation > Page 3094 2. Start engine and allow to reach operating temperature, then measure resistance across switch terminals. 3. A change in resistance should be noted at cold and warm engine temperature readings. 4. Check vacuum portion of switch as described above. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Vacuum Delay Valve, EVAP > Component Information > Description and Operation Vacuum Delay Valve: Description and Operation Vacuum Delay Valves (VDV) are used for a gradual application or release of vacuum to a vacuum-operated device to help control emissions. The four valves currently in use are illustrated below with an arrow to show the direction in which air flow is restricted (Fig. 1). Note that, although each valve is named for a given system application, it may be used elsewhere. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Vacuum Delay Valve, EVAP > Component Information > Description and Operation > Page 3098 Vacuum Delay Valve: Testing and Inspection Connect a hand vacuum pump to the VDV as shown in Fig. 2 and pump. 1. Valves with one side black or white and the other side colored are good if vacuum can be built-up in one direction, but not the other direction and if that built-up vacuum can be seen to slowly decrease. 2. Valves with both sides the same color are good if vacuum can be built-up in both directions before visibly decreasing. NOTE: Exorcise care in order to prevent oil or dirt from getting into the valve. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Backpressure Transducer > Component Information > Description and Operation EGR Backpressure Transducer: Description and Operation Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Control Module > Component Information > Locations EGR Control Module: Locations Back View Of I/P On I/P, To Left Of Steering Column Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Control Solenoid > Component Information > Locations > Component Locations EGR Control Solenoid: Component Locations RH Side Of V8-351/5. Attached To LH Valve Cover Applicable to: 8L Engine With EEC-IV Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Control Solenoid > Component Information > Locations > Component Locations > Page 3110 Engine View Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Control Solenoid > Component Information > Locations > Page 3111 EGR Control Solenoid: Description and Operation EGR solenoid valve assembly (dithering type) Dithering Type The dual EGR solenoid valve assembly consists of two dithering solenoid valves. One is a vacuum valve which supplies vacuum to the sonic EGR valve when energized. The second valve is a vent valve which vents the EGR valve to the atmosphere when de-energized. Both solenoid valves receive variable duty cycle signals from ECU (EEC IV) according to EGR requirements. A restrictor is added in vacuum valve inlet port to reduce its flow compared to vent valve. So in case vacuum valve sticks open, the vent valve will be capable of venting the vacuum flow immediately without affecting the devices being controlled. It is used with the EGR valve in EEC IV systems. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Control Solenoid > Component Information > Locations > Page 3112 EGR Control Solenoid: Testing and Inspection The resistance of each solenoid should be between 32 and 64 ohms. If the solenoid is not within these values, the solenoid should be replaced. The vent valve should flow when the solenoid is de-energized. The control valve should flow air when the solenoid is energized. For additional information, Refer to Powertrain Management/Computers and Control Systems/System Diagnosis NOTE: The valves can be expected to have a very small leakage rate when energized or de-energized. This leakage is not measurable in the field and is not detrimental to valve function. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Vacuum Regulator Solenoid <--> [EGR Electronic Vacuum Regulator Solenoid] > Component Information > Locations EGR Vacuum Regulator Solenoid: Locations RH Side Of V8-351/5. Attached To LH Valve Cover Applicable to: 8L Engine With EEC-IV Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Vacuum Regulator Solenoid <--> [EGR Electronic Vacuum Regulator Solenoid] > Component Information > Locations > Page 3116 EGR Vacuum Regulator Solenoid: Description and Operation EGR solenoid valve assembly (dithering type) Dithering Type The dual EGR solenoid valve assembly consists of two dithering solenoid valves. One is a vacuum valve which supplies vacuum to the sonic EGR valve when energized. The second valve is a vent valve which vents the EGR valve to the atmosphere when de-energized. Both solenoid valves receive variable duty cycle signals from ECU (EEC IV) according to EGR requirements. A restrictor is added in vacuum valve inlet port to reduce its flow compared to vent valve. So in case vacuum valve sticks open, the vent valve will be capable of venting the vacuum flow immediately without affecting the devices being controlled. It is used with the EGR valve in EEC IV systems. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Vacuum Regulator Solenoid <--> [EGR Electronic Vacuum Regulator Solenoid] > Component Information > Locations > Page 3117 EGR Vacuum Regulator Solenoid: Testing and Inspection The resistance of each solenoid should be between 32 and 64 ohms. If the solenoid is not within these values, the solenoid should be replaced. The vent valve should flow when the solenoid is de-energized. The control valve should flow air when the solenoid is energized. For additional information, Refer to Powertrain Management/Computers and Control Systems/System Diagnosis NOTE: The valves can be expected to have a very small leakage rate when energized or de-energized. This leakage is not measurable in the field and is not detrimental to valve function. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Filter > Component Information > Description and Operation EGR Filter: Description and Operation The EGR vacuum control valve filter is used to vent various emission control components to atmosphere. If the filter is blocked, replace it. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Maintenance Light > Component Information > Locations EGR Maintenance Light: Locations Back View Of I/P On I/P, To Left Of Steering Column Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Description and Operation > EGR Valve - Electronic EGR Valve: Description and Operation EGR Valve - Electronic The Electronic EGR Valve, is required in EEC systems where EGR flow is controlled according to computer demands by means of an EGR valve position (EVP) sensor attached to the valve. The valve is operated by a vacuum signal from the dual EGR Solenoid Valves (9D474) or the electronic vacuum regulator (9J459) which actuates the valve diaphragm. As supply vacuum overcomes the spring load the diaphragm is actuated which lifts the pintle off its seat allowing exhaust gas to recirculate (flow). The amount of flow is proportional to the pintle position The EVP sensor mounted on the valve sends an electrical signal of its position to the Electronic Control Assembly (12A650). The Electronic EGR Valve Assembly (9F483) is not serviceable. The EVP sensor (9G428) and EGR valve (9H473) must be serviced separately. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Description and Operation > EGR Valve - Electronic > Page 3128 EGR Valve: Description and Operation EGR Valve - Integral Backpressure Transducer The Integral backpressure transducer EGR valve combines inputs of backpressure and EGR port vacuum into one unit. The valve requires BOTH inputs to operate. The valve will not operated on vacuum alone. The backpressure valve has two types; poppet and tapered pintle. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Description and Operation > EGR Valve - Electronic > Page 3129 EGR Valve: Description and Operation EGR Valve - Ported The ported EGR Valve is operated by a vacuum signal (only) from the carburetor EGR port signal which actuates the valve diaphragm. As the vacuum increases sufficiently to overcome the power spring, the valve is opened allowing EGR flow. The amount of flow is dependent on the tapered pintle or the poppet position which is a direct result of vacuum signal. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Description and Operation > EGR Valve - Electronic > Page 3130 EGR Valve: Description and Operation EGR Valve and Transducer Assembly The Valve and Transducer Assembly (9H495) which consists of a modified ported EGR valve and a remote transducer, is used on selected 2.0/2.3L engines. This assembly operates the same as the Integral Backpressure Transducer EGR Valve (9D448) and is diagnosed and serviced as an assembly only. Valve function checks are the same as those for the Integral Backpressure Transducer EGR Valve. When servicing the assembly or any related vacuum harness, it is important to ensure proper orientation of the transducer. The nipple of the transducer attached to the metal tube from the EGR valve base must point straight down after installation. This allows drainage of exhaust gas condensation that may accumulate. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Description and Operation > EGR Valve - Electronic > Page 3131 EGR Valve: Description and Operation Pressure Feedback Electronic EGR Valve The Pressure Feedback Electronic (PFE) EGR valve is a conventional ported EGR valve with a backpressure sensing to be attached to it. The valve is used in conjunction with a pressure transducer (9F460) which supplies valve position feedback to the EEC IV processor. The EGR flow rate is proportional to the pressure drop across a remotely mounted sharp edged orifice. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Testing and Inspection > Backpressure Variable Transducer (BVT) System EGR Valve: Testing and Inspection Backpressure Variable Transducer (BVT) System 1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked, crimped or broken hoses. 2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating temperature. 3. Install a tachometer. 4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (EFI engines only). 5. Remove vacuum supply hose from the EGR valve nipple. Plug the hose. 6. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If necessary, adjust idle speed to the emission decal specification. 7. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand vacuum pump. 8. When vacuum is applied to the EGR valve and any of the following occur, replace the valve: ^ Engine does not install. ^ Idle speed does not drop more than 100 rpm. ^ Idle speed does not return to normal (± 25 rpm) after the vacuum is removed. 9. Reconnect the idle air bypass valve electrical connector. 10. Unplug and reconnect the EGR vacuum supply hose. 11. Disconnect the vacuum connection at he 9J431 Backpressure Variable Transducer (BVT). 12. Gently blow into the hose to Port C until the relief valve closes and at the same time apply 5-10 inches of mercury vacuum to Port E with a hand vacuum pump. Port E should hold vacuum as long as there is pressure on Port C. 13. Apply a minimum of 5-10 inches of mercury vacuum to Ports B and C using a hard vacuum pump Ports B and C should hold vacuum. 14. Replace the BVT if any of the Ports do not hold vacuum. 15. Reconnect the vacuum at the BVT. 16. If neither the EGR valve nor the BVT were replaced, the system is OK. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Testing and Inspection > Backpressure Variable Transducer (BVT) System > Page 3134 EGR Valve: Testing and Inspection Electronic Valve 1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked, crimped or broken hoses. 2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating temperature. 3. Install a tachometer 4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (EFI engines only). 5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose. 6. Disconnect the 9G428 EVP sensor electrical connector mounted on top of the 9H473 valve. 7. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If necessary, adjust idle speed to the emission decal specification. 8. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand vacuum pump. 9. When vacuum is applied to the EGR valve and any of the following occur, replace the valve. Engine does not stall. Idle speed does not drop more than 100 rpm. Idle speed does not return to normal (±25 rpm) after the vacuum is removed. 10. Reconnect the idle air bypass valve electrical connector. 11. Unplug ana reconnect the EGR vacuum supply hose. 12. Reconnect the EVP sensor electrical connector. 13. The EGR valve is OK, REPLACE EVP sensor if the Continuous Code 32 was present. If the Continuous Code 32 was not present, refer to Powertrain Management/Computers and Control Systems/System Diagnosis Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Testing and Inspection > Backpressure Variable Transducer (BVT) System > Page 3135 EGR Valve: Testing and Inspection Integral Backpressure Transducer EGR Valve 1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked, crimped or broken hoses. 2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating temperature. 3. Install a tachometer. 4. Plug the tailpipe(s) to increase the exhaust system backpressure, leaving a 1/2-inch diameter opening to allow exhaust gases to escape. 5. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (EFI engines only). 6. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose. 7. Start engine, idle with transmission in NEUTRAL, and observe idle speed. If necessary, adjust idle speed to the emission decal specification. 8. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand Vacuum pump. 9. When vacuum is applied to the EGR valve and any of the following occur, replace the valve: ^ Engine does not stall. ^ Idle speed does not drop more than 100 rpm. ^ Idle speed does not return to normal (± 25 rpm) after the vacuum is removed. 10. If the EGR valve is not replaced, reconnect the idle air bypass valve electrical connector. 11. Unplug and reconnect the EGR vacuum supply hose. 12. Remove the tailpipe plug(s). 13. The EGR system is OK. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Testing and Inspection > Backpressure Variable Transducer (BVT) System > Page 3136 EGR Valve: Testing and Inspection Ported EGR Valve 1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked crimped or broken hoses. 2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating temperature. 3. Install a tachometer. 4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (EFI engines only). 5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose. 6. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If necessary, adjust idle speed to the emission decal specification. 7. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand vacuum pump. 6. When vacuum is applied to the EGR valve and any of the following occur, replace the valve: ^ Engine does not stall. ^ Idle speed does not drop more than 100 rpm. ^ Idle speed does not return to normal (±25 rpm) after the vacuum is removed. 9. Reconnect the idle air bypass valve electrical connector. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Testing and Inspection > Backpressure Variable Transducer (BVT) System > Page 3137 10. Unplug and reconnect the EGR vacuum supply hose. 11. The EGR system is OK. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Testing and Inspection > Backpressure Variable Transducer (BVT) System > Page 3138 EGR Valve: Testing and Inspection Valve and Transducer Assembly 1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked, crimped or broken hoses. 2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating temperature. 3. Install a tachometer. 4. Plug the tailpipe(s) to increase the exhaust system backpressure, leaving a 1/2-inch diameter opening to allow exhaust gases to escape. 5. Remove the vacuum supply hose from the exhaust backpressure transducer nipple and plug the hose. Do not disconnect the transducer from the EGR valve. 6. Start engine idle with transmission in NEUTRAL, and observe the engine idle speed. If necessary, adjust idle speed to the emission decal specification. 7. Slowly apply 5-10 inches of mercury vacuum to the Backpressure Transducer vacuum nipple using a hand vacuum pump. 8. When vacuum is applied to the Backpressure Transducer and any of the following occur, replace the valve: ^ Engine does not stall. ^ Idle speed does not drop more than 100 rpm. ^ Idle speed does not return to normal (±25 rpm) after the vacuum is removed. 9. Unplug and reconnect the vacuum .supply hose to the exhaust backpressure transducer. 10. Remove the tailpipe plug(s). 11. The EGR system is OK. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision Technical Service Bulletin # 8918A9 Date: 890915 EVP Sensor - Manual Revision ENGINE EMISSIONS DIAGNOSTIC MANUALS, VOLUME H - 1985 THROUGH 1989 - EGR VALVE POSITION SENSOR (EVP) DIAGNOSTIC PROCEDURES REVISED Article No. 89-18A-9 FORD: 1985-89 CROWN VICTORIA, ESCORT 1985-88 EXP 1985-86 LTD 1985-89 MUSTANG, TEMPO, THUNDERBIRD 1986-89 TAURUS 1988-89 FESTIVA 1989 PROBE LINCOLN-MERCURY: 1985-86 CAPRI 1985-89 CONTINENTAL, COUGAR, GRAND MARQUIS 1985-87 LYNX 1985-89 MARK VII 1985-86 MARQUIS 1985-89 TOPAZ, TOWN CAR 1986-89 SABLE 1987-89 TRACER MERKUR: 1986-89 XR4TI 1988-89 SCORPIO LIGHT TRUCK: 1985-89 BRONCO, BRONCO II, ECONOLINE, F-150, F-250, F-350, RANGER 1986-89 AEROSTAR ISSUE: The EGR Valve Position Sensor (EVP) diagnostic procedures in 1985 through 1989 Engine Emissions Diagnosis Shop Manuals, Volume H, have been revised. EVP Sensors may exhibit internal wear problems that can cause driveability symptoms and display a Continuous Self-Test Code 32. This is not associated to correcting the problem using the existing diagnostic procedures. ACTION: Refer to the pages following this TSB article for the revised diagnostic procedures. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 680000 1985 Pinpoint Tests - DM - EGR, EVP and EVR Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 3143 1985 EEC IV - Pinpoint Tests - All Vehicles 22-77 EGR Valve Position Sensor (EVP) EGR Valve Regulator (EVR) Pinpoint DM Test 1985 Pinpoint Tests - Fa - Neutral Drive Switch -A/C Input Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 3144 1985 22-78 EEC IV - Pinpoint Tests - All Vehicles Neutral Drive Switch FA A/C Input PinpointTest 1986 (EGR) Systems Functional Diagnosis 1986 Exhaust Gas Recirculation (EGR) Systems 6-11 Functional Diagnosis Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 3145 PORTED EGR VALVE 1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked, crimped or broken hoses. 2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating temperature. 3. Install a tachometer. 4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (EFI engines only). 5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose. 6. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If necessary, adjust idle speed to the emission decal specification. 7. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand vacuum pump. 8. When vacuum is applied to the EGR valve and any of the following occur, replace the valve: ^ Engine does not stall. ^ Idle speed does not drop more than 100 rpm. ^ Idle speed does not return to normal (+/- 25 rpm) after the vacuum is removed. 9. Reconnect the idle air bypass valve electrical connector. 10. Unplug and reconnect the EGR vacuum supply hose. 11. The EGR system is OK, refer to the Diagnostic Routines in Section 2. 1986 6-12 Exhaust Gas Recirculation (EGR) Systems Functional Diagnosis ELECTRONIC VALVE 1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked, crimped or broken hoses. 2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating temperature. 3. Install a tachometer. 4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (EFI engines only). Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 3146 5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose. 6. Disconnect the 9G428 EVP sensor electrical connector mounted on top of the 9H473 valve. 7. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If necessary, adjust idle speed to the emission decal specification. 8. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand vacuum pump. 9. When vacuum is applied to the EGR valve and any of the following occur, replace the valve: ^ Engine does not stall. ^ Idle speed does not drop more than 100 rpm. ^ Idle speed does not return to normal (+/- 25 rpm) after the vacuum is removed. 10. Reconnect the idle air bypass valve electrical connector. 11. Unplug and reconnect the EGR vacuum supply hose. 12. Reconnect the EVP sensor electrical connector. 13. The EGR valve is OK, REPLACE EVP sensor if the Continuous Code 32 was present. If the Continuous Code 32 was not present, refer to the Diagnostic Routines in Section 2. 1986 Quick Test: Continuous Self-Test 6.0 EEC IV - Quick Test - All Engines 18-13 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 3147 QUICK TEST: Continuous Self-Test 6.0 1986 18-14 EEC IV-Quick Test-All Engines QUICK TEST: Continuous Self-Test 6.0 Pinpoint Test - DN - EGR - EVP & EVR Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 3148 1986 EEC IV-Pinpoint Tests - All Vehicles 21-95 EGR Valve Position Sensor (EVP) PinpointTest DN EGR Valve Regulator (EVR) Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 3149 21-96 1986 EEC IV-Pinpoint Tests-All Vehicles EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Valve Regulator (EVR) Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 3150 EEC IV-Pinpoint Tests-All Vehicles 1986 21-97A EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Valve Regulator (EVR) Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 3151 1986 21-97B EEC IV-Pinpoint Tests-All Vehicles EGR Valve Position Sensor (EVP) EGR Valve Regulator (EVR) Pinpoint Test DN Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 3152 1986 EEC IV-Pinpoint Tests-All Vehicles 21-98 EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Valve Regulator (EVR) 1987 (EGR) Systems - Functional Diagnosis 1987 6-11 Exhaust Gas Recirculation (EGR) Systems Functional Diagnosis PORTED EGR VALVE 1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked, crimped or broken hoses. 2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating temperature. 3. Install a tachometer, Rotunda 059-00010 or equivalent. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 3153 4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (EFI engines only). 5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose. 6. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If necessary, adjust idle speed according to Section 4. 7. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand vacuum pump, Rotunda 021-00014 or equivalent. 8. When vacuum is applied to the EGR valve and any of the following occur, replace the valve: ^ Engine does not stall. ^ Idle speed does not drop more than 100 rpm. ^ Idle speed does not return to normal (+/- 25 rpm) after the vacuum is removed. 9. Reconnect the idle air bypass valve electrical connector. 10. Unplug and reconnect the EGR vacuum supply hose. 11. The EGR system is OK, refer to the Diagnostic Routines in Section 2. 1987 6-12 Exhaust Gas Recirculation (EGR) Systems Functional Diagnosis ELECTRONIC EGR (EEGR) VALVE 1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked, crimped or broken hoses. 2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating temperature. 3. Install a tachometer, Rotunda 059-00010 or equivalent. 4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (EFI engines only). 5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose. 6. Disconnect the 9G428 EVP sensor electrical connector mounted on top of the 9H473 valve. 7. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If necessary, adjust idle speed according to Section 4. 8. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand vacuum pump, Rotunda 021-00014 or equivalent. 9. When vacuum is applied to the EGR valve and any of the following occur, replace the valve: ^ Engine does not stall. ^ Idle speed does not drop more than 100 rpm. ^ Idle speed does not return to normal (+/- 25 rpm) after the vacuum is removed. 10. Reconnect the idle air bypass valve electrical connector. 11. Unplug and reconnect the EGR vacuum supply hose. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 3154 12. Reconnect the EVP sensor electrical connector. 13. The EGR valve is OK, REPLACE EVP sensor if the Continuous Code 32 was present. If the Continous Code 32 was not present, refer to the Diagnostic Routines in Section 2. 1987 Quick Test: Continuous Self-Test - 6.0 1987 EEC-IV Quick Test-All Engines 16-15 QUICK TEST: Continuous 6.0 Self-Test Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 3155 16-16 1987 EEC-IV Quick Test-All Engines QUICK TEST: Continuous 6.0 Self-Test Pinpoint Test - DN - EGR - EVP & EVR 1987 EEC IV - Pinpoint Tests - All Vehicles 19-91 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 3156 EGR VALVE Position Sensor (EVP) EGR Valve Regulator (EVR) - 2.3L HSC, 2.5L, 5.0L SEFI Passenger Car and 4.9L and 5.0L Truck Pinpoint Test DN 19-92A 1987 EEC IV Pinpoint Tests-All Vehicles EGR Valve Position Sensor (EVP) EGR Valve Regulator (EVR) - 2.3L HSC, 2.5L, Pinpoint Test DN 5.0L SEFI Passenger Car and 4.9L and 5.0L Truck Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 3157 1987 EEC IV-Pinpoint Tests-All Vehicles 19-92B EGR Valve Position Sensor (EVP) EGR Valve Regulator (EVR) - 2.3L HSC, 2.5L, 5.0L SEFI Passenger Car and 4.9L and 5.0L Truck Pinpoint Test DN Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 3158 1987 19-93-A EEC IV-Pinpoint Tests-All Vehicles EGR Valve Position Sensor (EVP) EGR Valve Regulator (EVR) - 2.3L HSC, 2.5L, 5.0L SEFI Passenger Car 4.9L and 5.0L Truck Pinpoint Test DN Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 3159 EEC IV-Pinpoint Tests-All Vehicles 1987 19-94 EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Valve Regulator (EVR) (EGR) Systems - Functional Diagnosis 1988 Exhaust Gas Recirculation (EGR) Systems 6-11 Functional Diagnosis Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 3160 PORTED EGR VALVE 1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked, crimped or broken hoses. 2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating temperature. 3. Install a tachometer, Rotunda 059-00010 or equivalent. 4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (EFI engines only). 5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose. 6. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If necessary, adjust idle speed according to Section 4. 7. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand vacuum pump, Rotunda 021-00014 or equivalent. 8. When vacuum is fully applied to the EGR valve: ^ If idle speed drops more than 100 rpm or if engine stalls, perform the next step. Otherwise, replace the EGR valve. ^ Remove the vacuum from the EGR valve. If idle speed does not return to normal (+/- 25 rpm), replace the EGR valve. 9. Reconnect the idle air bypass valve electrical connector. 10. Unplug and reconnect the EGR vacuum supply hose. 11. The EGR system is OK, refer to the Diagnostic Routines in Section 2. 6-12 1988 Exhaust Gas Recirculation (EGR) Systems Functional Diagnosis ELECTRONIC EGR (EEGR) VALVE 1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked, crimped or broken hoses. 2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating temperature. NOTE: The EVR solenoid has a constant internal leak. You will notice a small vacuum signal. This signal should be less than 2-1/2 in-Hg at idle. 3. Install a tachometer, Rotunda 059-00010 or equivalent. 4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (1.9L EFI engines only). 5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose. 6. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If necessary, adjust idle speed according to Section 4. 7. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand vacuum pump, Rotunda 021-00014 or equivalent. 8. When vacuum is applied to the EGR valve and any of the following occur, replace the valve: ^ Engine does not stall. ^ Idle speed does not drop more than 100 rpm. ^ Idle speed does not return to normal (+/- 25 rpm) after the vacuum is removed. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 3161 9. Reconnect the idle air bypass valve electrical connector. 10. Unplug and reconnect the EGR vacuum supply hose. 11. The EGR is OK, REPLACE EVP sensor if the Continuous Code 32 was present. If the Continuous Code 32 was not present, refer to the Diagnostic Routines in Section 2. Quick Test:Continuous Self-Test - 6.0 1988 EEC-IV - Quick Test - All Engines 16-15 QUICK TEST: Continuous Self-Test 6.0 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 3162 1988 16-16 EEC-IV - Quick Test - All Engines QUICK TEST: Continuous 6.0 Self-Test Pinpoint Test - DN - EGR - EVP & EVR Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 3163 EEC-IV - Pinpoint Tests - All Vehicles 1988 19-101 EGR Valve Position Sensor (EVP) EGR Valve Regulator (EVR) Pinpoint Test DN Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 3164 19-102 1988 EEC-IV - Pinpoint Tests - All Vehicles EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Valve Regulator (EVR) Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 3165 1988 EEC-IV - Pinpoint Tests - All Vehicles 19-102A EGR Valve Position Sensor (EVP) EGR Valve Regulator (EVR) Pinpoint Test DN Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 3166 1988 19-103 EEC-IV - Pinpoint Tests - All Vehicles EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Valve Regulator (EVR) Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 3167 1988 EEC-IV - Pinpoint Tests - All Vehicles 19-104 EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Valve Regulator (EVR) (EGR) Systems - Functional Diagnosis 1989 6-11 Exhaust Gas Recirculation (EGR) Systems Functional Diagnosis Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 3168 PORTED EGR VALVE 1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked, crimped or broken hoses. 2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating temperature. 3. Install a tachometer, Rotunda 059-00010 or equivalent. 4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (EFI engines only). 5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose. 6. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If necessary, adjust idle speed according to Section 4. 7. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand vacuum pump, Rotunda 021-00014 or equivalent. 8. When vacuum is fully applied to the EGR valve: ^ If idle speed drops more than 100 rpm or if engine stalls, perform the next step. Otherwise, for vacuum leak at EGR valve, replace the valve. ^ If EGR passages are blocked, clean the valve using Rotunda 021-80056 EGR valve cleaner. ^ Remove the vacuum from the EGR valve. If idle speed does not return to normal (+/- 25 rpm), check for contamination, clean the valve. ^ Make sure there is no sand left in the valve or pick-up tube. Replace the valve if necessary. 9. Reconnect the idle air bypass valve electrical connector. 10. Unplug and reconnect the EGR vacuum supply hose. 11. The EGR system is OK, refer to the Diagnostic Routines in Section 2. 1989 6-12 Exhaust Gas Recirculation (EGR) Systems Functional Diagnosis ELECTRONIC EGR (EEGR) VALVE 1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked, crimped or broken hoses. 2. Make certain there is less than 2.5 in-Hg vacuum to the EGR valve at idle with the engine at normal operating temperature. NOTE: The EVR solenoid has a constant internal leak. You will notice a small vacuum signal. This signal should be less than 1.0 in-Hg at idle. 3. Install a tachometer, Rotunda 059-00010 or equivalent. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 3169 4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (1.9L EFI engines only). 5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose. 6. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If necessary, adjust idle speed according to Section 4. 7. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand vacuum pump, Rotunda 021-00014 or equivalent. 8. When vacuum is applied to the EGR valve and any of the following occur: ^ Engine does not stall ^ Idle speed does not drop more than 100 rpm ^ Idle speed does not return to normal (+/- 25 rpm) after the vacuum is removed Then: ^ For vacuum leak at EGR valve, replace the valve. ^ Check for contamination, clean the EGR valve, using Rotunda 021-80056 EGR valve cleaner or equivalent. ^ Make sure there is no sand left in the valve. ^ Replace the EGR valve if necessary. 9. Reconnect the idle air bypass valve electrical connector. Unplug and reconnect the EGR vacuum supply hose. 10. If EGR valve is OK, REPLACE EVP sensor if Continuous Code 32 was present. If the Continuous Code 32 was not present, refer to the Diagnostic Routines in Section 2. Quick Test:Continuous Self-Test - 6.0 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 3170 1989 EEC-IV - Quick Test - All Engines 14-17 QUICK TEST: Continuous 6.0 Self-Test Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 3171 1989 14-18 EEC-IV - Quick Test - All Engines QUICK TEST: Continuous 6.0 Self-Test 1989 EEC-IV - Quick Test - All Engines 14-19 QUICK TEST: Continuous 6.0 Self-Test Quick Test:Diagnostic By Symptom - 7.0 1989 14-20 EEC-IV - Quick Test - All Engines QUICK TEST: Diagnostic By Symptom 7.0 A DIAGNOSTIC BY SYMPTOM SPECIAL NOTES: ^ Verify that a Pass Code 11 was received in Key On Engine Off, Engine Running and Continuous Self-Tests before continuing with this test. ^ If a symptom is present and the EEC system is suspected, Go to part B of Diagnostic By Symptom. If the EEC system is not suspected, GO to Section 2, Diagnostic Routines. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 3172 Pinpoint Test - DN - EGR - EVP & EVR 1989 EEC-IV - Pinpoint Tests-All Vehicles 17-133 EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Vacuum Regulator Solenoid (EVR) Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 3173 1989 17-134 EEC-IV - Pinpoint Tests - All Vehicles EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Vacuum Regulator Solenoid (EVR) Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 3174 1989 EEC-IV-Pinpoint Tests - All Vehicles 17-134A Pinpoint Test DN EGR Valve Position Sensor (EVP) EGR Vacuum Regulator Solenoid (EVR) Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 3175 1989 17-135 EEC-IV - Pinpoint Tests - All Vehicles EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Vacuum Regulator Solenoid (EVR) Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 3176 1989 EEC-IV - Pinpoint Tests - All Vehicles 17-136A EGR Valve Position Sensor (EVP) 04GPinpoint Test DN EGR Vacuum Regulator Solenoid (EVR) Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > Page 3177 EGR Valve Position Sensor: Locations Attached To EGR Valve Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > Page 3178 EGR Valve Position Sensor: Description and Operation The EVP Sensor provides EEC System with a signal indicating position of the EGR valve. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Wide Open Throttle Valve > Component Information > Description and Operation EGR Wide Open Throttle Valve: Description and Operation This valve dumps EGR vacuum at or near WOT. The normal path between Ports A and B is vented to atmosphere when sufficient vacuum is applied to Port C Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Wide Open Throttle Valve > Component Information > Description and Operation > Page 3182 EGR Wide Open Throttle Valve: Testing and Inspection Functional Check ^ With the engine running at normal operating temperature, set throttle on kickdown step (high cam for 2.3L). ^ Connect a vacuum gauge to the EGR side of the WOT valve, and note the reading. ^ Apply a vacuum of at least 20.26 kPa (6 in-Hg) to the WOT venturi port (Port C). ^ Gauge should drop to zero. If not, replace the valve. ^ Remove test equipment, and restore connections. Functional Check (Adjustment) Adjust so that hand pump vacuum at the vacuum nipple will drop when WOT is approached without limiting throttle travel. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Exhaust Pressure Regulator Vacuum Valve, EGR > Component Information > Description and Operation Exhaust Pressure Regulator Vacuum Valve: Description and Operation The Electronic Vacuum Regulator (EVR) is an electromagnetic device which controls vacuum out-put to the EGR valve. The EVR replaces the EGR Solenoid Vacuum Vent Valve Assembly (9D474). An electric current in the coil induces a magnetic field in the armature. The magnetic field pushes against a spring loaded disc increasing the vacuum level. The vacuum source is either manifold or port vacuum. As the current is increased an increased vacuum signal goes to the EGR. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Exhaust Pressure Regulator Vacuum Valve, EGR > Component Information > Description and Operation > Page 3186 Exhaust Pressure Regulator Vacuum Valve: Testing and Inspection Ford provides trouble code/symptom driven diagnostics for this component. For complete diagnosis and pinpoint testing, refer to Computers and Control Systems, System Diagnosis. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure Feedback Exhaust Sensor, EGR > Component Information > Description and Operation Pressure Feedback Exhaust Sensor: Description and Operation The Pressure Feedback Electronic (PFE) EGR transducer converts a varying exhaust pressure signal into a proportional analog voltage which is digitized by the EEC IV processor. The EEC IV processor uses the signal received from the PFE transducer to complete the optimum EGR flow. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Thermal Vacuum Valve, EGR > Component Information > Technical Service Bulletins > Customer Interest for Thermal Vacuum Valve: > 86631 > Mar > 86 > Engine - Hesitation/Stumble On Cold Start Driveaway Thermal Vacuum Valve: Customer Interest Engine - Hesitation/Stumble On Cold Start Driveaway Article No. 86-6-31 HESITATION/STUMBLE (5.8L(W)) - DURING COLD START DRIVEAWAY CALIBRATION 4-64Z-R14 LIGHT TRUCK 1986 E, F SERIES, BRONCO The subject concerns may be caused by an incorrect EGR vacuum control valve. For servicing the concerns, the following procedure is recommended: 1. Drain cooling system to level that will allow removal of EGR vacuum control valve (color: black). Discard the valve. 2. Obtain EGR vacuum control valve (part number E3TZ-9D473-A) and install. The valve is blue in color. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Thermal Vacuum Valve, EGR > Component Information > Technical Service Bulletins > Customer Interest for Thermal Vacuum Valve: > 86631 > Mar > 86 > Engine - Hesitation/Stumble On Cold Start Driveaway > Page 3198 Figure 26 3. Valve is to be installed in water heater elbow and torqued to 6-10 ft.lbs (8.1-13.6 N-m). Then rotate clockwise in installed position, not more than one full turn (see Figure 26 for valve orientation). 4. Fill cooling system to specification. 5. Start engine and check for coolant and vacuum leaks. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Thermal Vacuum Valve, EGR > Component Information > Technical Service Bulletins > Customer Interest for Thermal Vacuum Valve: > 86631 > Mar > 86 > Engine - Hesitation/Stumble On Cold Start Driveaway > Page 3199 Obtain an Authorized Modifications Decal and list the date, dealer number, and summary of alterations performed. Select a prominent place adjacent to the Vehicle Emission Control Information Decal suitable for installing the Authorized Modifications Decal. Clean the area, install the decal, and cover it with a clear plastic decal shield. PART NUMBER PART NAME CLASS E3TZ-9D473-A EGR Vacuum Control AG Valve OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION: SP9473A86 TIME: 0.4 Hr. DLR. CODING: Basic Part No. 9D473 - Code: K2 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Thermal Vacuum Valve, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Thermal Vacuum Valve: > 86631 > Mar > 86 > Engine - Hesitation/Stumble On Cold Start Driveaway Thermal Vacuum Valve: All Technical Service Bulletins Engine - Hesitation/Stumble On Cold Start Driveaway Article No. 86-6-31 HESITATION/STUMBLE (5.8L(W)) - DURING COLD START DRIVEAWAY CALIBRATION 4-64Z-R14 LIGHT TRUCK 1986 E, F SERIES, BRONCO The subject concerns may be caused by an incorrect EGR vacuum control valve. For servicing the concerns, the following procedure is recommended: 1. Drain cooling system to level that will allow removal of EGR vacuum control valve (color: black). Discard the valve. 2. Obtain EGR vacuum control valve (part number E3TZ-9D473-A) and install. The valve is blue in color. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Thermal Vacuum Valve, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Thermal Vacuum Valve: > 86631 > Mar > 86 > Engine - Hesitation/Stumble On Cold Start Driveaway > Page 3205 Figure 26 3. Valve is to be installed in water heater elbow and torqued to 6-10 ft.lbs (8.1-13.6 N-m). Then rotate clockwise in installed position, not more than one full turn (see Figure 26 for valve orientation). 4. Fill cooling system to specification. 5. Start engine and check for coolant and vacuum leaks. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Thermal Vacuum Valve, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Thermal Vacuum Valve: > 86631 > Mar > 86 > Engine - Hesitation/Stumble On Cold Start Driveaway > Page 3206 Obtain an Authorized Modifications Decal and list the date, dealer number, and summary of alterations performed. Select a prominent place adjacent to the Vehicle Emission Control Information Decal suitable for installing the Authorized Modifications Decal. Clean the area, install the decal, and cover it with a clear plastic decal shield. PART NUMBER PART NAME CLASS E3TZ-9D473-A EGR Vacuum Control AG Valve OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION: SP9473A86 TIME: 0.4 Hr. DLR. CODING: Basic Part No. 9D473 - Code: K2 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Vacuum Amplifier, EGR > Component Information > Description and Operation Vacuum Amplifier: Description and Operation The EGR Venturi Vacuum Amplifier (Figs. 1 and 2) uses a relatively weak venturi vacuum to control a manifold vacuum signal to operate the EGR valve. It contains a check valve and a relief valve that opens whenever the venturi vacuum signal is equal to or greater than manifold vacuum Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Vacuum Amplifier, EGR > Component Information > Description and Operation > Page 3210 Vacuum Amplifier: Testing and Inspection Conditions ^ Normally warm engine. ^ Proper Curb Idle. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Vacuum Amplifier, EGR > Component Information > Description and Operation > Page 3211 ^ Adequate Manifold Vacuum. Test ^ Connect a vacuum gauge to the hose at the EGR Port O. The gauge may read as much as 6.8 kPa(2 in-Hg) at idle. ^ Disconnect the venturi hose at the carburetor, and increase engine speed to 2000 rpm. Vacuum should not change. ^ Maintain high engine speed, and connect venturi hose. Gauge should register at least 13.5 kPa (4 in-Hg). ^ Return to idle. Gauge should return to initial reading. ^ If the above conditions are not met, replace the VVA. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Hot Idle Compensator (Non Comp. Controlled) > Component Information > Technical Service Bulletins > Customer Interest for Hot Idle Compensator (Non Comp. Controlled): > 871913 > Sep > 87 > Engine - Hard Start After Hot Soak Hot Idle Compensator (Non Comp. Controlled): Customer Interest Engine - Hard Start After Hot Soak HARD START AFTER HOT SOAK - Article No. 5.8L AND 7.5L ENGINE WITH HOLLEY 87-19-13 4V CARBURETOR - OVER 8500 LBS. GVW LIGHT TRUCK: 1983-87 E SERIES, F SERIES ISSUE: Hard starting at normal engine operating temperature after a 15 to 60 minute hot soak may be caused by fuel vapor getting to the engine through the fuel bowl and evaporative emissions system. The fuel vapor will cause an over-rich engine during restart. Volatility of gasoline may also cause increased amounts of vapor when gasoline is warm. The affected vehicles are 1984-87 E and F Series with a 5.8L engine and Holley 4V carburetor and 1983-87 E and F Series with a 7.5L engine and Holley 4V carburetor. ACTION: To correct this, install a Hot Idle Compensator (HIC) valve using the following service procedure. 5.8L Engine NOTE: Use original production PCV line. Figure 10 1. Assemble HIC valve (E1TZ-9B532-A) and Tee (379507-S), Figure 10. 2. Install the HIC valve in the PCV line, Figure 10. NOTE: Position the HIC valve in the PCV line over exhaust heat cross-over and under spark plug wires. 7.5L Engine 1. Remove steel PCV line. 2. Install a new PCV line (E6HZ-6A664-A). The new PCV line fits from the PCV valve to the front of the carburetor. PCV line must be routed along the right rocker arm cover under spark plug wires. 3. Assemble HIC valve (E1TZ-9B532-A) and Tee (379507-S), Figure 10. 4. Install HIC valve in the PCV line, Figure 10. NOTE: Position the HIC valve in the PCV line over exhaust heat cross-over and under spark plug wires. PART NUMBER PART NAME CLASS Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Hot Idle Compensator (Non Comp. Controlled) > Component Information > Technical Service Bulletins > Customer Interest for Hot Idle Compensator (Non Comp. Controlled): > 871913 > Sep > 87 > Engine - Hard Start After Hot Soak > Page 3220 E1TZ-9B532-A HIC Valve C 379507-S Tee RS E6HZ-6A664-A PCV Line CQ OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION: SP871913A TIME: 0.4 Hr. - F Series 0.6 Hr. - Econoline DLR. CODING: Basic Pan No. 9510 - Code: H5 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Hot Idle Compensator (Non Comp. Controlled) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hot Idle Compensator (Non Comp. Controlled): > 871913 > Sep > 87 > Engine - Hard Start After Hot Soak Hot Idle Compensator (Non Comp. Controlled): All Technical Service Bulletins Engine - Hard Start After Hot Soak HARD START AFTER HOT SOAK - Article No. 5.8L AND 7.5L ENGINE WITH HOLLEY 87-19-13 4V CARBURETOR - OVER 8500 LBS. GVW LIGHT TRUCK: 1983-87 E SERIES, F SERIES ISSUE: Hard starting at normal engine operating temperature after a 15 to 60 minute hot soak may be caused by fuel vapor getting to the engine through the fuel bowl and evaporative emissions system. The fuel vapor will cause an over-rich engine during restart. Volatility of gasoline may also cause increased amounts of vapor when gasoline is warm. The affected vehicles are 1984-87 E and F Series with a 5.8L engine and Holley 4V carburetor and 1983-87 E and F Series with a 7.5L engine and Holley 4V carburetor. ACTION: To correct this, install a Hot Idle Compensator (HIC) valve using the following service procedure. 5.8L Engine NOTE: Use original production PCV line. Figure 10 1. Assemble HIC valve (E1TZ-9B532-A) and Tee (379507-S), Figure 10. 2. Install the HIC valve in the PCV line, Figure 10. NOTE: Position the HIC valve in the PCV line over exhaust heat cross-over and under spark plug wires. 7.5L Engine 1. Remove steel PCV line. 2. Install a new PCV line (E6HZ-6A664-A). The new PCV line fits from the PCV valve to the front of the carburetor. PCV line must be routed along the right rocker arm cover under spark plug wires. 3. Assemble HIC valve (E1TZ-9B532-A) and Tee (379507-S), Figure 10. 4. Install HIC valve in the PCV line, Figure 10. NOTE: Position the HIC valve in the PCV line over exhaust heat cross-over and under spark plug wires. PART NUMBER PART NAME CLASS Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Hot Idle Compensator (Non Comp. Controlled) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hot Idle Compensator (Non Comp. Controlled): > 871913 > Sep > 87 > Engine - Hard Start After Hot Soak > Page 3226 E1TZ-9B532-A HIC Valve C 379507-S Tee RS E6HZ-6A664-A PCV Line CQ OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION: SP871913A TIME: 0.4 Hr. - F Series 0.6 Hr. - Econoline DLR. CODING: Basic Pan No. 9510 - Code: H5 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Positive Crankcase Ventilation Valve > Component Information > Technical Service Bulletins > Vehicle - High Altitude Modification Positive Crankcase Ventilation Valve: Technical Service Bulletins Vehicle - High Altitude Modification Article No. 86-15-16 ALTITUDE (5.8L (W)) - MODIFICATION OF SEA LEVEL CALIBRATION FOR ALTITUDE APPLICATION - VEHICLES WITH 4V CARBURETORS ONLY - OVER 8500 LBS. GVWR LIGHT TRUCK 1986 E SERIES, F SERIES CALIBRATION: 5-76J-R17 (Manual Transmission) WARNING: This modification is authorized only for the listed engines. Performing this modification on other engine calibrations is unauthorized and could create liability under applicable federal or local laws. Customers who may have relocated and/or continually operate the subject vehicles in high altitude (above 4,000 ft. alt.) may have the following procedure performed to improve performance. 1. Remove existing PCV valve and replace with new PCV valve (part number D90Z-6A666-A). 2. Advance initial ignition timing 6~ from nominal setting of 8~ BTDC to 14~ BTDC. Refer to 1986 Light Truck Shop Manual, Volume B, Section 23-01. 3. Increase choke pull down hard gauge setting to .193". Refer to 1986 Light Truck Shop Manual, Volume B, Section 24-26. 4. Remove existing choke cap and replace with new choke cap 47R-776-A (part number E5PZ-9848-B). 5. Reset hi-cam and curb idle speeds to specification (refer to Vehicle Emission Control Information Decal). Obtain a Vehicle Emission Control Information Update Decal (available at all Ford or Lincoln-Mercury dealers) and fill in the appropriate information as indicated. If the vehicle is returned to continuous sea level (below 4,000 ft. alt.) operation, the above procedure should be reversed and the Vehicle Emission Control Information Update Decal should be removed from the vehicle. PART NUMBER PART NAME CLASS D90Z-6A666-A PCV Valve A E5PZ-9848-B Choke Cap C OTHER APPLICABLE ARTICLES: 85-21-16 WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION: SP9514A86 TIME: 1.3 Hrs. DLR. CODING: Basic Part No. DRIVE - Code: N4, P6, T5 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Relays and Modules - Emission Control Systems > EGR Control Module > Component Information > Locations EGR Control Module: Locations Back View Of I/P On I/P, To Left Of Steering Column Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor Manual Revision Technical Service Bulletin # 8918A9 Date: 890915 EVP Sensor - Manual Revision ENGINE EMISSIONS DIAGNOSTIC MANUALS, VOLUME H - 1985 THROUGH 1989 - EGR VALVE POSITION SENSOR (EVP) DIAGNOSTIC PROCEDURES REVISED Article No. 89-18A-9 FORD: 1985-89 CROWN VICTORIA, ESCORT 1985-88 EXP 1985-86 LTD 1985-89 MUSTANG, TEMPO, THUNDERBIRD 1986-89 TAURUS 1988-89 FESTIVA 1989 PROBE LINCOLN-MERCURY: 1985-86 CAPRI 1985-89 CONTINENTAL, COUGAR, GRAND MARQUIS 1985-87 LYNX 1985-89 MARK VII 1985-86 MARQUIS 1985-89 TOPAZ, TOWN CAR 1986-89 SABLE 1987-89 TRACER MERKUR: 1986-89 XR4TI 1988-89 SCORPIO LIGHT TRUCK: 1985-89 BRONCO, BRONCO II, ECONOLINE, F-150, F-250, F-350, RANGER 1986-89 AEROSTAR ISSUE: The EGR Valve Position Sensor (EVP) diagnostic procedures in 1985 through 1989 Engine Emissions Diagnosis Shop Manuals, Volume H, have been revised. EVP Sensors may exhibit internal wear problems that can cause driveability symptoms and display a Continuous Self-Test Code 32. This is not associated to correcting the problem using the existing diagnostic procedures. ACTION: Refer to the pages following this TSB article for the revised diagnostic procedures. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 680000 1985 Pinpoint Tests - DM - EGR, EVP and EVR Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor Manual Revision > Page 3241 1985 EEC IV - Pinpoint Tests - All Vehicles 22-77 EGR Valve Position Sensor (EVP) EGR Valve Regulator (EVR) Pinpoint DM Test 1985 Pinpoint Tests - Fa - Neutral Drive Switch -A/C Input Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor Manual Revision > Page 3242 1985 22-78 EEC IV - Pinpoint Tests - All Vehicles Neutral Drive Switch FA A/C Input PinpointTest 1986 (EGR) Systems Functional Diagnosis 1986 Exhaust Gas Recirculation (EGR) Systems 6-11 Functional Diagnosis Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor Manual Revision > Page 3243 PORTED EGR VALVE 1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked, crimped or broken hoses. 2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating temperature. 3. Install a tachometer. 4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (EFI engines only). 5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose. 6. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If necessary, adjust idle speed to the emission decal specification. 7. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand vacuum pump. 8. When vacuum is applied to the EGR valve and any of the following occur, replace the valve: ^ Engine does not stall. ^ Idle speed does not drop more than 100 rpm. ^ Idle speed does not return to normal (+/- 25 rpm) after the vacuum is removed. 9. Reconnect the idle air bypass valve electrical connector. 10. Unplug and reconnect the EGR vacuum supply hose. 11. The EGR system is OK, refer to the Diagnostic Routines in Section 2. 1986 6-12 Exhaust Gas Recirculation (EGR) Systems Functional Diagnosis ELECTRONIC VALVE 1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked, crimped or broken hoses. 2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating temperature. 3. Install a tachometer. 4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (EFI engines only). Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor Manual Revision > Page 3244 5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose. 6. Disconnect the 9G428 EVP sensor electrical connector mounted on top of the 9H473 valve. 7. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If necessary, adjust idle speed to the emission decal specification. 8. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand vacuum pump. 9. When vacuum is applied to the EGR valve and any of the following occur, replace the valve: ^ Engine does not stall. ^ Idle speed does not drop more than 100 rpm. ^ Idle speed does not return to normal (+/- 25 rpm) after the vacuum is removed. 10. Reconnect the idle air bypass valve electrical connector. 11. Unplug and reconnect the EGR vacuum supply hose. 12. Reconnect the EVP sensor electrical connector. 13. The EGR valve is OK, REPLACE EVP sensor if the Continuous Code 32 was present. If the Continuous Code 32 was not present, refer to the Diagnostic Routines in Section 2. 1986 Quick Test: Continuous Self-Test 6.0 EEC IV - Quick Test - All Engines 18-13 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor Manual Revision > Page 3245 QUICK TEST: Continuous Self-Test 6.0 1986 18-14 EEC IV-Quick Test-All Engines QUICK TEST: Continuous Self-Test 6.0 Pinpoint Test - DN - EGR - EVP & EVR Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor Manual Revision > Page 3246 1986 EEC IV-Pinpoint Tests - All Vehicles 21-95 EGR Valve Position Sensor (EVP) PinpointTest DN EGR Valve Regulator (EVR) Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor Manual Revision > Page 3247 21-96 1986 EEC IV-Pinpoint Tests-All Vehicles EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Valve Regulator (EVR) Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor Manual Revision > Page 3248 EEC IV-Pinpoint Tests-All Vehicles 1986 21-97A EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Valve Regulator (EVR) Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor Manual Revision > Page 3249 1986 21-97B EEC IV-Pinpoint Tests-All Vehicles EGR Valve Position Sensor (EVP) EGR Valve Regulator (EVR) Pinpoint Test DN Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor Manual Revision > Page 3250 1986 EEC IV-Pinpoint Tests-All Vehicles 21-98 EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Valve Regulator (EVR) 1987 (EGR) Systems - Functional Diagnosis 1987 6-11 Exhaust Gas Recirculation (EGR) Systems Functional Diagnosis PORTED EGR VALVE 1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked, crimped or broken hoses. 2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating temperature. 3. Install a tachometer, Rotunda 059-00010 or equivalent. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor Manual Revision > Page 3251 4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (EFI engines only). 5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose. 6. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If necessary, adjust idle speed according to Section 4. 7. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand vacuum pump, Rotunda 021-00014 or equivalent. 8. When vacuum is applied to the EGR valve and any of the following occur, replace the valve: ^ Engine does not stall. ^ Idle speed does not drop more than 100 rpm. ^ Idle speed does not return to normal (+/- 25 rpm) after the vacuum is removed. 9. Reconnect the idle air bypass valve electrical connector. 10. Unplug and reconnect the EGR vacuum supply hose. 11. The EGR system is OK, refer to the Diagnostic Routines in Section 2. 1987 6-12 Exhaust Gas Recirculation (EGR) Systems Functional Diagnosis ELECTRONIC EGR (EEGR) VALVE 1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked, crimped or broken hoses. 2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating temperature. 3. Install a tachometer, Rotunda 059-00010 or equivalent. 4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (EFI engines only). 5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose. 6. Disconnect the 9G428 EVP sensor electrical connector mounted on top of the 9H473 valve. 7. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If necessary, adjust idle speed according to Section 4. 8. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand vacuum pump, Rotunda 021-00014 or equivalent. 9. When vacuum is applied to the EGR valve and any of the following occur, replace the valve: ^ Engine does not stall. ^ Idle speed does not drop more than 100 rpm. ^ Idle speed does not return to normal (+/- 25 rpm) after the vacuum is removed. 10. Reconnect the idle air bypass valve electrical connector. 11. Unplug and reconnect the EGR vacuum supply hose. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor Manual Revision > Page 3252 12. Reconnect the EVP sensor electrical connector. 13. The EGR valve is OK, REPLACE EVP sensor if the Continuous Code 32 was present. If the Continous Code 32 was not present, refer to the Diagnostic Routines in Section 2. 1987 Quick Test: Continuous Self-Test - 6.0 1987 EEC-IV Quick Test-All Engines 16-15 QUICK TEST: Continuous 6.0 Self-Test Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor Manual Revision > Page 3253 16-16 1987 EEC-IV Quick Test-All Engines QUICK TEST: Continuous 6.0 Self-Test Pinpoint Test - DN - EGR - EVP & EVR 1987 EEC IV - Pinpoint Tests - All Vehicles 19-91 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor Manual Revision > Page 3254 EGR VALVE Position Sensor (EVP) EGR Valve Regulator (EVR) - 2.3L HSC, 2.5L, 5.0L SEFI Passenger Car and 4.9L and 5.0L Truck Pinpoint Test DN 19-92A 1987 EEC IV Pinpoint Tests-All Vehicles EGR Valve Position Sensor (EVP) EGR Valve Regulator (EVR) - 2.3L HSC, 2.5L, Pinpoint Test DN 5.0L SEFI Passenger Car and 4.9L and 5.0L Truck Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor Manual Revision > Page 3255 1987 EEC IV-Pinpoint Tests-All Vehicles 19-92B EGR Valve Position Sensor (EVP) EGR Valve Regulator (EVR) - 2.3L HSC, 2.5L, 5.0L SEFI Passenger Car and 4.9L and 5.0L Truck Pinpoint Test DN Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor Manual Revision > Page 3256 1987 19-93-A EEC IV-Pinpoint Tests-All Vehicles EGR Valve Position Sensor (EVP) EGR Valve Regulator (EVR) - 2.3L HSC, 2.5L, 5.0L SEFI Passenger Car 4.9L and 5.0L Truck Pinpoint Test DN Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor Manual Revision > Page 3257 EEC IV-Pinpoint Tests-All Vehicles 1987 19-94 EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Valve Regulator (EVR) (EGR) Systems - Functional Diagnosis 1988 Exhaust Gas Recirculation (EGR) Systems 6-11 Functional Diagnosis Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor Manual Revision > Page 3258 PORTED EGR VALVE 1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked, crimped or broken hoses. 2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating temperature. 3. Install a tachometer, Rotunda 059-00010 or equivalent. 4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (EFI engines only). 5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose. 6. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If necessary, adjust idle speed according to Section 4. 7. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand vacuum pump, Rotunda 021-00014 or equivalent. 8. When vacuum is fully applied to the EGR valve: ^ If idle speed drops more than 100 rpm or if engine stalls, perform the next step. Otherwise, replace the EGR valve. ^ Remove the vacuum from the EGR valve. If idle speed does not return to normal (+/- 25 rpm), replace the EGR valve. 9. Reconnect the idle air bypass valve electrical connector. 10. Unplug and reconnect the EGR vacuum supply hose. 11. The EGR system is OK, refer to the Diagnostic Routines in Section 2. 6-12 1988 Exhaust Gas Recirculation (EGR) Systems Functional Diagnosis ELECTRONIC EGR (EEGR) VALVE 1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked, crimped or broken hoses. 2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating temperature. NOTE: The EVR solenoid has a constant internal leak. You will notice a small vacuum signal. This signal should be less than 2-1/2 in-Hg at idle. 3. Install a tachometer, Rotunda 059-00010 or equivalent. 4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (1.9L EFI engines only). 5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose. 6. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If necessary, adjust idle speed according to Section 4. 7. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand vacuum pump, Rotunda 021-00014 or equivalent. 8. When vacuum is applied to the EGR valve and any of the following occur, replace the valve: ^ Engine does not stall. ^ Idle speed does not drop more than 100 rpm. ^ Idle speed does not return to normal (+/- 25 rpm) after the vacuum is removed. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor Manual Revision > Page 3259 9. Reconnect the idle air bypass valve electrical connector. 10. Unplug and reconnect the EGR vacuum supply hose. 11. The EGR is OK, REPLACE EVP sensor if the Continuous Code 32 was present. If the Continuous Code 32 was not present, refer to the Diagnostic Routines in Section 2. Quick Test:Continuous Self-Test - 6.0 1988 EEC-IV - Quick Test - All Engines 16-15 QUICK TEST: Continuous Self-Test 6.0 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor Manual Revision > Page 3260 1988 16-16 EEC-IV - Quick Test - All Engines QUICK TEST: Continuous 6.0 Self-Test Pinpoint Test - DN - EGR - EVP & EVR Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor Manual Revision > Page 3261 EEC-IV - Pinpoint Tests - All Vehicles 1988 19-101 EGR Valve Position Sensor (EVP) EGR Valve Regulator (EVR) Pinpoint Test DN Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor Manual Revision > Page 3262 19-102 1988 EEC-IV - Pinpoint Tests - All Vehicles EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Valve Regulator (EVR) Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor Manual Revision > Page 3263 1988 EEC-IV - Pinpoint Tests - All Vehicles 19-102A EGR Valve Position Sensor (EVP) EGR Valve Regulator (EVR) Pinpoint Test DN Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor Manual Revision > Page 3264 1988 19-103 EEC-IV - Pinpoint Tests - All Vehicles EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Valve Regulator (EVR) Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor Manual Revision > Page 3265 1988 EEC-IV - Pinpoint Tests - All Vehicles 19-104 EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Valve Regulator (EVR) (EGR) Systems - Functional Diagnosis 1989 6-11 Exhaust Gas Recirculation (EGR) Systems Functional Diagnosis Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor Manual Revision > Page 3266 PORTED EGR VALVE 1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked, crimped or broken hoses. 2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating temperature. 3. Install a tachometer, Rotunda 059-00010 or equivalent. 4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (EFI engines only). 5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose. 6. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If necessary, adjust idle speed according to Section 4. 7. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand vacuum pump, Rotunda 021-00014 or equivalent. 8. When vacuum is fully applied to the EGR valve: ^ If idle speed drops more than 100 rpm or if engine stalls, perform the next step. Otherwise, for vacuum leak at EGR valve, replace the valve. ^ If EGR passages are blocked, clean the valve using Rotunda 021-80056 EGR valve cleaner. ^ Remove the vacuum from the EGR valve. If idle speed does not return to normal (+/- 25 rpm), check for contamination, clean the valve. ^ Make sure there is no sand left in the valve or pick-up tube. Replace the valve if necessary. 9. Reconnect the idle air bypass valve electrical connector. 10. Unplug and reconnect the EGR vacuum supply hose. 11. The EGR system is OK, refer to the Diagnostic Routines in Section 2. 1989 6-12 Exhaust Gas Recirculation (EGR) Systems Functional Diagnosis ELECTRONIC EGR (EEGR) VALVE 1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked, crimped or broken hoses. 2. Make certain there is less than 2.5 in-Hg vacuum to the EGR valve at idle with the engine at normal operating temperature. NOTE: The EVR solenoid has a constant internal leak. You will notice a small vacuum signal. This signal should be less than 1.0 in-Hg at idle. 3. Install a tachometer, Rotunda 059-00010 or equivalent. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor Manual Revision > Page 3267 4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (1.9L EFI engines only). 5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose. 6. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If necessary, adjust idle speed according to Section 4. 7. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand vacuum pump, Rotunda 021-00014 or equivalent. 8. When vacuum is applied to the EGR valve and any of the following occur: ^ Engine does not stall ^ Idle speed does not drop more than 100 rpm ^ Idle speed does not return to normal (+/- 25 rpm) after the vacuum is removed Then: ^ For vacuum leak at EGR valve, replace the valve. ^ Check for contamination, clean the EGR valve, using Rotunda 021-80056 EGR valve cleaner or equivalent. ^ Make sure there is no sand left in the valve. ^ Replace the EGR valve if necessary. 9. Reconnect the idle air bypass valve electrical connector. Unplug and reconnect the EGR vacuum supply hose. 10. If EGR valve is OK, REPLACE EVP sensor if Continuous Code 32 was present. If the Continuous Code 32 was not present, refer to the Diagnostic Routines in Section 2. Quick Test:Continuous Self-Test - 6.0 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor Manual Revision > Page 3268 1989 EEC-IV - Quick Test - All Engines 14-17 QUICK TEST: Continuous 6.0 Self-Test Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor Manual Revision > Page 3269 1989 14-18 EEC-IV - Quick Test - All Engines QUICK TEST: Continuous 6.0 Self-Test 1989 EEC-IV - Quick Test - All Engines 14-19 QUICK TEST: Continuous 6.0 Self-Test Quick Test:Diagnostic By Symptom - 7.0 1989 14-20 EEC-IV - Quick Test - All Engines QUICK TEST: Diagnostic By Symptom 7.0 A DIAGNOSTIC BY SYMPTOM SPECIAL NOTES: ^ Verify that a Pass Code 11 was received in Key On Engine Off, Engine Running and Continuous Self-Tests before continuing with this test. ^ If a symptom is present and the EEC system is suspected, Go to part B of Diagnostic By Symptom. If the EEC system is not suspected, GO to Section 2, Diagnostic Routines. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor Manual Revision > Page 3270 Pinpoint Test - DN - EGR - EVP & EVR 1989 EEC-IV - Pinpoint Tests-All Vehicles 17-133 EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Vacuum Regulator Solenoid (EVR) Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor Manual Revision > Page 3271 1989 17-134 EEC-IV - Pinpoint Tests - All Vehicles EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Vacuum Regulator Solenoid (EVR) Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor Manual Revision > Page 3272 1989 EEC-IV-Pinpoint Tests - All Vehicles 17-134A Pinpoint Test DN EGR Valve Position Sensor (EVP) EGR Vacuum Regulator Solenoid (EVR) Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor Manual Revision > Page 3273 1989 17-135 EEC-IV - Pinpoint Tests - All Vehicles EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Vacuum Regulator Solenoid (EVR) Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor Manual Revision > Page 3274 1989 EEC-IV - Pinpoint Tests - All Vehicles 17-136A EGR Valve Position Sensor (EVP) 04GPinpoint Test DN EGR Vacuum Regulator Solenoid (EVR) Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > Page 3275 EGR Valve Position Sensor: Locations Attached To EGR Valve Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > Page 3276 EGR Valve Position Sensor: Description and Operation The EVP Sensor provides EEC System with a signal indicating position of the EGR valve. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Description and Operation Pressure Feedback Exhaust Sensor: Description and Operation The Pressure Feedback Electronic (PFE) EGR transducer converts a varying exhaust pressure signal into a proportional analog voltage which is digitized by the EEC IV processor. The EEC IV processor uses the signal received from the PFE transducer to complete the optimum EGR flow. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Inlet Air Temperature Control <--> [Thermostatic Air Cleaner] > Thermostatic Air Cleaner Vacuum Motor > Component Information > Description and Operation Thermostatic Air Cleaner Vacuum Motor: Description and Operation The air cleaner vacuum motor operates the door within the duct, which allows either warm or cold air to enter the engine, depending upon the temperature within the air cleaner. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Inlet Air Temperature Control <--> [Thermostatic Air Cleaner] > Thermostatic Air Cleaner Vacuum Motor > Component Information > Description and Operation > Page 3284 Thermostatic Air Cleaner Vacuum Motor: Testing and Inspection When vacuum is applied to the vacuum motor, the door stem should pull up and stay as long as vacuum is applied to the vacuum motor. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Inlet Air Temperature Control <--> [Thermostatic Air Cleaner] > Thermostatic Air Cleaner Vacuum Switch > Component Information > Description and Operation > Air Cleaner Cold Weather Modulator Thermostatic Air Cleaner Vacuum Switch: Description and Operation Air Cleaner Cold Weather Modulator A cold weather modulator is some times used in addition to the air cleaner temperature control (bi-metal) sensor to control the inlet air temperature. The cold weather modulator traps vacuum in the system, so the door will not switch to cold air when the vacuum drops during acceleration. The cold weather modulator only works when the outside air is cold. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Inlet Air Temperature Control <--> [Thermostatic Air Cleaner] > Thermostatic Air Cleaner Vacuum Switch > Component Information > Description and Operation > Air Cleaner Cold Weather Modulator > Page 3289 Thermostatic Air Cleaner Vacuum Switch: Description and Operation Air Cleaner Temperature Sensor The sensor is installed in the cleaner tray and is subjected to temperature changes within the air cleaner. At a given increase in temperature, the sensor bleeds off vacuum, permitting the vacuum motor to open the duct door to allow fresh air in while shutting off full heat. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Inlet Air Temperature Control <--> [Thermostatic Air Cleaner] > Thermostatic Air Cleaner Vacuum Switch > Component Information > Testing and Inspection > Air Cleaner Cold Weather Modulator Thermostatic Air Cleaner Vacuum Switch: Testing and Inspection Air Cleaner Cold Weather Modulator A 54 kPa (16 inches Hg) vacuum applied to motor side of the modulator holds or leaks as follows: Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Inlet Air Temperature Control <--> [Thermostatic Air Cleaner] > Thermostatic Air Cleaner Vacuum Switch > Component Information > Testing and Inspection > Air Cleaner Cold Weather Modulator > Page 3292 Thermostatic Air Cleaner Vacuum Switch: Testing and Inspection Air Cleaner Temperature Sensor At an ambient temperature of less than 24°C (75°F), the sensor will allow vacuum to close the duct door to fresh air. The sensor will bleed off vacuum to allow the duct door to open and let in fresh air at or above the following temperatures: Brown 24°C (75°F) Pink, black, or clear 32.2°C (90°F) Blue, yellow or green 40.6°C (105°F) Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Vacuum Restrictor > Component Information > Description and Operation Vacuum Restrictor: Description and Operation This orifice-type flow restrictor (Fig. 1) is used in several emission calibrations to control the flow rate and/or timing inactions to the following emission component systems: a. EGR valve timing-opening and closing. b. Part throttle spark advance c. Purge system d. Thermactor system Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Vacuum Restrictor > Component Information > Description and Operation > Page 3296 Vacuum Restrictor: Testing and Inspection The flow rate through the restrictor is the same in both directions. If it is blocked, replace it. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > Technical Service Bulletins > By Symptom Fuel Pressure: By Symptom Technical Service Bulletin # 911211 Date: 910612 Engine - Lack of Power/No Start Diagnosis Article No. 91-12-11 06/12/91 LACK OF POWER 7.5L, 5.8L, 5.0L, 4.9L - CATALYTIC CONVERTER DIAGNOSTIC TIPS LIGHT TRUCK: 1986-91 BRONCO, ECONOLINE, F-150-350 SERIES 1988-91 F SUPER DUTY, F47 ISSUE: Lack of power or a no start condition may be diagnosed as an exhaust restriction caused by a plugged catalytic converter. A plugged catalytic converter (internal deterioration) is usually caused by abnormal engine operation. ACTION: Diagnose the catalytic converter to confirm internal failure. Refer to the Catalyst and Exhaust System Diagnostic Section, in the Engine/Emissions Diagnostic Shop Manual and the following procedures for service details. 1. Lack of proper HEGO operation may cause, or be the result of a rich or lean fuel condition, which could cause additional heat in the catalyst. Perform self test KOEO and KOER, service any codes. NOTE: IF TWO DIGIT CODES 41, 42, 85 OR THREE DIGIT CODES 171, 172, 173, 179, 181, 182, 183 AND 565 ARE RECEIVED, CHECK FOR PROPER HEGO GROUND. If the HEGO ground is good, the following areas may be at fault: ^ Ignition Coil ^ Distributor Cap ^ Distributor Rotor ^ Fouled Spark Plug ^ Spark Plug Wires ^ Air Filter ^ Stuck Open Injector ^ Fuel Contamination Engine OIL ^ Manifold Leaks Intake/ Exhaust ^ Fuel Pressure ^ Poor Power Ground ^ Engine Not At Normal Operating Temperature ^ HEGO Sensor 2. Spark timing that is retarded from specification may increase exhaust gas temperature and shorten catalyst life. Refer to the following procedure for service details. a. Check spark timing. Check base timing with spout disconnected. Set base timing to the specification on the vehicle emission decal. b. Check computed timing with spout connected. NOTE: COMPUTED TIMING IS EQUAL TO BASE TIMING PLUS 20~ BTDC +/- 3~. 3. Misfiring spark plugs may cause an unburned fuel air mixture to pass through the catalyst, which could cause higher than normal catalyst Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > Technical Service Bulletins > By Symptom > Page 3302 temperatures. Refer to the following procedure for service details. a. Check secondary ignition, hook the vehicle up to an engine analyzer and check for a secondary ignition misfire. NOTE: SERVICE ANY ITEM THAT IS NOT PERFORMING AT PROPER SPECIFICATIONS BEFORE CONTINUING. 4. Fuel pressure that is too high may cause rich air fuel mixtures to pass through the catalyst which could cause higher than normal catalyst temperatures. Refer to the following procedure for service details. a. Check fuel pressure, install fuel pressure gauge, start and run the engine at idle. Fuel pressures between 28 and 34 PSI are typical (4.9L typically is 15 PSI higher). b. Disconnect the vacuum line going to the fuel pressure regulator. Fuel pressure typically jumps to 40 PSI +/- 3 PSI (4.9L typically is 15 PSI higher). Visually inspect vacuum line for raw fuel. NOTE: FUEL PRESSURES ABOVE THESE VALUES SHOULD BE CORRECTED. HOWEVER, THIS MAY NOT BE THE CAUSE OF THE CONCERN. SERVICE AS NECESSARY. 5. Throttle plates in the throttle body not returning to the proper closed position may cause excessive catalyst temperatures during downhill grades. Refer to the following procedure for service details. a. Visually inspect the throttle body and linkage for: ^ Binding or sticking throttle linkage. ^ Tight speed control linkage or cable. ^ Vacuum line interference. ^ Electrical harness interference. NOTE: AFTERMARKET GOVERNORS, THROTTLE LINKAGE AND CABLES ASSOCIATED WITH POWER TAKE-OFF UNITS, MAY ALSO INTERFERE WITH PROPER THROTTLE RETURN. SERVICE AS NECESSARY. 6. It is extremely important that all systems related to the engine and emission systems operate properly. a. Visually inspect the engine compartment to make sure all vacuum hoses and spark plug wires are properly routed and securely connected. b. Inspect all wiring harnesses and connectors for insulation damage, burned, overheated, loose or broken conditions. c. Verify proper operation of the thermactor system. Thermactor systems that fail to dump thermactor air to the atmosphere properly or at the correct time can cause high catalyst temperatures. d. Visually inspect thermactor system for damaged or kinked hoses and perform a function test on following components: air control valve, check valve, silencer, filter and the air bypass solenoid. e. Verify proper operation of the engine cooling system thermostat. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under Basic Warranty Coverage, Emissions Warranty Coverage OPERATION DESCRIPTION TIME 911211A Diagnostics - Perform 0.5 Hrs. KOEO And KOER Self Tests 911211B Timing - Check Or Adjust 0.5 Hrs. Spark Timing, Check Computed Timing And Check Secondary Ignition System With Engine Analyzer. 911211C Check - Fuel Pressure And 0.2 Hrs. Inspect Vacuum Line For Raw Fuel. 911211D Inspect - Throttle Body And 0.1 Hrs. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > Technical Service Bulletins > By Symptom > Page 3303 Linkage. 911211E Inspect - Vacuum Hoses, 0.1 Hrs. Electrical Harnesses, Connectors And Spark Plug Wires For Routing Damage. 911211F Thermactor System - 0.3 Hrs. Inspect For Proper Operation And Damaged Component. Includes Function Check Of Air Control Valve, Thermactor Air Bypass Solenoid, Check Valves, Silencer And Filter. 911211G Thermostat - Check For 0.2 Hrs. Proper Operation. DEALER CODING BASIC PART NO. CONDITION CODE 5E212 25 OASIS CODES: 403000, 603300, 614000 Technical Service Bulletin # 911211 Date: 910612 Engine - Lack of Power/No Start Diagnosis Article No. 91-12-11 06/12/91 LACK OF POWER 7.5L, 5.8L, 5.0L, 4.9L - CATALYTIC CONVERTER DIAGNOSTIC TIPS LIGHT TRUCK: 1986-91 BRONCO, ECONOLINE, F-150-350 SERIES 1988-91 F SUPER DUTY, F47 ISSUE: Lack of power or a no start condition may be diagnosed as an exhaust restriction caused by a plugged catalytic converter. A plugged catalytic converter (internal deterioration) is usually caused by abnormal engine operation. ACTION: Diagnose the catalytic converter to confirm internal failure. Refer to the Catalyst and Exhaust System Diagnostic Section, in the Engine/Emissions Diagnostic Shop Manual and the following procedures for service details. 1. Lack of proper HEGO operation may cause, or be the result of a rich or lean fuel condition, which could cause additional heat in the catalyst. Perform self test KOEO and KOER, service any codes. NOTE: IF TWO DIGIT CODES 41, 42, 85 OR THREE DIGIT CODES 171, 172, 173, 179, 181, 182, 183 AND 565 ARE RECEIVED, CHECK FOR PROPER HEGO GROUND. If the HEGO ground is good, the following areas may be at fault: ^ Ignition Coil ^ Distributor Cap ^ Distributor Rotor ^ Fouled Spark Plug ^ Spark Plug Wires ^ Air Filter ^ Stuck Open Injector ^ Fuel Contamination Engine OIL ^ Manifold Leaks Intake/ Exhaust Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > Technical Service Bulletins > By Symptom > Page 3304 ^ Fuel Pressure ^ Poor Power Ground ^ Engine Not At Normal Operating Temperature ^ HEGO Sensor 2. Spark timing that is retarded from specification may increase exhaust gas temperature and shorten catalyst life. Refer to the following procedure for service details. a. Check spark timing. Check base timing with spout disconnected. Set base timing to the specification on the vehicle emission decal. b. Check computed timing with spout connected. NOTE: COMPUTED TIMING IS EQUAL TO BASE TIMING PLUS 20~ BTDC +/- 3~. 3. Misfiring spark plugs may cause an unburned fuel air mixture to pass through the catalyst, which could cause higher than normal catalyst temperatures. Refer to the following procedure for service details. a. Check secondary ignition, hook the vehicle up to an engine analyzer and check for a secondary ignition misfire. NOTE: SERVICE ANY ITEM THAT IS NOT PERFORMING AT PROPER SPECIFICATIONS BEFORE CONTINUING. 4. Fuel pressure that is too high may cause rich air fuel mixtures to pass through the catalyst which could cause higher than normal catalyst temperatures. Refer to the following procedure for service details. a. Check fuel pressure, install fuel pressure gauge, start and run the engine at idle. Fuel pressures between 28 and 34 PSI are typical (4.9L typically is 15 PSI higher). b. Disconnect the vacuum line going to the fuel pressure regulator. Fuel pressure typically jumps to 40 PSI +/- 3 PSI (4.9L typically is 15 PSI higher). Visually inspect vacuum line for raw fuel. NOTE: FUEL PRESSURES ABOVE THESE VALUES SHOULD BE CORRECTED. HOWEVER, THIS MAY NOT BE THE CAUSE OF THE CONCERN. SERVICE AS NECESSARY. 5. Throttle plates in the throttle body not returning to the proper closed position may cause excessive catalyst temperatures during downhill grades. Refer to the following procedure for service details. a. Visually inspect the throttle body and linkage for: ^ Binding or sticking throttle linkage. ^ Tight speed control linkage or cable. ^ Vacuum line interference. ^ Electrical harness interference. NOTE: AFTERMARKET GOVERNORS, THROTTLE LINKAGE AND CABLES ASSOCIATED WITH POWER TAKE-OFF UNITS, MAY ALSO INTERFERE WITH PROPER THROTTLE RETURN. SERVICE AS NECESSARY. 6. It is extremely important that all systems related to the engine and emission systems operate properly. a. Visually inspect the engine compartment to make sure all vacuum hoses and spark plug wires are properly routed and securely connected. b. Inspect all wiring harnesses and connectors for insulation damage, burned, overheated, loose or broken conditions. c. Verify proper operation of the thermactor system. Thermactor systems that fail to dump thermactor air to the atmosphere properly or at the correct time can cause high catalyst temperatures. d. Visually inspect thermactor system for damaged or kinked hoses and perform a function test on following components: air control valve, check valve, silencer, filter and the air bypass solenoid. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > Technical Service Bulletins > By Symptom > Page 3305 e. Verify proper operation of the engine cooling system thermostat. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under Basic Warranty Coverage, Emissions Warranty Coverage OPERATION DESCRIPTION TIME 911211A Diagnostics - Perform 0.5 Hrs. KOEO And KOER Self Tests 911211B Timing - Check Or Adjust 0.5 Hrs. Spark Timing, Check Computed Timing And Check Secondary Ignition System With Engine Analyzer. 911211C Check - Fuel Pressure And 0.2 Hrs. Inspect Vacuum Line For Raw Fuel. 911211D Inspect - Throttle Body And 0.1 Hrs. Linkage. 911211E Inspect - Vacuum Hoses, 0.1 Hrs. Electrical Harnesses, Connectors And Spark Plug Wires For Routing Damage. 911211F Thermactor System - 0.3 Hrs. Inspect For Proper Operation And Damaged Component. Includes Function Check Of Air Control Valve, Thermactor Air Bypass Solenoid, Check Valves, Silencer And Filter. 911211G Thermostat - Check For 0.2 Hrs. Proper Operation. DEALER CODING BASIC PART NO. CONDITION CODE 5E212 25 OASIS CODES: 403000, 603300, 614000 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Pressure: > 911211 > Jun > 91 > Engine - Lack of Power/No Start Diagnosis Fuel Pressure: All Technical Service Bulletins Engine - Lack of Power/No Start Diagnosis Article No. 91-12-11 06/12/91 LACK OF POWER 7.5L, 5.8L, 5.0L, 4.9L - CATALYTIC CONVERTER DIAGNOSTIC TIPS LIGHT TRUCK: 1986-91 BRONCO, ECONOLINE, F-150-350 SERIES 1988-91 F SUPER DUTY, F47 ISSUE: Lack of power or a no start condition may be diagnosed as an exhaust restriction caused by a plugged catalytic converter. A plugged catalytic converter (internal deterioration) is usually caused by abnormal engine operation. ACTION: Diagnose the catalytic converter to confirm internal failure. Refer to the Catalyst and Exhaust System Diagnostic Section, in the Engine/Emissions Diagnostic Shop Manual and the following procedures for service details. 1. Lack of proper HEGO operation may cause, or be the result of a rich or lean fuel condition, which could cause additional heat in the catalyst. Perform self test KOEO and KOER, service any codes. NOTE: IF TWO DIGIT CODES 41, 42, 85 OR THREE DIGIT CODES 171, 172, 173, 179, 181, 182, 183 AND 565 ARE RECEIVED, CHECK FOR PROPER HEGO GROUND. If the HEGO ground is good, the following areas may be at fault: ^ Ignition Coil ^ Distributor Cap ^ Distributor Rotor ^ Fouled Spark Plug ^ Spark Plug Wires ^ Air Filter ^ Stuck Open Injector ^ Fuel Contamination Engine OIL ^ Manifold Leaks Intake/ Exhaust ^ Fuel Pressure ^ Poor Power Ground ^ Engine Not At Normal Operating Temperature ^ HEGO Sensor 2. Spark timing that is retarded from specification may increase exhaust gas temperature and shorten catalyst life. Refer to the following procedure for service details. a. Check spark timing. Check base timing with spout disconnected. Set base timing to the specification on the vehicle emission decal. b. Check computed timing with spout connected. NOTE: COMPUTED TIMING IS EQUAL TO BASE TIMING PLUS 20~ BTDC +/- 3~. 3. Misfiring spark plugs may cause an unburned fuel air mixture to pass through the catalyst, which could cause higher than normal catalyst temperatures. Refer to the following procedure for service details. a. Check secondary ignition, hook the vehicle up to an engine analyzer and check for a secondary ignition misfire. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Pressure: > 911211 > Jun > 91 > Engine - Lack of Power/No Start Diagnosis > Page 3311 NOTE: SERVICE ANY ITEM THAT IS NOT PERFORMING AT PROPER SPECIFICATIONS BEFORE CONTINUING. 4. Fuel pressure that is too high may cause rich air fuel mixtures to pass through the catalyst which could cause higher than normal catalyst temperatures. Refer to the following procedure for service details. a. Check fuel pressure, install fuel pressure gauge, start and run the engine at idle. Fuel pressures between 28 and 34 PSI are typical (4.9L typically is 15 PSI higher). b. Disconnect the vacuum line going to the fuel pressure regulator. Fuel pressure typically jumps to 40 PSI +/- 3 PSI (4.9L typically is 15 PSI higher). Visually inspect vacuum line for raw fuel. NOTE: FUEL PRESSURES ABOVE THESE VALUES SHOULD BE CORRECTED. HOWEVER, THIS MAY NOT BE THE CAUSE OF THE CONCERN. SERVICE AS NECESSARY. 5. Throttle plates in the throttle body not returning to the proper closed position may cause excessive catalyst temperatures during downhill grades. Refer to the following procedure for service details. a. Visually inspect the throttle body and linkage for: ^ Binding or sticking throttle linkage. ^ Tight speed control linkage or cable. ^ Vacuum line interference. ^ Electrical harness interference. NOTE: AFTERMARKET GOVERNORS, THROTTLE LINKAGE AND CABLES ASSOCIATED WITH POWER TAKE-OFF UNITS, MAY ALSO INTERFERE WITH PROPER THROTTLE RETURN. SERVICE AS NECESSARY. 6. It is extremely important that all systems related to the engine and emission systems operate properly. a. Visually inspect the engine compartment to make sure all vacuum hoses and spark plug wires are properly routed and securely connected. b. Inspect all wiring harnesses and connectors for insulation damage, burned, overheated, loose or broken conditions. c. Verify proper operation of the thermactor system. Thermactor systems that fail to dump thermactor air to the atmosphere properly or at the correct time can cause high catalyst temperatures. d. Visually inspect thermactor system for damaged or kinked hoses and perform a function test on following components: air control valve, check valve, silencer, filter and the air bypass solenoid. e. Verify proper operation of the engine cooling system thermostat. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under Basic Warranty Coverage, Emissions Warranty Coverage OPERATION DESCRIPTION TIME 911211A Diagnostics - Perform 0.5 Hrs. KOEO And KOER Self Tests 911211B Timing - Check Or Adjust 0.5 Hrs. Spark Timing, Check Computed Timing And Check Secondary Ignition System With Engine Analyzer. 911211C Check - Fuel Pressure And 0.2 Hrs. Inspect Vacuum Line For Raw Fuel. 911211D Inspect - Throttle Body And 0.1 Hrs. Linkage. 911211E Inspect - Vacuum Hoses, 0.1 Hrs. Electrical Harnesses, Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Pressure: > 911211 > Jun > 91 > Engine - Lack of Power/No Start Diagnosis > Page 3312 Connectors And Spark Plug Wires For Routing Damage. 911211F Thermactor System - 0.3 Hrs. Inspect For Proper Operation And Damaged Component. Includes Function Check Of Air Control Valve, Thermactor Air Bypass Solenoid, Check Valves, Silencer And Filter. 911211G Thermostat - Check For 0.2 Hrs. Proper Operation. DEALER CODING BASIC PART NO. CONDITION CODE 5E212 25 OASIS CODES: 403000, 603300, 614000 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > Technical Service Bulletins > Page 3313 Fuel Pressure: Specifications FUEL PRESSURE Pump Pressure .................................................................................................................................... ...................................................................... 6 - 8 psi Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Test Fuel Pressure: Testing and Inspection Fuel Pressure Test NOTE: Perform Fuel System Capacity Test prior to performing Pressure Test. See: Fuel System Capacity Test PRESSURE TEST 1. Connect a suitable pressure gauge (0-15 PSI) to the carburetor end of the fuel line. WARNING: Use care to prevent combustion of spilled fuel. 2. Start the engine (it should be able to run for over 30 seconds on the fuel in the carburetor bowl) and read the pressure after 10 seconds. If pump pressure is too low or too high install a new fuel pump. Fuel Pump Pressure ............................................................................................................................ ................................................. 6.0-8.0 PSI 3. Reconnect fuel line at filter and install air cleaner. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Test > Page 3316 Fuel Pressure: Testing and Inspection Fuel System Capacity Test FUEL CAPACITY (VOLUME) TEST - Remove the carburetor air cleaner. - Slowly (fuel line is pressurized) disconnect the fuel line at the fuel filter. WARNING: Use care to prevent combustion of spilled fuel. - Place a suitable non-breakable container (1/2 liter or 1 pint minimum) at the end of the disconnected fuel line (a piece of hose may be needed on the fuel line end). - Disconnect high tension wire from coil. - Crank engine 10 seconds, the fuel pump should deliver 0.158 liters (1/3 pint) of fuel or more. - If fuel flow is to specification perform pressure test. See: Fuel Pressure Test - If fuel flow is low repeat procedure using a non-breakable container of gasoline connected to the fuel pump inlet. If fuel pressure is to specification, the problem is either a plugged in-tank filter, or a kinked or leaking fuel pump inlet hose. - If fuel flow is still below specification, replace fuel pump. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > Customer Interest: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up Technical Service Bulletin # 91257 Date: 911213 Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up Article No. 91-25-7 12/13/91 ^ HARD COLD START - DURING INITIAL START-UP, IDLE OR DECEL - EFI ENGINES SLUDGE IN THROTTLE BODY AND/OR IDLE AIR BY-PASS VALVE ^ HESITATION/STALLS - DURING INITIAL START-UP, IDLE OR DECEL - EFI ENGINES SLUDGE IN THROTTLE BODY AND/OR IDLE AIR BY-PASS VALVE FORD: 1983-87 EXP 1983-91 ESCORT 1984-90 MUSTANG, THUNDERBIRD 1986-90 TAURUS 1986-91 CROWN VICTORIA 1988-90 TEMPO LINCOLN-MERCURY: 1983-85 LN7 1983-87 LYNX 1984-88 CAPRI 1984-90 COUGAR 1986-90 CONTINENTAL, MARK VII, SABLE 1986-91 GRAND MARQUIS, TOWN CAR 1988-90 TOPAZ 1991 TRACER LIGHT TRUCK: 1985-90 BRONCO II, BRONCO 1985-91 ECONOLINE, F-150-350 SERIES 1985-92 RANGER 1986-91 AEROSTAR 1991 EXPLORER ISSUE: Hard cold starts, hesitation and stalls on initial start-up or during idle or decel may be caused by sludge in the throttle body and/or idle by-pass valve. Sludge deposits or oil film on the throttle body bore and plate or the idle air by-pass valve may cause one or more of the following conditions. ^ Hard Cold Start ^ Stall On Initial Start-Up ^ Stall During Idle ^ Stall During Decel ^ Rough Idle ^ Rolling Idle ^ Hesitation During Acceleration ACTION: A new idle air by-pass service kit (F2PZ-9F939-A) is now available for service use to correct sludge contamination concerns of the throttle bore and plate only. It eliminates the need to clean the majority of past model throttle body applications. Cleaning is not required on sludge tolerant throttle body designs released for 1991 and newer model years. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > Customer Interest: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3325 Figure 1 Install an idle air by-pass service kit (F2PZ-9F939-A) as applicable to provide a permanent correction for symptoms caused by throttle body sludge deposits. Refer to the instruction sheet included in the kit for installation details. Refer to Figure 1 for a specific application list of EFI (port fuel Injection) engines involved in this TSB article. The idle air by-pass service kit (F2PZ-9F939-A) includes the following items. ^ One (1) Idle Adjust Spacer ^ Two (2) Gaskets Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > Customer Interest: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3326 ^ Two (2) Attaching Bolts ^ One (1) "Attention" Sticker ^ One (1) Instruction Sheet Figure 2 Refer to Figure 2 for a pictorial of the kits components. NOTE: EFFECTIVE WITH THIS TSB, THROTTLE BODY CLEANING IS NO LONGER COVERED UNDER 5/50 EMISSIONS WARRANTY, UNLESS AS SPECIFIED IN THE FOLLOWING APPLICATION CHARTS. FAILURE TO FOLLOW THE CORRECT PROCEDURE MAY RESULT IN THE CLAIM BEING DISALLOWED. The idle air adjust spacer incorporates sludge tolerant design features that eliminate throttle body sludge related conditions. Once installed, throttle body cleaning is not allowed and periodic adjustment of the throttle body is not required. Procedures, Warranty and Labor CHECKS TO MAKE PRIOR TO SERVICE KIT INSTALLATION Confirm that the following items are not causing the idle quality concern before proceeding with the service kit installation. ^ Contamination within the idle air by-pass solenoid ^ Lack of fuel system control (excessively rich or lean) ^ Ignition timing change ^ Incorrect or malfunctioning EGR system ^ Incorrect or malfunctioning cooling system ^ Vacuum leaks (air intake manifold, vacuum hoses, vacuum reservoirs, power brake booster where applicable) ^ EEC diagnostics have been performed and vehicle malfunction indicated service output codes have been resolved and cleared. If any of the areas listed above are found to be at fault, correct them before proceeding with the service kit installation. Idle Speed Adjustment Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > Customer Interest: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3327 WARNING: BEFORE PROCEEDING WITH THE IDLE SPEED ADJUSTMENT, VERIFY THAT THE FOLLOWING ITEMS ARE TAKEN CARE OF PROPERLY. ^ The transmission is in PARK or Neutral. ^ The parking brake is applied. ^ The wheels are properly blocked. ^ The engine is at operating temperature. ^ The heater, A/C, cooling fan and other accessories are OFF. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > Customer Interest: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3328 Figure 3 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > Customer Interest: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3329 Figure 4 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > Customer Interest: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3330 Figure 5 The EFI throttle body idle speed adjustment procedures for the various model year passenger cars and light trucks are outlined in step-by-step procedures featured in Figures 3, 4 and 5. Select the appropriate procedure for the vehicle involved and adjust the throttle body idle RPM accordingly, after service kit installation. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > Customer Interest: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3331 Figure 6 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > Customer Interest: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3332 Figure 7 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > Customer Interest: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3333 Figure 8 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > Customer Interest: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3334 Figure 9 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > Customer Interest: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3335 Figure 10 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > Customer Interest: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3336 Figure 11 THROTTLE BODY AND IDLE AIR BY-PASS SOLENOID SERVICE PROCEDURE Detailed application charts for throttle body and idle air by-pass solenoid service procedures by engine VIN # /engine displacement/vehicle application and model year are shown in Figures 6 through 11. Refer to these charts to see if the service kit is to be installed and which service cleaning procedure, if any, is to be used. SERVICE CLEANING PROCEDURES The following items should be noted prior to beginning the service cleaning procedure. ^ Confirm that the correct service cleaning procedure is identified in the Application Charts, Figures 6-11, for the vehicle/engine combination being Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > Customer Interest: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3337 serviced. ^ Do not clean throttle bodies identified to accept service kit (F2PZ-9F939-A), IDLE AIR ADJUST SPACER. ^ Use a 1" (25.4 mm) to 1-1/2" (38.1 mm) wire stemmed horse hair or nylon bottle cleaner type brush. ^ Use rubber gloves and eye protection. ^ Do not clean throttle bodies identified with a yellow/black "ATTENTION" label. ^ Do not clean "Black" plastic air by-pass valves. Refer to TSB 89-13-8 for service details. ^ Do not run vehicles with air flow meters when the air duct is removed. ^ Do not use carburetor cleaner as a cleaning solvent. Use Carburetor Tune-up Cleaner (D9AZ-19579-AA). Procedure # 1 THROTTLE BODY AND IDLE AIR BY-PASS VALVE CLEANING CAUTION: DO NOT RUN VEHICLES EQUIPPED WITH AIR FLOW METERS DURING THE CLEANING PROCEDURE. IF THERE IS A YELLOW/BLACK "ATTENTION" LABEL ON THE THROTTLE BODY ADVISING NOT TO CLEAN, OR IF THE VEHICLE IS IDENTIFIED AS ACCEPTING SERVICE KIT (F2PZ-9F939-A), USE PROCEDURE # 2 FOR IDLE AIR BY-PASS VALVE CLEANING ONLY. 1. Plug the actuator into the connector in the Rotunda Cleaner/Tester, Tool 113-00009. 2. Remove the air duct to the throttle body inlet. 3. Disoonnect the idle air by-pass valve signal lead. 4. Attach the actuator harness plug to the idle air by-pass valve. 5. Start the actuator and then start the engine. Do not start engines that have air flow meters. 6. Spray just enough Carburetor Tune-up Cleaner (D9AZ-19579-AA) into the throttle bore to wet the bore and throttle plate. 7. Spray the Carburetor Tune-up Cleaner for about five (5) seconds into the idle air by-pass valve inlet passage while the actuator is operating. 8. Stop the engine and actuator. Let everything soak for fifteen (15) minutes. 9. After a fifteen (15) minute soak, saturate the cleaning brush with solvent and scrub between the throttle body bore and plate while holding the throttle wide open. NOTE: IT IS NECESSARY TO APPLY SOME PRESSURE ON THE BRUSH WHILE SCRUBBING. 10. Repeat saturating the brush and scrubbing for one (1) to two (2) minutes, making sure to reach into the corners where the throttle shaft meets the bore wall. 11. Start the actuator and the start the engine. Do not start engines that have air flow meters. 12. Spray Carburetor Tune-up Cleaner into the throttle bore for up to one (1) minute to wash away residue. Do not spray for longer than six (6) continuous seconds on engines that have air flow meters and are not running. 13. Spray Carburetor Tune-up Cleaner into the idle by-pass valve passage leading to the inlet of the valve for up to one (1) minute. Do not spray for longer than six (6) continuous seconds on engines that have air flow meters and are not running. 14. Stop actuator and stop engine, if running. NOTE: MAKE SURE THE THROTTLE PLATES OPERATE FREELY AND CLOSE PROPERLY. 15. Reinstall the air duct. 16. Start and run the engine for about one (1) minute to dry out the solvent residue. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > Customer Interest: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3338 17. Operate the actuator to make sure the solvent is purged from the idle by-pass valve. 18. Disconnect the actuator from the idle air by-pass valve. 19. Reattach the control signal lead to the air by-pass valve. 20. Check engine for normal operation. It may be necessary to reset the idle speed due to a previous adjustment for an idle concern. (Refer to the respective Powertrain/Emissions Diagnosis Service Manual, Throttle Body Section, for idle speed adjust procedure.) Procedure # 2 Idle Air By-Pass Valve Cleaning Only CAUTION: THIS CLEANING PROCEDURE MAY BE USED WITH SLUDGE TOLERANT THROTTLE BODIES WHICH ARE IDENTIFIED WITH A YELLOW/BLACK "ATTENTION" LABEL AND THOSE USING SERVICE KIT (F2PZ-9F939-A). NO ATTEMPT SHOULD BE MADE TO CLEAN THROTTLE BODY BORE/PLATE AREA BY DIRECT SPRAYING OR SCRUBBING. DO NOT RUN VEHICLES WITH AIR FLOW METERS DURING CLEANING PROCEDURE. 1. Plug the actuator into the connector in the Rotunda Air By-Pass Valve Adapter 113-00009, or equivalent. 2. Remove the air duct to the throttle body inlet. 3. Disconnect the idle air by-pass valve signal lead. 4. Attach the actuator harness plug to the idle air by-pass valve. 5. Start the actuator and then start the engine. NOTE: DO NOT START ENGINES THAT HAVE AIR FLOW METERS. 6. Spray the Carburetor Tune-up Cleaner for about five (5) seconds into the idle air by-pass valve inlet passage while the actuator is operating. CAUTION: AVOID DIRECT SPRAYING ON THROTTLE PLATE/BORE AREA. 7. Stop the engine and actuator. Let everything soak for fifteen (15) minutes. 8. Start the actuator and the start the engine. CAUTION: DO NOT START ENGINES THAT HAVE AIR FLOW METERS. 9. Spray Carburetor Tune-up Cleaner into the throttle bore for up to one (1) minute. CAUTION: DO NOT SPRAY FOR LONGER THAN SIX (6) CONTINUOUS SECONDS ON ENGINES THAT HAVE AIR FLOW METERS AND ARE NOT RUNNING. 10. Stop actuator and stop engine if running. 11. Reinstall the air duct. 12. Start and run the engine for about one (1) minute to dry out the solvent residue. 13. Operate the actuator to make sure the solvent is purged from the idle by-pass valve. 14. Disconnect the actuator from the idle air by-pass valve. 15. Reattach the control signal lead to the air by-pass valve. 16. Check engine for normal operation. NOTE: IT SHOULD NOT BE NECESSARY TO RESET THE IDLE SPEED SINCE ONLY THE IDLE AIR BY-PASS VALVE WAS SERVICED IN THIS PROCEDURE Warranty Coverage Throttle bodies and idle air by-pass valves on all EFI (Port Fuel Injection) engines through the 1992 model year that can be cleaned (as identified in the application charts) are covered under 5/50 Emissions Warranty Coverage. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > Customer Interest: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3339 For those throttle bodies identified as having sludge tolerant designs or using service kit (F2PZ-9F939-A) where cleaning is not allowed per the application charts, the warranty claims for cleaning will not be reimbursed even within the 12/12 warranty coverage period. Cleaning is not allowed. Service kit installation (single time) is covered under 5/50 emission warranty. Labor Standards Operations The labor operations shown in the following Operation/Description/Time columns are identified by procedure number and vehicle line. Specific engines for various vehicles are identified in the sludge cleaning procedure application charts. The throttle body cleaning operations with combinations and the air by-pass valve cleaning combinations will appear in future Labor Manuals under the following operation numbers. ^ 9926 B - Throttle body and idle air by-pass valve cleaning ^ 9926 B2 - Adjust idle speed ^ 9715 A - Air by-pass valve cleaning only ^ 9715 A1 - Adjust idle speed PART NUMBER PART NAME CLASS F2PZ-9F939-A Idle Air By-pass Service Kit B D9AZ-19579-AA Carburstor Tune-Up Cleaner BG OTHER APPLICABLE ARTICLES: 89-13-8 SUPERSEDES: 88-24-5, 88-24-6, 89-16-5, 91-10-9, 91-7-4 Operation Description WARRANTY STATUS: Eligible Under Warranty Coverage As Stated In The Text Of This Article OPERATION DESCRIPTION TIME 912507A Idle Air By-Pass Valve 0.5 Hr. Cleaning - 1983-85 Escort, EXP, LN7, LYNX 1.6L EFI. 912507B Idle Air By-Pass Valve 0.5 Hr. Cleaning - 1986-91 Escort 1.9L EFI, 1986/87 EXP, Lynx 1.9L EFI, 1991 Tracer 1.9L EFI. 912507C Idle Air By Pass Valve 0.5 Hr. Cleaning - 1984-87 Mustang 2.3L T/C, 1986/87 Capri, Cougar 2.3L T/C, 1984-88 T-Bird 2.3L T/C, 1987/92 Mustang 2.3L EFI. 912507D Idle By-Pass Valve Cleaning 0.6 Hr. - 1988-91 Tempo, Topaz 2.3L HSC, 1985-92 Ranger 2.3L EFI. 912507E Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1986/87 Aerostar 2.3L EFI, 1985 Bronco II 2.3L EFI. 912507F Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1986-90 Bronco II 2.9L EFI, 1986-92 Ranger 2.9L EFI. 912507G Idle Air By-Pass Valve 0.6 Hr. Cleaning - 1991/92 Probe 3.0L EFI, 1986-91 Taurus 3.0L EFI, 1987-91 Sable 3.0L EFI. 912507H Idle Air By-Pass Valve 0.7 Hr. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > Customer Interest: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3340 Cleaning - 1986-91 Aerostar 3.0L EFI, 1991 Ranger 3.0L EFI. 912507I Idle Air By-Pass Valve 0.6 Hr. Cleaning - 1988 Continental, Cougar, Taurus, T-Bird, Sable 3.8L EFI. 1988 Cougar, T-Bird 3.8L S/C. 912507J Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1990-92 Aerostar 4.0L EFI, 1990 Bronco II 4.0L EFI, 1991/92 Explorer 4.0L EFI, 1990-92 Ranger 4.0L EFI. 912507K Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1987-92 Bronco 4.9L EFI, 1987-92 F-Series 4.9L EFI, 1987/90 Econoline (Without Rear Heater) 4.9L EFI, 1991/92 Econoline (All) 4.9L EFI. 912507L Idle Air By-Pass Valve 0.6 Hr. Cleaning - 1986-88 Cougar, T-Bird 5.0L EFI, 1986-87 Continental, Mark VII 5.OL EFI, 1986/91 Crn - Victoria, Grn - Marquis 5.0L EFI, 1986-92 Mark VII 5.0L HO, 1982-92 Mustang 5.0L HO. 912507M Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1985-92 Bronco, E-Series, F-Series 5.0L EFI. 912507N Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1988-90 Bronco, F-Series 5.8L. 1991 Econo, F-Series, Bronco 5.8L (Do not Clean Solenoid, Calib; 1-64E-R10, 1-64H-R10, 1-64J-R10, 1-64K-R10, 1-64M-R10, 1-64P-R10, 1-64R-R10, 1-75A-R00, 1-76A-R00, 1-76B-R00, 1-76C-R00. 912507O Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1991/92 F And B Series, 7.0L EFI. 912507P Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1987-92 E-Series, F-Series 7.5L EFI. 912507Q Throttle Body And Idle Air 0.9 Hr. By-Pass Valve Cleaning - 1989/90 Probe 3.0L EFI. 912507R Throttle Body And Idle Air 0.8 Hr. By-Pass Valve Cleaning - 1987-90 Econoline (With Rear Heat) 4.9L EFI. 912507S Throttle Body And Idle Air 0.9 Hr. By-Pass Valve Cleaning - 1988-90 Econoline 5.8L EFI. 912507T Service Kit Install - All Cars 1.0 Hr. And Light Trucks (Except Aerostar And Econoline) - Refer To The Service Procedure Application Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > Customer Interest: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3341 Charts, For Vehicle Application. 912507U Service Kit Install - 1.2 Hr. Aerostar, Econoline - Refer To Service Procedure Application Charts - For Vehicle Application. DEALER CODING BASIC PART NO. CONDITION CODE 9E926 49 OASIS CODES: 602300, 607000, 607400, 607700, 608400, 611500, 618400 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up Technical Service Bulletin # 91257 Date: 911213 Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up Article No. 91-25-7 12/13/91 ^ HARD COLD START - DURING INITIAL START-UP, IDLE OR DECEL - EFI ENGINES SLUDGE IN THROTTLE BODY AND/OR IDLE AIR BY-PASS VALVE ^ HESITATION/STALLS - DURING INITIAL START-UP, IDLE OR DECEL - EFI ENGINES SLUDGE IN THROTTLE BODY AND/OR IDLE AIR BY-PASS VALVE FORD: 1983-87 EXP 1983-91 ESCORT 1984-90 MUSTANG, THUNDERBIRD 1986-90 TAURUS 1986-91 CROWN VICTORIA 1988-90 TEMPO LINCOLN-MERCURY: 1983-85 LN7 1983-87 LYNX 1984-88 CAPRI 1984-90 COUGAR 1986-90 CONTINENTAL, MARK VII, SABLE 1986-91 GRAND MARQUIS, TOWN CAR 1988-90 TOPAZ 1991 TRACER LIGHT TRUCK: 1985-90 BRONCO II, BRONCO 1985-91 ECONOLINE, F-150-350 SERIES 1985-92 RANGER 1986-91 AEROSTAR 1991 EXPLORER ISSUE: Hard cold starts, hesitation and stalls on initial start-up or during idle or decel may be caused by sludge in the throttle body and/or idle by-pass valve. Sludge deposits or oil film on the throttle body bore and plate or the idle air by-pass valve may cause one or more of the following conditions. ^ Hard Cold Start ^ Stall On Initial Start-Up ^ Stall During Idle ^ Stall During Decel ^ Rough Idle ^ Rolling Idle ^ Hesitation During Acceleration ACTION: A new idle air by-pass service kit (F2PZ-9F939-A) is now available for service use to correct sludge contamination concerns of the throttle bore and plate only. It eliminates the need to clean the majority of past model throttle body applications. Cleaning is not required on sludge tolerant throttle body designs released for 1991 and newer model years. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3347 Figure 1 Install an idle air by-pass service kit (F2PZ-9F939-A) as applicable to provide a permanent correction for symptoms caused by throttle body sludge deposits. Refer to the instruction sheet included in the kit for installation details. Refer to Figure 1 for a specific application list of EFI (port fuel Injection) engines involved in this TSB article. The idle air by-pass service kit (F2PZ-9F939-A) includes the following items. ^ One (1) Idle Adjust Spacer ^ Two (2) Gaskets Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3348 ^ Two (2) Attaching Bolts ^ One (1) "Attention" Sticker ^ One (1) Instruction Sheet Figure 2 Refer to Figure 2 for a pictorial of the kits components. NOTE: EFFECTIVE WITH THIS TSB, THROTTLE BODY CLEANING IS NO LONGER COVERED UNDER 5/50 EMISSIONS WARRANTY, UNLESS AS SPECIFIED IN THE FOLLOWING APPLICATION CHARTS. FAILURE TO FOLLOW THE CORRECT PROCEDURE MAY RESULT IN THE CLAIM BEING DISALLOWED. The idle air adjust spacer incorporates sludge tolerant design features that eliminate throttle body sludge related conditions. Once installed, throttle body cleaning is not allowed and periodic adjustment of the throttle body is not required. Procedures, Warranty and Labor CHECKS TO MAKE PRIOR TO SERVICE KIT INSTALLATION Confirm that the following items are not causing the idle quality concern before proceeding with the service kit installation. ^ Contamination within the idle air by-pass solenoid ^ Lack of fuel system control (excessively rich or lean) ^ Ignition timing change ^ Incorrect or malfunctioning EGR system ^ Incorrect or malfunctioning cooling system ^ Vacuum leaks (air intake manifold, vacuum hoses, vacuum reservoirs, power brake booster where applicable) ^ EEC diagnostics have been performed and vehicle malfunction indicated service output codes have been resolved and cleared. If any of the areas listed above are found to be at fault, correct them before proceeding with the service kit installation. Idle Speed Adjustment Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3349 WARNING: BEFORE PROCEEDING WITH THE IDLE SPEED ADJUSTMENT, VERIFY THAT THE FOLLOWING ITEMS ARE TAKEN CARE OF PROPERLY. ^ The transmission is in PARK or Neutral. ^ The parking brake is applied. ^ The wheels are properly blocked. ^ The engine is at operating temperature. ^ The heater, A/C, cooling fan and other accessories are OFF. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3350 Figure 3 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3351 Figure 4 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3352 Figure 5 The EFI throttle body idle speed adjustment procedures for the various model year passenger cars and light trucks are outlined in step-by-step procedures featured in Figures 3, 4 and 5. Select the appropriate procedure for the vehicle involved and adjust the throttle body idle RPM accordingly, after service kit installation. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3353 Figure 6 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3354 Figure 7 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3355 Figure 8 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3356 Figure 9 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3357 Figure 10 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3358 Figure 11 THROTTLE BODY AND IDLE AIR BY-PASS SOLENOID SERVICE PROCEDURE Detailed application charts for throttle body and idle air by-pass solenoid service procedures by engine VIN # /engine displacement/vehicle application and model year are shown in Figures 6 through 11. Refer to these charts to see if the service kit is to be installed and which service cleaning procedure, if any, is to be used. SERVICE CLEANING PROCEDURES The following items should be noted prior to beginning the service cleaning procedure. ^ Confirm that the correct service cleaning procedure is identified in the Application Charts, Figures 6-11, for the vehicle/engine combination being Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3359 serviced. ^ Do not clean throttle bodies identified to accept service kit (F2PZ-9F939-A), IDLE AIR ADJUST SPACER. ^ Use a 1" (25.4 mm) to 1-1/2" (38.1 mm) wire stemmed horse hair or nylon bottle cleaner type brush. ^ Use rubber gloves and eye protection. ^ Do not clean throttle bodies identified with a yellow/black "ATTENTION" label. ^ Do not clean "Black" plastic air by-pass valves. Refer to TSB 89-13-8 for service details. ^ Do not run vehicles with air flow meters when the air duct is removed. ^ Do not use carburetor cleaner as a cleaning solvent. Use Carburetor Tune-up Cleaner (D9AZ-19579-AA). Procedure # 1 THROTTLE BODY AND IDLE AIR BY-PASS VALVE CLEANING CAUTION: DO NOT RUN VEHICLES EQUIPPED WITH AIR FLOW METERS DURING THE CLEANING PROCEDURE. IF THERE IS A YELLOW/BLACK "ATTENTION" LABEL ON THE THROTTLE BODY ADVISING NOT TO CLEAN, OR IF THE VEHICLE IS IDENTIFIED AS ACCEPTING SERVICE KIT (F2PZ-9F939-A), USE PROCEDURE # 2 FOR IDLE AIR BY-PASS VALVE CLEANING ONLY. 1. Plug the actuator into the connector in the Rotunda Cleaner/Tester, Tool 113-00009. 2. Remove the air duct to the throttle body inlet. 3. Disoonnect the idle air by-pass valve signal lead. 4. Attach the actuator harness plug to the idle air by-pass valve. 5. Start the actuator and then start the engine. Do not start engines that have air flow meters. 6. Spray just enough Carburetor Tune-up Cleaner (D9AZ-19579-AA) into the throttle bore to wet the bore and throttle plate. 7. Spray the Carburetor Tune-up Cleaner for about five (5) seconds into the idle air by-pass valve inlet passage while the actuator is operating. 8. Stop the engine and actuator. Let everything soak for fifteen (15) minutes. 9. After a fifteen (15) minute soak, saturate the cleaning brush with solvent and scrub between the throttle body bore and plate while holding the throttle wide open. NOTE: IT IS NECESSARY TO APPLY SOME PRESSURE ON THE BRUSH WHILE SCRUBBING. 10. Repeat saturating the brush and scrubbing for one (1) to two (2) minutes, making sure to reach into the corners where the throttle shaft meets the bore wall. 11. Start the actuator and the start the engine. Do not start engines that have air flow meters. 12. Spray Carburetor Tune-up Cleaner into the throttle bore for up to one (1) minute to wash away residue. Do not spray for longer than six (6) continuous seconds on engines that have air flow meters and are not running. 13. Spray Carburetor Tune-up Cleaner into the idle by-pass valve passage leading to the inlet of the valve for up to one (1) minute. Do not spray for longer than six (6) continuous seconds on engines that have air flow meters and are not running. 14. Stop actuator and stop engine, if running. NOTE: MAKE SURE THE THROTTLE PLATES OPERATE FREELY AND CLOSE PROPERLY. 15. Reinstall the air duct. 16. Start and run the engine for about one (1) minute to dry out the solvent residue. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3360 17. Operate the actuator to make sure the solvent is purged from the idle by-pass valve. 18. Disconnect the actuator from the idle air by-pass valve. 19. Reattach the control signal lead to the air by-pass valve. 20. Check engine for normal operation. It may be necessary to reset the idle speed due to a previous adjustment for an idle concern. (Refer to the respective Powertrain/Emissions Diagnosis Service Manual, Throttle Body Section, for idle speed adjust procedure.) Procedure # 2 Idle Air By-Pass Valve Cleaning Only CAUTION: THIS CLEANING PROCEDURE MAY BE USED WITH SLUDGE TOLERANT THROTTLE BODIES WHICH ARE IDENTIFIED WITH A YELLOW/BLACK "ATTENTION" LABEL AND THOSE USING SERVICE KIT (F2PZ-9F939-A). NO ATTEMPT SHOULD BE MADE TO CLEAN THROTTLE BODY BORE/PLATE AREA BY DIRECT SPRAYING OR SCRUBBING. DO NOT RUN VEHICLES WITH AIR FLOW METERS DURING CLEANING PROCEDURE. 1. Plug the actuator into the connector in the Rotunda Air By-Pass Valve Adapter 113-00009, or equivalent. 2. Remove the air duct to the throttle body inlet. 3. Disconnect the idle air by-pass valve signal lead. 4. Attach the actuator harness plug to the idle air by-pass valve. 5. Start the actuator and then start the engine. NOTE: DO NOT START ENGINES THAT HAVE AIR FLOW METERS. 6. Spray the Carburetor Tune-up Cleaner for about five (5) seconds into the idle air by-pass valve inlet passage while the actuator is operating. CAUTION: AVOID DIRECT SPRAYING ON THROTTLE PLATE/BORE AREA. 7. Stop the engine and actuator. Let everything soak for fifteen (15) minutes. 8. Start the actuator and the start the engine. CAUTION: DO NOT START ENGINES THAT HAVE AIR FLOW METERS. 9. Spray Carburetor Tune-up Cleaner into the throttle bore for up to one (1) minute. CAUTION: DO NOT SPRAY FOR LONGER THAN SIX (6) CONTINUOUS SECONDS ON ENGINES THAT HAVE AIR FLOW METERS AND ARE NOT RUNNING. 10. Stop actuator and stop engine if running. 11. Reinstall the air duct. 12. Start and run the engine for about one (1) minute to dry out the solvent residue. 13. Operate the actuator to make sure the solvent is purged from the idle by-pass valve. 14. Disconnect the actuator from the idle air by-pass valve. 15. Reattach the control signal lead to the air by-pass valve. 16. Check engine for normal operation. NOTE: IT SHOULD NOT BE NECESSARY TO RESET THE IDLE SPEED SINCE ONLY THE IDLE AIR BY-PASS VALVE WAS SERVICED IN THIS PROCEDURE Warranty Coverage Throttle bodies and idle air by-pass valves on all EFI (Port Fuel Injection) engines through the 1992 model year that can be cleaned (as identified in the application charts) are covered under 5/50 Emissions Warranty Coverage. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3361 For those throttle bodies identified as having sludge tolerant designs or using service kit (F2PZ-9F939-A) where cleaning is not allowed per the application charts, the warranty claims for cleaning will not be reimbursed even within the 12/12 warranty coverage period. Cleaning is not allowed. Service kit installation (single time) is covered under 5/50 emission warranty. Labor Standards Operations The labor operations shown in the following Operation/Description/Time columns are identified by procedure number and vehicle line. Specific engines for various vehicles are identified in the sludge cleaning procedure application charts. The throttle body cleaning operations with combinations and the air by-pass valve cleaning combinations will appear in future Labor Manuals under the following operation numbers. ^ 9926 B - Throttle body and idle air by-pass valve cleaning ^ 9926 B2 - Adjust idle speed ^ 9715 A - Air by-pass valve cleaning only ^ 9715 A1 - Adjust idle speed PART NUMBER PART NAME CLASS F2PZ-9F939-A Idle Air By-pass Service Kit B D9AZ-19579-AA Carburstor Tune-Up Cleaner BG OTHER APPLICABLE ARTICLES: 89-13-8 SUPERSEDES: 88-24-5, 88-24-6, 89-16-5, 91-10-9, 91-7-4 Operation Description WARRANTY STATUS: Eligible Under Warranty Coverage As Stated In The Text Of This Article OPERATION DESCRIPTION TIME 912507A Idle Air By-Pass Valve 0.5 Hr. Cleaning - 1983-85 Escort, EXP, LN7, LYNX 1.6L EFI. 912507B Idle Air By-Pass Valve 0.5 Hr. Cleaning - 1986-91 Escort 1.9L EFI, 1986/87 EXP, Lynx 1.9L EFI, 1991 Tracer 1.9L EFI. 912507C Idle Air By Pass Valve 0.5 Hr. Cleaning - 1984-87 Mustang 2.3L T/C, 1986/87 Capri, Cougar 2.3L T/C, 1984-88 T-Bird 2.3L T/C, 1987/92 Mustang 2.3L EFI. 912507D Idle By-Pass Valve Cleaning 0.6 Hr. - 1988-91 Tempo, Topaz 2.3L HSC, 1985-92 Ranger 2.3L EFI. 912507E Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1986/87 Aerostar 2.3L EFI, 1985 Bronco II 2.3L EFI. 912507F Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1986-90 Bronco II 2.9L EFI, 1986-92 Ranger 2.9L EFI. 912507G Idle Air By-Pass Valve 0.6 Hr. Cleaning - 1991/92 Probe 3.0L EFI, 1986-91 Taurus 3.0L EFI, 1987-91 Sable 3.0L EFI. 912507H Idle Air By-Pass Valve 0.7 Hr. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3362 Cleaning - 1986-91 Aerostar 3.0L EFI, 1991 Ranger 3.0L EFI. 912507I Idle Air By-Pass Valve 0.6 Hr. Cleaning - 1988 Continental, Cougar, Taurus, T-Bird, Sable 3.8L EFI. 1988 Cougar, T-Bird 3.8L S/C. 912507J Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1990-92 Aerostar 4.0L EFI, 1990 Bronco II 4.0L EFI, 1991/92 Explorer 4.0L EFI, 1990-92 Ranger 4.0L EFI. 912507K Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1987-92 Bronco 4.9L EFI, 1987-92 F-Series 4.9L EFI, 1987/90 Econoline (Without Rear Heater) 4.9L EFI, 1991/92 Econoline (All) 4.9L EFI. 912507L Idle Air By-Pass Valve 0.6 Hr. Cleaning - 1986-88 Cougar, T-Bird 5.0L EFI, 1986-87 Continental, Mark VII 5.OL EFI, 1986/91 Crn - Victoria, Grn - Marquis 5.0L EFI, 1986-92 Mark VII 5.0L HO, 1982-92 Mustang 5.0L HO. 912507M Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1985-92 Bronco, E-Series, F-Series 5.0L EFI. 912507N Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1988-90 Bronco, F-Series 5.8L. 1991 Econo, F-Series, Bronco 5.8L (Do not Clean Solenoid, Calib; 1-64E-R10, 1-64H-R10, 1-64J-R10, 1-64K-R10, 1-64M-R10, 1-64P-R10, 1-64R-R10, 1-75A-R00, 1-76A-R00, 1-76B-R00, 1-76C-R00. 912507O Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1991/92 F And B Series, 7.0L EFI. 912507P Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1987-92 E-Series, F-Series 7.5L EFI. 912507Q Throttle Body And Idle Air 0.9 Hr. By-Pass Valve Cleaning - 1989/90 Probe 3.0L EFI. 912507R Throttle Body And Idle Air 0.8 Hr. By-Pass Valve Cleaning - 1987-90 Econoline (With Rear Heat) 4.9L EFI. 912507S Throttle Body And Idle Air 0.9 Hr. By-Pass Valve Cleaning - 1988-90 Econoline 5.8L EFI. 912507T Service Kit Install - All Cars 1.0 Hr. And Light Trucks (Except Aerostar And Econoline) - Refer To The Service Procedure Application Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3363 Charts, For Vehicle Application. 912507U Service Kit Install - 1.2 Hr. Aerostar, Econoline - Refer To Service Procedure Application Charts - For Vehicle Application. DEALER CODING BASIC PART NO. CONDITION CODE 9E926 49 OASIS CODES: 602300, 607000, 607400, 607700, 608400, 611500, 618400 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 861516 > Jul > 86 > Vehicle - High Altitude Modification Idle Speed: All Technical Service Bulletins Vehicle - High Altitude Modification Article No. 86-15-16 ALTITUDE (5.8L (W)) - MODIFICATION OF SEA LEVEL CALIBRATION FOR ALTITUDE APPLICATION - VEHICLES WITH 4V CARBURETORS ONLY - OVER 8500 LBS. GVWR LIGHT TRUCK 1986 E SERIES, F SERIES CALIBRATION: 5-76J-R17 (Manual Transmission) WARNING: This modification is authorized only for the listed engines. Performing this modification on other engine calibrations is unauthorized and could create liability under applicable federal or local laws. Customers who may have relocated and/or continually operate the subject vehicles in high altitude (above 4,000 ft. alt.) may have the following procedure performed to improve performance. 1. Remove existing PCV valve and replace with new PCV valve (part number D90Z-6A666-A). 2. Advance initial ignition timing 6~ from nominal setting of 8~ BTDC to 14~ BTDC. Refer to 1986 Light Truck Shop Manual, Volume B, Section 23-01. 3. Increase choke pull down hard gauge setting to .193". Refer to 1986 Light Truck Shop Manual, Volume B, Section 24-26. 4. Remove existing choke cap and replace with new choke cap 47R-776-A (part number E5PZ-9848-B). 5. Reset hi-cam and curb idle speeds to specification (refer to Vehicle Emission Control Information Decal). Obtain a Vehicle Emission Control Information Update Decal (available at all Ford or Lincoln-Mercury dealers) and fill in the appropriate information as indicated. If the vehicle is returned to continuous sea level (below 4,000 ft. alt.) operation, the above procedure should be reversed and the Vehicle Emission Control Information Update Decal should be removed from the vehicle. PART NUMBER PART NAME CLASS D90Z-6A666-A PCV Valve A E5PZ-9848-B Choke Cap C OTHER APPLICABLE ARTICLES: 85-21-16 WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION: SP9514A86 TIME: 1.3 Hrs. DLR. CODING: Basic Part No. DRIVE - Code: N4, P6, T5 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > All Other Service Bulletins for Idle Speed: > 861516 > Jul > 86 > Vehicle - High Altitude Modification Idle Speed: All Technical Service Bulletins Vehicle - High Altitude Modification Article No. 86-15-16 ALTITUDE (5.8L (W)) - MODIFICATION OF SEA LEVEL CALIBRATION FOR ALTITUDE APPLICATION - VEHICLES WITH 4V CARBURETORS ONLY - OVER 8500 LBS. GVWR LIGHT TRUCK 1986 E SERIES, F SERIES CALIBRATION: 5-76J-R17 (Manual Transmission) WARNING: This modification is authorized only for the listed engines. Performing this modification on other engine calibrations is unauthorized and could create liability under applicable federal or local laws. Customers who may have relocated and/or continually operate the subject vehicles in high altitude (above 4,000 ft. alt.) may have the following procedure performed to improve performance. 1. Remove existing PCV valve and replace with new PCV valve (part number D90Z-6A666-A). 2. Advance initial ignition timing 6~ from nominal setting of 8~ BTDC to 14~ BTDC. Refer to 1986 Light Truck Shop Manual, Volume B, Section 23-01. 3. Increase choke pull down hard gauge setting to .193". Refer to 1986 Light Truck Shop Manual, Volume B, Section 24-26. 4. Remove existing choke cap and replace with new choke cap 47R-776-A (part number E5PZ-9848-B). 5. Reset hi-cam and curb idle speeds to specification (refer to Vehicle Emission Control Information Decal). Obtain a Vehicle Emission Control Information Update Decal (available at all Ford or Lincoln-Mercury dealers) and fill in the appropriate information as indicated. If the vehicle is returned to continuous sea level (below 4,000 ft. alt.) operation, the above procedure should be reversed and the Vehicle Emission Control Information Update Decal should be removed from the vehicle. PART NUMBER PART NAME CLASS D90Z-6A666-A PCV Valve A E5PZ-9848-B Choke Cap C OTHER APPLICABLE ARTICLES: 85-21-16 WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION: SP9514A86 TIME: 1.3 Hrs. DLR. CODING: Basic Part No. DRIVE - Code: N4, P6, T5 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > All Other Service Bulletins for Idle Speed: > Page 3373 Idle Speed: By Symptom Technical Service Bulletin # 91257 Date: 911213 Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up Article No. 91-25-7 12/13/91 ^ HARD COLD START - DURING INITIAL START-UP, IDLE OR DECEL - EFI ENGINES SLUDGE IN THROTTLE BODY AND/OR IDLE AIR BY-PASS VALVE ^ HESITATION/STALLS - DURING INITIAL START-UP, IDLE OR DECEL - EFI ENGINES SLUDGE IN THROTTLE BODY AND/OR IDLE AIR BY-PASS VALVE FORD: 1983-87 EXP 1983-91 ESCORT 1984-90 MUSTANG, THUNDERBIRD 1986-90 TAURUS 1986-91 CROWN VICTORIA 1988-90 TEMPO LINCOLN-MERCURY: 1983-85 LN7 1983-87 LYNX 1984-88 CAPRI 1984-90 COUGAR 1986-90 CONTINENTAL, MARK VII, SABLE 1986-91 GRAND MARQUIS, TOWN CAR 1988-90 TOPAZ 1991 TRACER LIGHT TRUCK: 1985-90 BRONCO II, BRONCO 1985-91 ECONOLINE, F-150-350 SERIES 1985-92 RANGER 1986-91 AEROSTAR 1991 EXPLORER ISSUE: Hard cold starts, hesitation and stalls on initial start-up or during idle or decel may be caused by sludge in the throttle body and/or idle by-pass valve. Sludge deposits or oil film on the throttle body bore and plate or the idle air by-pass valve may cause one or more of the following conditions. ^ Hard Cold Start ^ Stall On Initial Start-Up ^ Stall During Idle ^ Stall During Decel ^ Rough Idle ^ Rolling Idle ^ Hesitation During Acceleration ACTION: A new idle air by-pass service kit (F2PZ-9F939-A) is now available for service use to correct sludge contamination concerns of the throttle bore and plate only. It eliminates the need to clean the majority of past model throttle body applications. Cleaning is not required on sludge tolerant throttle body designs released for 1991 and newer model years. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > All Other Service Bulletins for Idle Speed: > Page 3374 Figure 1 Install an idle air by-pass service kit (F2PZ-9F939-A) as applicable to provide a permanent correction for symptoms caused by throttle body sludge deposits. Refer to the instruction sheet included in the kit for installation details. Refer to Figure 1 for a specific application list of EFI (port fuel Injection) engines involved in this TSB article. The idle air by-pass service kit (F2PZ-9F939-A) includes the following items. ^ One (1) Idle Adjust Spacer ^ Two (2) Gaskets Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > All Other Service Bulletins for Idle Speed: > Page 3375 ^ Two (2) Attaching Bolts ^ One (1) "Attention" Sticker ^ One (1) Instruction Sheet Figure 2 Refer to Figure 2 for a pictorial of the kits components. NOTE: EFFECTIVE WITH THIS TSB, THROTTLE BODY CLEANING IS NO LONGER COVERED UNDER 5/50 EMISSIONS WARRANTY, UNLESS AS SPECIFIED IN THE FOLLOWING APPLICATION CHARTS. FAILURE TO FOLLOW THE CORRECT PROCEDURE MAY RESULT IN THE CLAIM BEING DISALLOWED. The idle air adjust spacer incorporates sludge tolerant design features that eliminate throttle body sludge related conditions. Once installed, throttle body cleaning is not allowed and periodic adjustment of the throttle body is not required. Procedures, Warranty and Labor CHECKS TO MAKE PRIOR TO SERVICE KIT INSTALLATION Confirm that the following items are not causing the idle quality concern before proceeding with the service kit installation. ^ Contamination within the idle air by-pass solenoid ^ Lack of fuel system control (excessively rich or lean) ^ Ignition timing change ^ Incorrect or malfunctioning EGR system ^ Incorrect or malfunctioning cooling system ^ Vacuum leaks (air intake manifold, vacuum hoses, vacuum reservoirs, power brake booster where applicable) ^ EEC diagnostics have been performed and vehicle malfunction indicated service output codes have been resolved and cleared. If any of the areas listed above are found to be at fault, correct them before proceeding with the service kit installation. Idle Speed Adjustment Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > All Other Service Bulletins for Idle Speed: > Page 3376 WARNING: BEFORE PROCEEDING WITH THE IDLE SPEED ADJUSTMENT, VERIFY THAT THE FOLLOWING ITEMS ARE TAKEN CARE OF PROPERLY. ^ The transmission is in PARK or Neutral. ^ The parking brake is applied. ^ The wheels are properly blocked. ^ The engine is at operating temperature. ^ The heater, A/C, cooling fan and other accessories are OFF. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > All Other Service Bulletins for Idle Speed: > Page 3377 Figure 3 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > All Other Service Bulletins for Idle Speed: > Page 3378 Figure 4 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > All Other Service Bulletins for Idle Speed: > Page 3379 Figure 5 The EFI throttle body idle speed adjustment procedures for the various model year passenger cars and light trucks are outlined in step-by-step procedures featured in Figures 3, 4 and 5. Select the appropriate procedure for the vehicle involved and adjust the throttle body idle RPM accordingly, after service kit installation. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > All Other Service Bulletins for Idle Speed: > Page 3380 Figure 6 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > All Other Service Bulletins for Idle Speed: > Page 3381 Figure 7 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > All Other Service Bulletins for Idle Speed: > Page 3382 Figure 8 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > All Other Service Bulletins for Idle Speed: > Page 3383 Figure 9 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > All Other Service Bulletins for Idle Speed: > Page 3384 Figure 10 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > All Other Service Bulletins for Idle Speed: > Page 3385 Figure 11 THROTTLE BODY AND IDLE AIR BY-PASS SOLENOID SERVICE PROCEDURE Detailed application charts for throttle body and idle air by-pass solenoid service procedures by engine VIN # /engine displacement/vehicle application and model year are shown in Figures 6 through 11. Refer to these charts to see if the service kit is to be installed and which service cleaning procedure, if any, is to be used. SERVICE CLEANING PROCEDURES The following items should be noted prior to beginning the service cleaning procedure. ^ Confirm that the correct service cleaning procedure is identified in the Application Charts, Figures 6-11, for the vehicle/engine combination being Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > All Other Service Bulletins for Idle Speed: > Page 3386 serviced. ^ Do not clean throttle bodies identified to accept service kit (F2PZ-9F939-A), IDLE AIR ADJUST SPACER. ^ Use a 1" (25.4 mm) to 1-1/2" (38.1 mm) wire stemmed horse hair or nylon bottle cleaner type brush. ^ Use rubber gloves and eye protection. ^ Do not clean throttle bodies identified with a yellow/black "ATTENTION" label. ^ Do not clean "Black" plastic air by-pass valves. Refer to TSB 89-13-8 for service details. ^ Do not run vehicles with air flow meters when the air duct is removed. ^ Do not use carburetor cleaner as a cleaning solvent. Use Carburetor Tune-up Cleaner (D9AZ-19579-AA). Procedure # 1 THROTTLE BODY AND IDLE AIR BY-PASS VALVE CLEANING CAUTION: DO NOT RUN VEHICLES EQUIPPED WITH AIR FLOW METERS DURING THE CLEANING PROCEDURE. IF THERE IS A YELLOW/BLACK "ATTENTION" LABEL ON THE THROTTLE BODY ADVISING NOT TO CLEAN, OR IF THE VEHICLE IS IDENTIFIED AS ACCEPTING SERVICE KIT (F2PZ-9F939-A), USE PROCEDURE # 2 FOR IDLE AIR BY-PASS VALVE CLEANING ONLY. 1. Plug the actuator into the connector in the Rotunda Cleaner/Tester, Tool 113-00009. 2. Remove the air duct to the throttle body inlet. 3. Disoonnect the idle air by-pass valve signal lead. 4. Attach the actuator harness plug to the idle air by-pass valve. 5. Start the actuator and then start the engine. Do not start engines that have air flow meters. 6. Spray just enough Carburetor Tune-up Cleaner (D9AZ-19579-AA) into the throttle bore to wet the bore and throttle plate. 7. Spray the Carburetor Tune-up Cleaner for about five (5) seconds into the idle air by-pass valve inlet passage while the actuator is operating. 8. Stop the engine and actuator. Let everything soak for fifteen (15) minutes. 9. After a fifteen (15) minute soak, saturate the cleaning brush with solvent and scrub between the throttle body bore and plate while holding the throttle wide open. NOTE: IT IS NECESSARY TO APPLY SOME PRESSURE ON THE BRUSH WHILE SCRUBBING. 10. Repeat saturating the brush and scrubbing for one (1) to two (2) minutes, making sure to reach into the corners where the throttle shaft meets the bore wall. 11. Start the actuator and the start the engine. Do not start engines that have air flow meters. 12. Spray Carburetor Tune-up Cleaner into the throttle bore for up to one (1) minute to wash away residue. Do not spray for longer than six (6) continuous seconds on engines that have air flow meters and are not running. 13. Spray Carburetor Tune-up Cleaner into the idle by-pass valve passage leading to the inlet of the valve for up to one (1) minute. Do not spray for longer than six (6) continuous seconds on engines that have air flow meters and are not running. 14. Stop actuator and stop engine, if running. NOTE: MAKE SURE THE THROTTLE PLATES OPERATE FREELY AND CLOSE PROPERLY. 15. Reinstall the air duct. 16. Start and run the engine for about one (1) minute to dry out the solvent residue. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > All Other Service Bulletins for Idle Speed: > Page 3387 17. Operate the actuator to make sure the solvent is purged from the idle by-pass valve. 18. Disconnect the actuator from the idle air by-pass valve. 19. Reattach the control signal lead to the air by-pass valve. 20. Check engine for normal operation. It may be necessary to reset the idle speed due to a previous adjustment for an idle concern. (Refer to the respective Powertrain/Emissions Diagnosis Service Manual, Throttle Body Section, for idle speed adjust procedure.) Procedure # 2 Idle Air By-Pass Valve Cleaning Only CAUTION: THIS CLEANING PROCEDURE MAY BE USED WITH SLUDGE TOLERANT THROTTLE BODIES WHICH ARE IDENTIFIED WITH A YELLOW/BLACK "ATTENTION" LABEL AND THOSE USING SERVICE KIT (F2PZ-9F939-A). NO ATTEMPT SHOULD BE MADE TO CLEAN THROTTLE BODY BORE/PLATE AREA BY DIRECT SPRAYING OR SCRUBBING. DO NOT RUN VEHICLES WITH AIR FLOW METERS DURING CLEANING PROCEDURE. 1. Plug the actuator into the connector in the Rotunda Air By-Pass Valve Adapter 113-00009, or equivalent. 2. Remove the air duct to the throttle body inlet. 3. Disconnect the idle air by-pass valve signal lead. 4. Attach the actuator harness plug to the idle air by-pass valve. 5. Start the actuator and then start the engine. NOTE: DO NOT START ENGINES THAT HAVE AIR FLOW METERS. 6. Spray the Carburetor Tune-up Cleaner for about five (5) seconds into the idle air by-pass valve inlet passage while the actuator is operating. CAUTION: AVOID DIRECT SPRAYING ON THROTTLE PLATE/BORE AREA. 7. Stop the engine and actuator. Let everything soak for fifteen (15) minutes. 8. Start the actuator and the start the engine. CAUTION: DO NOT START ENGINES THAT HAVE AIR FLOW METERS. 9. Spray Carburetor Tune-up Cleaner into the throttle bore for up to one (1) minute. CAUTION: DO NOT SPRAY FOR LONGER THAN SIX (6) CONTINUOUS SECONDS ON ENGINES THAT HAVE AIR FLOW METERS AND ARE NOT RUNNING. 10. Stop actuator and stop engine if running. 11. Reinstall the air duct. 12. Start and run the engine for about one (1) minute to dry out the solvent residue. 13. Operate the actuator to make sure the solvent is purged from the idle by-pass valve. 14. Disconnect the actuator from the idle air by-pass valve. 15. Reattach the control signal lead to the air by-pass valve. 16. Check engine for normal operation. NOTE: IT SHOULD NOT BE NECESSARY TO RESET THE IDLE SPEED SINCE ONLY THE IDLE AIR BY-PASS VALVE WAS SERVICED IN THIS PROCEDURE Warranty Coverage Throttle bodies and idle air by-pass valves on all EFI (Port Fuel Injection) engines through the 1992 model year that can be cleaned (as identified in the application charts) are covered under 5/50 Emissions Warranty Coverage. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > All Other Service Bulletins for Idle Speed: > Page 3388 For those throttle bodies identified as having sludge tolerant designs or using service kit (F2PZ-9F939-A) where cleaning is not allowed per the application charts, the warranty claims for cleaning will not be reimbursed even within the 12/12 warranty coverage period. Cleaning is not allowed. Service kit installation (single time) is covered under 5/50 emission warranty. Labor Standards Operations The labor operations shown in the following Operation/Description/Time columns are identified by procedure number and vehicle line. Specific engines for various vehicles are identified in the sludge cleaning procedure application charts. The throttle body cleaning operations with combinations and the air by-pass valve cleaning combinations will appear in future Labor Manuals under the following operation numbers. ^ 9926 B - Throttle body and idle air by-pass valve cleaning ^ 9926 B2 - Adjust idle speed ^ 9715 A - Air by-pass valve cleaning only ^ 9715 A1 - Adjust idle speed PART NUMBER PART NAME CLASS F2PZ-9F939-A Idle Air By-pass Service Kit B D9AZ-19579-AA Carburstor Tune-Up Cleaner BG OTHER APPLICABLE ARTICLES: 89-13-8 SUPERSEDES: 88-24-5, 88-24-6, 89-16-5, 91-10-9, 91-7-4 Operation Description WARRANTY STATUS: Eligible Under Warranty Coverage As Stated In The Text Of This Article OPERATION DESCRIPTION TIME 912507A Idle Air By-Pass Valve 0.5 Hr. Cleaning - 1983-85 Escort, EXP, LN7, LYNX 1.6L EFI. 912507B Idle Air By-Pass Valve 0.5 Hr. Cleaning - 1986-91 Escort 1.9L EFI, 1986/87 EXP, Lynx 1.9L EFI, 1991 Tracer 1.9L EFI. 912507C Idle Air By Pass Valve 0.5 Hr. Cleaning - 1984-87 Mustang 2.3L T/C, 1986/87 Capri, Cougar 2.3L T/C, 1984-88 T-Bird 2.3L T/C, 1987/92 Mustang 2.3L EFI. 912507D Idle By-Pass Valve Cleaning 0.6 Hr. - 1988-91 Tempo, Topaz 2.3L HSC, 1985-92 Ranger 2.3L EFI. 912507E Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1986/87 Aerostar 2.3L EFI, 1985 Bronco II 2.3L EFI. 912507F Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1986-90 Bronco II 2.9L EFI, 1986-92 Ranger 2.9L EFI. 912507G Idle Air By-Pass Valve 0.6 Hr. Cleaning - 1991/92 Probe 3.0L EFI, 1986-91 Taurus 3.0L EFI, 1987-91 Sable 3.0L EFI. 912507H Idle Air By-Pass Valve 0.7 Hr. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > All Other Service Bulletins for Idle Speed: > Page 3389 Cleaning - 1986-91 Aerostar 3.0L EFI, 1991 Ranger 3.0L EFI. 912507I Idle Air By-Pass Valve 0.6 Hr. Cleaning - 1988 Continental, Cougar, Taurus, T-Bird, Sable 3.8L EFI. 1988 Cougar, T-Bird 3.8L S/C. 912507J Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1990-92 Aerostar 4.0L EFI, 1990 Bronco II 4.0L EFI, 1991/92 Explorer 4.0L EFI, 1990-92 Ranger 4.0L EFI. 912507K Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1987-92 Bronco 4.9L EFI, 1987-92 F-Series 4.9L EFI, 1987/90 Econoline (Without Rear Heater) 4.9L EFI, 1991/92 Econoline (All) 4.9L EFI. 912507L Idle Air By-Pass Valve 0.6 Hr. Cleaning - 1986-88 Cougar, T-Bird 5.0L EFI, 1986-87 Continental, Mark VII 5.OL EFI, 1986/91 Crn - Victoria, Grn - Marquis 5.0L EFI, 1986-92 Mark VII 5.0L HO, 1982-92 Mustang 5.0L HO. 912507M Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1985-92 Bronco, E-Series, F-Series 5.0L EFI. 912507N Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1988-90 Bronco, F-Series 5.8L. 1991 Econo, F-Series, Bronco 5.8L (Do not Clean Solenoid, Calib; 1-64E-R10, 1-64H-R10, 1-64J-R10, 1-64K-R10, 1-64M-R10, 1-64P-R10, 1-64R-R10, 1-75A-R00, 1-76A-R00, 1-76B-R00, 1-76C-R00. 912507O Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1991/92 F And B Series, 7.0L EFI. 912507P Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1987-92 E-Series, F-Series 7.5L EFI. 912507Q Throttle Body And Idle Air 0.9 Hr. By-Pass Valve Cleaning - 1989/90 Probe 3.0L EFI. 912507R Throttle Body And Idle Air 0.8 Hr. By-Pass Valve Cleaning - 1987-90 Econoline (With Rear Heat) 4.9L EFI. 912507S Throttle Body And Idle Air 0.9 Hr. By-Pass Valve Cleaning - 1988-90 Econoline 5.8L EFI. 912507T Service Kit Install - All Cars 1.0 Hr. And Light Trucks (Except Aerostar And Econoline) - Refer To The Service Procedure Application Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > All Other Service Bulletins for Idle Speed: > Page 3390 Charts, For Vehicle Application. 912507U Service Kit Install - 1.2 Hr. Aerostar, Econoline - Refer To Service Procedure Application Charts - For Vehicle Application. DEALER CODING BASIC PART NO. CONDITION CODE 9E926 49 OASIS CODES: 602300, 607000, 607400, 607700, 608400, 611500, 618400 Technical Service Bulletin # 91257 Date: 911213 Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up Article No. 91-25-7 12/13/91 ^ HARD COLD START - DURING INITIAL START-UP, IDLE OR DECEL - EFI ENGINES SLUDGE IN THROTTLE BODY AND/OR IDLE AIR BY-PASS VALVE ^ HESITATION/STALLS - DURING INITIAL START-UP, IDLE OR DECEL - EFI ENGINES SLUDGE IN THROTTLE BODY AND/OR IDLE AIR BY-PASS VALVE FORD: 1983-87 EXP 1983-91 ESCORT 1984-90 MUSTANG, THUNDERBIRD 1986-90 TAURUS 1986-91 CROWN VICTORIA 1988-90 TEMPO LINCOLN-MERCURY: 1983-85 LN7 1983-87 LYNX 1984-88 CAPRI 1984-90 COUGAR 1986-90 CONTINENTAL, MARK VII, SABLE 1986-91 GRAND MARQUIS, TOWN CAR 1988-90 TOPAZ 1991 TRACER LIGHT TRUCK: 1985-90 BRONCO II, BRONCO 1985-91 ECONOLINE, F-150-350 SERIES 1985-92 RANGER 1986-91 AEROSTAR 1991 EXPLORER ISSUE: Hard cold starts, hesitation and stalls on initial start-up or during idle or decel may be caused by sludge in the throttle body and/or idle by-pass valve. Sludge deposits or oil film on the throttle body bore and plate or the idle air by-pass valve may cause one or more of the following conditions. ^ Hard Cold Start ^ Stall On Initial Start-Up ^ Stall During Idle ^ Stall During Decel ^ Rough Idle ^ Rolling Idle Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > All Other Service Bulletins for Idle Speed: > Page 3391 ^ Hesitation During Acceleration ACTION: A new idle air by-pass service kit (F2PZ-9F939-A) is now available for service use to correct sludge contamination concerns of the throttle bore and plate only. It eliminates the need to clean the majority of past model throttle body applications. Cleaning is not required on sludge tolerant throttle body designs released for 1991 and newer model years. Figure 1 Install an idle air by-pass service kit (F2PZ-9F939-A) as applicable to provide a permanent correction for symptoms caused by throttle body sludge deposits. Refer to the instruction sheet included in the kit for installation details. Refer to Figure 1 for a specific application list of EFI (port fuel Injection) engines involved in this TSB article. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > All Other Service Bulletins for Idle Speed: > Page 3392 The idle air by-pass service kit (F2PZ-9F939-A) includes the following items. ^ One (1) Idle Adjust Spacer ^ Two (2) Gaskets ^ Two (2) Attaching Bolts ^ One (1) "Attention" Sticker ^ One (1) Instruction Sheet Figure 2 Refer to Figure 2 for a pictorial of the kits components. NOTE: EFFECTIVE WITH THIS TSB, THROTTLE BODY CLEANING IS NO LONGER COVERED UNDER 5/50 EMISSIONS WARRANTY, UNLESS AS SPECIFIED IN THE FOLLOWING APPLICATION CHARTS. FAILURE TO FOLLOW THE CORRECT PROCEDURE MAY RESULT IN THE CLAIM BEING DISALLOWED. The idle air adjust spacer incorporates sludge tolerant design features that eliminate throttle body sludge related conditions. Once installed, throttle body cleaning is not allowed and periodic adjustment of the throttle body is not required. Procedures, Warranty and Labor CHECKS TO MAKE PRIOR TO SERVICE KIT INSTALLATION Confirm that the following items are not causing the idle quality concern before proceeding with the service kit installation. ^ Contamination within the idle air by-pass solenoid ^ Lack of fuel system control (excessively rich or lean) ^ Ignition timing change ^ Incorrect or malfunctioning EGR system ^ Incorrect or malfunctioning cooling system ^ Vacuum leaks (air intake manifold, vacuum hoses, vacuum reservoirs, power brake booster where applicable) ^ EEC diagnostics have been performed and vehicle malfunction indicated service output codes have been resolved and cleared. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > All Other Service Bulletins for Idle Speed: > Page 3393 If any of the areas listed above are found to be at fault, correct them before proceeding with the service kit installation. Idle Speed Adjustment WARNING: BEFORE PROCEEDING WITH THE IDLE SPEED ADJUSTMENT, VERIFY THAT THE FOLLOWING ITEMS ARE TAKEN CARE OF PROPERLY. ^ The transmission is in PARK or Neutral. ^ The parking brake is applied. ^ The wheels are properly blocked. ^ The engine is at operating temperature. ^ The heater, A/C, cooling fan and other accessories are OFF. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > All Other Service Bulletins for Idle Speed: > Page 3394 Figure 3 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > All Other Service Bulletins for Idle Speed: > Page 3395 Figure 4 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > All Other Service Bulletins for Idle Speed: > Page 3396 Figure 5 The EFI throttle body idle speed adjustment procedures for the various model year passenger cars and light trucks are outlined in step-by-step procedures featured in Figures 3, 4 and 5. Select the appropriate procedure for the vehicle involved and adjust the throttle body idle RPM accordingly, after service kit installation. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > All Other Service Bulletins for Idle Speed: > Page 3397 Figure 6 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > All Other Service Bulletins for Idle Speed: > Page 3398 Figure 7 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > All Other Service Bulletins for Idle Speed: > Page 3399 Figure 8 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > All Other Service Bulletins for Idle Speed: > Page 3400 Figure 9 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > All Other Service Bulletins for Idle Speed: > Page 3401 Figure 10 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > All Other Service Bulletins for Idle Speed: > Page 3402 Figure 11 THROTTLE BODY AND IDLE AIR BY-PASS SOLENOID SERVICE PROCEDURE Detailed application charts for throttle body and idle air by-pass solenoid service procedures by engine VIN # /engine displacement/vehicle application and model year are shown in Figures 6 through 11. Refer to these charts to see if the service kit is to be installed and which service cleaning procedure, if any, is to be used. SERVICE CLEANING PROCEDURES The following items should be noted prior to beginning the service cleaning procedure. ^ Confirm that the correct service cleaning procedure is identified in the Application Charts, Figures 6-11, for the vehicle/engine combination being Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > All Other Service Bulletins for Idle Speed: > Page 3403 serviced. ^ Do not clean throttle bodies identified to accept service kit (F2PZ-9F939-A), IDLE AIR ADJUST SPACER. ^ Use a 1" (25.4 mm) to 1-1/2" (38.1 mm) wire stemmed horse hair or nylon bottle cleaner type brush. ^ Use rubber gloves and eye protection. ^ Do not clean throttle bodies identified with a yellow/black "ATTENTION" label. ^ Do not clean "Black" plastic air by-pass valves. Refer to TSB 89-13-8 for service details. ^ Do not run vehicles with air flow meters when the air duct is removed. ^ Do not use carburetor cleaner as a cleaning solvent. Use Carburetor Tune-up Cleaner (D9AZ-19579-AA). Procedure # 1 THROTTLE BODY AND IDLE AIR BY-PASS VALVE CLEANING CAUTION: DO NOT RUN VEHICLES EQUIPPED WITH AIR FLOW METERS DURING THE CLEANING PROCEDURE. IF THERE IS A YELLOW/BLACK "ATTENTION" LABEL ON THE THROTTLE BODY ADVISING NOT TO CLEAN, OR IF THE VEHICLE IS IDENTIFIED AS ACCEPTING SERVICE KIT (F2PZ-9F939-A), USE PROCEDURE # 2 FOR IDLE AIR BY-PASS VALVE CLEANING ONLY. 1. Plug the actuator into the connector in the Rotunda Cleaner/Tester, Tool 113-00009. 2. Remove the air duct to the throttle body inlet. 3. Disoonnect the idle air by-pass valve signal lead. 4. Attach the actuator harness plug to the idle air by-pass valve. 5. Start the actuator and then start the engine. Do not start engines that have air flow meters. 6. Spray just enough Carburetor Tune-up Cleaner (D9AZ-19579-AA) into the throttle bore to wet the bore and throttle plate. 7. Spray the Carburetor Tune-up Cleaner for about five (5) seconds into the idle air by-pass valve inlet passage while the actuator is operating. 8. Stop the engine and actuator. Let everything soak for fifteen (15) minutes. 9. After a fifteen (15) minute soak, saturate the cleaning brush with solvent and scrub between the throttle body bore and plate while holding the throttle wide open. NOTE: IT IS NECESSARY TO APPLY SOME PRESSURE ON THE BRUSH WHILE SCRUBBING. 10. Repeat saturating the brush and scrubbing for one (1) to two (2) minutes, making sure to reach into the corners where the throttle shaft meets the bore wall. 11. Start the actuator and the start the engine. Do not start engines that have air flow meters. 12. Spray Carburetor Tune-up Cleaner into the throttle bore for up to one (1) minute to wash away residue. Do not spray for longer than six (6) continuous seconds on engines that have air flow meters and are not running. 13. Spray Carburetor Tune-up Cleaner into the idle by-pass valve passage leading to the inlet of the valve for up to one (1) minute. Do not spray for longer than six (6) continuous seconds on engines that have air flow meters and are not running. 14. Stop actuator and stop engine, if running. NOTE: MAKE SURE THE THROTTLE PLATES OPERATE FREELY AND CLOSE PROPERLY. 15. Reinstall the air duct. 16. Start and run the engine for about one (1) minute to dry out the solvent residue. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > All Other Service Bulletins for Idle Speed: > Page 3404 17. Operate the actuator to make sure the solvent is purged from the idle by-pass valve. 18. Disconnect the actuator from the idle air by-pass valve. 19. Reattach the control signal lead to the air by-pass valve. 20. Check engine for normal operation. It may be necessary to reset the idle speed due to a previous adjustment for an idle concern. (Refer to the respective Powertrain/Emissions Diagnosis Service Manual, Throttle Body Section, for idle speed adjust procedure.) Procedure # 2 Idle Air By-Pass Valve Cleaning Only CAUTION: THIS CLEANING PROCEDURE MAY BE USED WITH SLUDGE TOLERANT THROTTLE BODIES WHICH ARE IDENTIFIED WITH A YELLOW/BLACK "ATTENTION" LABEL AND THOSE USING SERVICE KIT (F2PZ-9F939-A). NO ATTEMPT SHOULD BE MADE TO CLEAN THROTTLE BODY BORE/PLATE AREA BY DIRECT SPRAYING OR SCRUBBING. DO NOT RUN VEHICLES WITH AIR FLOW METERS DURING CLEANING PROCEDURE. 1. Plug the actuator into the connector in the Rotunda Air By-Pass Valve Adapter 113-00009, or equivalent. 2. Remove the air duct to the throttle body inlet. 3. Disconnect the idle air by-pass valve signal lead. 4. Attach the actuator harness plug to the idle air by-pass valve. 5. Start the actuator and then start the engine. NOTE: DO NOT START ENGINES THAT HAVE AIR FLOW METERS. 6. Spray the Carburetor Tune-up Cleaner for about five (5) seconds into the idle air by-pass valve inlet passage while the actuator is operating. CAUTION: AVOID DIRECT SPRAYING ON THROTTLE PLATE/BORE AREA. 7. Stop the engine and actuator. Let everything soak for fifteen (15) minutes. 8. Start the actuator and the start the engine. CAUTION: DO NOT START ENGINES THAT HAVE AIR FLOW METERS. 9. Spray Carburetor Tune-up Cleaner into the throttle bore for up to one (1) minute. CAUTION: DO NOT SPRAY FOR LONGER THAN SIX (6) CONTINUOUS SECONDS ON ENGINES THAT HAVE AIR FLOW METERS AND ARE NOT RUNNING. 10. Stop actuator and stop engine if running. 11. Reinstall the air duct. 12. Start and run the engine for about one (1) minute to dry out the solvent residue. 13. Operate the actuator to make sure the solvent is purged from the idle by-pass valve. 14. Disconnect the actuator from the idle air by-pass valve. 15. Reattach the control signal lead to the air by-pass valve. 16. Check engine for normal operation. NOTE: IT SHOULD NOT BE NECESSARY TO RESET THE IDLE SPEED SINCE ONLY THE IDLE AIR BY-PASS VALVE WAS SERVICED IN THIS PROCEDURE Warranty Coverage Throttle bodies and idle air by-pass valves on all EFI (Port Fuel Injection) engines through the 1992 model year that can be cleaned (as identified in the application charts) are covered under 5/50 Emissions Warranty Coverage. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > All Other Service Bulletins for Idle Speed: > Page 3405 For those throttle bodies identified as having sludge tolerant designs or using service kit (F2PZ-9F939-A) where cleaning is not allowed per the application charts, the warranty claims for cleaning will not be reimbursed even within the 12/12 warranty coverage period. Cleaning is not allowed. Service kit installation (single time) is covered under 5/50 emission warranty. Labor Standards Operations The labor operations shown in the following Operation/Description/Time columns are identified by procedure number and vehicle line. Specific engines for various vehicles are identified in the sludge cleaning procedure application charts. The throttle body cleaning operations with combinations and the air by-pass valve cleaning combinations will appear in future Labor Manuals under the following operation numbers. ^ 9926 B - Throttle body and idle air by-pass valve cleaning ^ 9926 B2 - Adjust idle speed ^ 9715 A - Air by-pass valve cleaning only ^ 9715 A1 - Adjust idle speed PART NUMBER PART NAME CLASS F2PZ-9F939-A Idle Air By-pass Service Kit B D9AZ-19579-AA Carburstor Tune-Up Cleaner BG OTHER APPLICABLE ARTICLES: 89-13-8 SUPERSEDES: 88-24-5, 88-24-6, 89-16-5, 91-10-9, 91-7-4 Operation Description WARRANTY STATUS: Eligible Under Warranty Coverage As Stated In The Text Of This Article OPERATION DESCRIPTION TIME 912507A Idle Air By-Pass Valve 0.5 Hr. Cleaning - 1983-85 Escort, EXP, LN7, LYNX 1.6L EFI. 912507B Idle Air By-Pass Valve 0.5 Hr. Cleaning - 1986-91 Escort 1.9L EFI, 1986/87 EXP, Lynx 1.9L EFI, 1991 Tracer 1.9L EFI. 912507C Idle Air By Pass Valve 0.5 Hr. Cleaning - 1984-87 Mustang 2.3L T/C, 1986/87 Capri, Cougar 2.3L T/C, 1984-88 T-Bird 2.3L T/C, 1987/92 Mustang 2.3L EFI. 912507D Idle By-Pass Valve Cleaning 0.6 Hr. - 1988-91 Tempo, Topaz 2.3L HSC, 1985-92 Ranger 2.3L EFI. 912507E Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1986/87 Aerostar 2.3L EFI, 1985 Bronco II 2.3L EFI. 912507F Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1986-90 Bronco II 2.9L EFI, 1986-92 Ranger 2.9L EFI. 912507G Idle Air By-Pass Valve 0.6 Hr. Cleaning - 1991/92 Probe 3.0L EFI, 1986-91 Taurus 3.0L EFI, 1987-91 Sable 3.0L EFI. 912507H Idle Air By-Pass Valve 0.7 Hr. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > All Other Service Bulletins for Idle Speed: > Page 3406 Cleaning - 1986-91 Aerostar 3.0L EFI, 1991 Ranger 3.0L EFI. 912507I Idle Air By-Pass Valve 0.6 Hr. Cleaning - 1988 Continental, Cougar, Taurus, T-Bird, Sable 3.8L EFI. 1988 Cougar, T-Bird 3.8L S/C. 912507J Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1990-92 Aerostar 4.0L EFI, 1990 Bronco II 4.0L EFI, 1991/92 Explorer 4.0L EFI, 1990-92 Ranger 4.0L EFI. 912507K Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1987-92 Bronco 4.9L EFI, 1987-92 F-Series 4.9L EFI, 1987/90 Econoline (Without Rear Heater) 4.9L EFI, 1991/92 Econoline (All) 4.9L EFI. 912507L Idle Air By-Pass Valve 0.6 Hr. Cleaning - 1986-88 Cougar, T-Bird 5.0L EFI, 1986-87 Continental, Mark VII 5.OL EFI, 1986/91 Crn - Victoria, Grn - Marquis 5.0L EFI, 1986-92 Mark VII 5.0L HO, 1982-92 Mustang 5.0L HO. 912507M Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1985-92 Bronco, E-Series, F-Series 5.0L EFI. 912507N Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1988-90 Bronco, F-Series 5.8L. 1991 Econo, F-Series, Bronco 5.8L (Do not Clean Solenoid, Calib; 1-64E-R10, 1-64H-R10, 1-64J-R10, 1-64K-R10, 1-64M-R10, 1-64P-R10, 1-64R-R10, 1-75A-R00, 1-76A-R00, 1-76B-R00, 1-76C-R00. 912507O Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1991/92 F And B Series, 7.0L EFI. 912507P Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1987-92 E-Series, F-Series 7.5L EFI. 912507Q Throttle Body And Idle Air 0.9 Hr. By-Pass Valve Cleaning - 1989/90 Probe 3.0L EFI. 912507R Throttle Body And Idle Air 0.8 Hr. By-Pass Valve Cleaning - 1987-90 Econoline (With Rear Heat) 4.9L EFI. 912507S Throttle Body And Idle Air 0.9 Hr. By-Pass Valve Cleaning - 1988-90 Econoline 5.8L EFI. 912507T Service Kit Install - All Cars 1.0 Hr. And Light Trucks (Except Aerostar And Econoline) - Refer To The Service Procedure Application Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > All Other Service Bulletins for Idle Speed: > Page 3407 Charts, For Vehicle Application. 912507U Service Kit Install - 1.2 Hr. Aerostar, Econoline - Refer To Service Procedure Application Charts - For Vehicle Application. DEALER CODING BASIC PART NO. CONDITION CODE 9E926 49 OASIS CODES: 602300, 607000, 607400, 607700, 608400, 611500, 618400 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > Page 3408 IDLE SPEED SPECIFICATIONS Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Adjustments > Curb Idle Speed Idle Speed: Adjustments Curb Idle Speed CURB IDLE SPEED ADJUSTMENT - Set parking brake, block wheels and place the transmission in Neutral (manual) or Park (automatic). - Bring engine to normal operating temperature (upper radiator hose hot). - Place A/C Heat selector to "OFF" (if equipped). - Disconnect and plug vacuum hoses at air bypass valve, EGR valve, and purge control valve. - Place the transmission in the specified gear. See: Specifications - Check curb idle rpm. Adjust to specification. See: Specifications - Place the transmission in Neutral (manual) or Park (automatic). Rev the engine momentarily. Place the transmission in specified position, and recheck curb idle rpm. Readjust if required. - If vehicle is equipped with A/C, perform the following additional steps: Connect an external vacuum source providing a minimum of 33.7 kPA (10 in-Hg) to the Vacuum Operated Throttle Modulator (VOTM) kicker. - Place the transmission selector in specified position. See: Specifications - Check/adjust VOTM kicker speed. If adjustment is required, loosen kicker locknut and turn kicker to required speed, tighten locknut. - Remove plugs and reconnect vacuum hoses. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Adjustments > Curb Idle Speed > Page 3411 Idle Speed: Adjustments Fast Idle Speed FAST IDLE SPEED ADJUSTMENT - Set parking brake, block wheels and place the transmission in Park (automatic) or Neutral (manual). - Bring the engine to normal operating temperature. - Disconnect the vacuum hose at the EGR valve, air bypass valve, and purge control valve and plug. - Place the fast idle adjustment mechanism on specified step of fast idle cam. Check/adjust fast idle rpm to specification. See: Specifications - Recheck for repeatability. - Remove plugs from the EGR valve, air bypass valve, and purge control valve vacuum hoses and reconnect. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air/Fuel Mixture > System Information > Technical Service Bulletins > Idle Fuel Mixture - Manual Revision Technical Service Bulletin # 8912A26 Date: 890627 Idle Fuel Mixture - Manual Revision ENGINE EMISSIONS DIAGNOSIS SHOP MANUAL- 1986-SECTION 4-IDLE FUEL MIXTURE-PROPANE ENRICHMENT METHOD ENGINE EMISSIONS DIAGNOSIS SHOP MANUAL- 1987-SECTION 4-IDLE FUEL MIXTURE-PROPANE ENRICHMENT METHOD Article No. 89-12A-26 FORD: 1986 ESCORT, LTD, MUSTANG 1986-87 TEMPO 1986 THUNDERBIRD LINCOLN-MERCURY: 1986 CAPRI, COUGAR, MARQUIS 1986-87 TOPAZ LIGHT TRUCK: 1986 AEROSTAR 1986-87 BRONCO, ECONOLINE, F-150, F-250, F-350, RANGER ISSUE: The tachometer reference "or equivalent" as shown in procedure I.-B in both 1986 and 1987 Engine Emissions Diagnosis Manuals is incorrect. This also applies to procedure I.-H in the 1986 Engine Emissions Diagnosis Manual. ACTION: Refer to the pages following this TSB article for the revised Volume H pages which show the correct tachometer designation as: "Connect an analog tachometer, Rotunda 059-000010 or an equivalent analog tachometer." This information should be inserted in your 1986 Engine Emissions Diagnosis Manual, pages 4-83, 4-87, 4-90, 4-93 and the 1987 Manual, pages 4-66 and 4-69. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 680000 Pages 4-83, 4-84 1986 Carburetors, Fuel Charging Assemblies and Throttle Bodies 4-83 Idle Mixture Setting Procedures IDLE FUEL MIXTURE-PROPANE ENRICHMENT METHOD Passenger Car. 1.9L w/740-2V, 2.3L OHC w/YFA-IV FB, 2.3L HSC w/1949-IV, 3.8L w/2150-A-2V and 5.0L w/4180C-4V. Truck, Under 8500 GVW: 5.8L w/4180C-4V. NOTE: This procedure is applicable to the above engines only. If CO and HC are not within specification, perform appropriate electrical diagnostic procedure in Section 15. I. Vehicle Preparation: All Carburetors as noted above. A. Apply the parking brake, and block the wheels. Disconnect the automatic brake release, if so equipped, and plug the vacuum connection. B. Connect an analog tachometer, Rotunda 059-000010 or an equivalent analog tachometer. C. If so equipped, insure that the hot idle compensator is in a closed position and remains so throughout the test. Idle vehicle on kickdown step of fast idle cam for three to five minutes to insure that HIC valve is closed. D. If so equipped, disconnect the fuel evaporative purge hose at the engine or the carburetor, (1.9L engines) and plug the connection. (Not applicable to 5.0L and 5.8L Truck and 5.0L Passenger Car engines). E. If so equipped, disconnect the fuel evaporative purge hose at the air cleaner and plug the nipple. (Not applicable to 5.0L and 5.8L Truck and 5.0L Passenger car engines). F. Disconnect the flexible fresh air tube from the air cleaner duct or adaptor. Using propane enrichment Tool T75L-9600-A or equivalent, insert the tool hose approximately 3/4 of the way into the duct or fresh air tube. If necessary, secure the hose with tape. G. For vehicles equipped with thermactor systems, revise the dump valve vacuum hoses as follows: (Not applicable to 1.9L engines). 1. For dump valves with two vacuum fittings, disconnect and plug the hose(s). Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air/Fuel Mixture > System Information > Technical Service Bulletins > Idle Fuel Mixture - Manual Revision > Page 3416 2. For dump valves with one fitting or combination air bypass/air control valve, remove the hose at the dump valve and plug it. Connect a slave hose from the dump valve vacuum fitting to an intake manifold vacuum fitting. (Not applicable to 5.0L and 5.8L Truck engines with 2150A-2VFB). 3. For 2.3L OHC engines: a. Equipped with a dump valve with two vacuum fittings: Disconnect and plug the hoses. b. Equipped with a combination dump valve and air diverter valve: Disconnect and plug the hoses (2-port) from the dump valve portion. c. Equipped with feedback carburetor: Disconnect electric lead wire from electric PVS. 4. On 3.8L engine Canadian 2150A-2V applications, do not make any thermactor system modifications. 5. For 5.8L 4180C-4V Truck Disconnect and Plug Vacuum Hose to Dump Valve. 1986 4-84 Carburetors, Fuel Charging Assemblies and Throttle Bodies Idle Mixture Setting Procedures H. For 1.9L ATX/MTX vehicles equipped with (Mechanical Vacuum) Idle Speed Control (ISC): 1. With engine off: a. Disconnect and plug the vacuum hose at the MVISC. b. Connect an alternate vacuum source (hand vacuum pump) capable of maintaining 22 inches Hg. to the ISC diaphragm on carburetor, and apply vacuum (retracting ISC plunger clear of throttle linkage). 2. With engine running and transmission in Drive (ATX) or Neutral (MTX): ^ Idle speed should be equal to the ISC retracted speed specified on the emission decal, if not readjust throttle stop adjustment screw under choke housing to specification, (fan On, A/C Off). I. When the above Steps have been completed, proceed to Section II. II. Propane Enrichment Method (Except as Noted) NOTE: Leave all vacuum signal hoses attached to the air cleaner assembly when relocating the assembly to perform carburetor adjustments. The air cleaner assembly must be in place however, when measuring engine speeds. CAUTION: Prolonged engine idling can result in catalyst overheating and excessive underbody temperatures. A. Verify that the timing is set to specification; reset if necessary, Section 15. B. Check engine curb idle rpm or A/C-off rpm, and, if necessary, reset to specification, Section 4. NOTE: Even If the vehicle has less than 160.9 km (100 miles) of operation, set the speed to the normal engine specification. NOTE: Remove PCV valve from grommet, and allow PCV valve to draw underhood air during idle fuel mixture check. (PCV should remain in vertical position). NOTE: Escort/Lynx, has an in-line fixed orifice crankcase vent, not a conventional PCV valve. The fixed orifice is located in the crankcase vent hose located between the vacuum fitting on the intake manifold and the plastic fitting attached to the air cleaner tray. Locate the crankcase vent hose and disconnect at the air cleaner end, allowing the hose to vent to underhood air during idle fuel/air mixture check. C. With the transmission in Neutral, run the engine at approximately 2500 rpm for 15 seconds before each mixture check. NOTE: On Escort/Lynx and Tempo/Topaz, run engine until electric fan comes On. Pages 4-87 Thru 4-90 1986 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air/Fuel Mixture > System Information > Technical Service Bulletins > Idle Fuel Mixture - Manual Revision > Page 3417 Carburetors, Fuel Charging Assemblies and Throttle Bodies 4-87 Idle Mixture Setting Procedures IDLE FUEL MIXTURE-PROPANE ENRICHMENT METHOD 2.0L TRUCK UNDER 8600 GVW w/YFA-IV NOTE: This procedure is for 2.0L Truck engines only, it is not for trucks over 8500 GVW. Propane specifications are not listed for these applications. If CO and HC are not within specification, perform appropriate electrical diagnostic procedure, Section 15. I. Vehicle Preparation A. Apply the parking brake and block the wheels. B. Connect an analog tachometer, Rotunda 059-000010 or an equivalent analog tachometer. C. Disconnect the flexible fresh air tube from the air cleaner duct or adaptor. Using propane enrichment Tool T75L-9600-A or equivalent, insert the tool hose approximately 3/4 of the way into the duct or fresh air tube. If necessary, secure the hose with tape. D. Disconnect and plug the hose at the air bypass valve. E. Disconnect and plug the hose between the purge valve and the spacer at the purge valve. F. When the above Steps have been completed, proceed to Section II. II. Propane Enrichment Method (Except as Noted) NOTE: Leave all vacuum signal hoses attached to the air cleaner assembly when relocating the assembly to perform carburetor adjustments. The air cleaner assembly must be in place, however, when measuring engine speeds. CAUTION: Prolonged engine idling can result in catalyst overheating and excessive underbody temperatures. A. Verify engine timing is set to specification - reset if necessary, Section 15. B. Verify that the curb idle speed is being controlled to specification. Then, electrically disconnect idle speed control (ISC) motor from wiring harness. C. Place A/C-heat selector in the Off position and verify that lamps are Off. NOTE: Remove PCV valve from grommet, locate the crankcase closure hose and disconnect at the air cleaner end (allowing the PCV valve and closure hose to vent to underhood air during idle fuel mixture check). D. With the transmission in Neutral, run the engine at approximately 2500 rpm for 15 seconds before each mixture check. If check is not completed within 60 seconds, repeat this cleanout Step. 1986 4-88 Carburetors, Fuel Charging Assemblies and Throttle Bodies Idle Mixture Setting Procedures E. With the engine idling at normal operating temperature gradually open the propane tool valve and watch for engine speed gain, on the tachometer. When the engine speed reaches a maximum and then begins to drop off, note the amount of speed gain. (Propane cartridge must be in vertical position). NOTE: If the engine speed will not drop off check the propane cartridge gas supply. If necessary repeat Steps D & E with a new propane cartridge gas supply. F. Compare measured speed gain to specified speed gain.* 1. If the measured speed gain is within specification, proceed to Step H. NOTE: The carburetor assembly is equipped with a tamper-resistant idle adjustment feature, the carburetor must be removed from the vehicle. Refer to Shop Manual, Group 24 for removal of the above feature. NOTE: If it is determined that idle fuel mixture adjustment will be necessary, adjust the mixture according to the reset rpm specification. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air/Fuel Mixture > System Information > Technical Service Bulletins > Idle Fuel Mixture - Manual Revision > Page 3418 2. If the measured speed gain is higher than the speed gain specification:* Turn the mixture screw counterclockwise (rich) and simultaneously repeat Steps D and E until the measured speed rise meets the reset rpm specification.* After final adjustment, proceed to Step G. 3. If the measured speed gain is lower than the speed gain specification:* Turn the mixture screw clockwise (lean) and simultaneously repeat Steps D and E until the measured speed rise meets the reset rpm specification.* After final adjustment, proceed to Step G. 4. If there is no rpm rise and the minimum speed gain specification is "0" rpm, perform the following speed drop test: NOTE: Speed drop test information is specified with the artificial enrichment requirements whenever the minimum speed gain specification is "0" rpm. * a. While watching the tachometer, adjust the mixture screw 1/4 turn clockwise (lean). Note the drop in engine speed. b. If the measured speed drop is greater "0" and less than or equal to 30 rpm, proceed to Step G. c. If the measured speed drop is more than 30 rpm, return the mixture screw to the position before adjustment. Proceed to Step G. d. If the measured speed drop is still "0" rpm repeat steps a, b, and c. G. The carburetor fuel air adjustment must have the tamper-resistant feature reinstalled, see Section III. *Refer to the Special Specifications Issue TSB Publications. 1986 Carburetors, Fuel Charging Assemblies and Throttle Bodies 4-89 Idle Mixture Setting Procedures H. Reinstall PCV valve in grommet. Reconnect air bypass valve, purge valve and crankcase closure hose. Reconnect ISC motor to wiring harness. I. Remove all test equipment. Reconnect all system components, reinstall air cleaner, and tighten the air cleaner wing nut(s) to specification. III. Removal and Installation for Tamper-Resistant Fuel Air Adjustment Feature: A. See appropriate carburetor disassembly instructions in Shop Manual, Group 24. 1986 4-90 Carburetors, Fuel Charging Assemblies and Throttle Bodies Idle Mixture Setting Procedures IDLE FUEL MIXTURE-PROPANE ENRICHMENT METHOD 2.8L AEROSTAR w/2150A FB NOTE: This procedure is for the 2.8L engine only. It is not for trucks over 8500 GVW. I. Vehicle Preparation A. Apply the parking brake and block the wheels. B. Verify that timing is set to specification. C. Remove the air cleaner assembly. D. Disconnect wiring harness from carburetor feedback solenoid, located in the rear of carburetor. E. Remove the PCV valve from the rocker cover grommet and move away from the crankcase vapors. F. Disconnect the fuel evaporating purge line (from the intake manifold spacer at the purge solenoid). Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air/Fuel Mixture > System Information > Technical Service Bulletins > Idle Fuel Mixture - Manual Revision > Page 3419 G. Install purge line tester (Tool T84T-9600-A) into the end of purge line that is still connected to the intake manifold spacer. H. Disconnect ISC motor from wiring harness as follows: Simultaneously: 1. Connect tachometer, Rotunda Model 059-00001, 099-00001 or equivalent. 2. Start engine. 3. Manually hold throttle above 1000 rpm. 4. Push ISC plunger until it retracts fully. 5. After plunger retracts, release throttle and quickly unplug the connection. NOTE: Before proceeding, verify that the throttle lever is resting on the speed screw and that the engine idles at specification for anti-dieseling rpm (750 rpm in neutral). I. Install air cleaner assembly, but do not connect the flexible fresh air tube to the air cleaner duct and valve assembly. Using a propane enrichment Tool T75L-9600-A or equivalent, insert the tool hose approximately 3/4 of the way into the duct and valve assembly. If necessary, secure the hose with tape. J. When the above Steps have been completed, proceed to Section II. Pages 4-93 & 4-94 1986 Carburetors, Fuel Charging Assemblies and Throttle Bodies 4-93 Idle Mixture Setting Procedures IDLE FUEL MIXTURE-PROPANE ENRICHMENT METHOD 4.9L TRUCK UNDER 8500 GVW w/YFA-IV FB NOTE: This procedure is for the 4.9L engine only. It is not for trucks over 8600 GVW. Propane specifications are not listed for these applications. If CO and HC are not within specification, perform appropriate electrical diagnostic procedure, Section 15. I. Vehicle Preparation A. Apply the parking brake and block the wheels. Disconnect the automatic brake release (if so equipped), and plug the vacuum connection. B. Connect an analog tachometer, Rotunda 059-000010 or an equivalent analog tachometer. C. Disconnect the flexible fresh air tube from the air cleaner duct or adapter. Using propane enrichment Tool T75L-9600-A or equivalent, insert the tool hose approximately 3/4 of the way into the duct or fresh air tube. If necessary, secure the hose with tape. D. When the above Steps have been completed, proceed to Section II. II. Propane Enrichment Method (Except as Noted) NOTE: Leave all vacuum signal hoses attached to the air cleaner assembly when relocating the assembly to perform carburetor adjustments. The air cleaner assembly must be in place, however, when measuring engine speeds. CAUTION: Prolonged engine idling can result in catalyst overheating and excessive underbody temperatures. A. Verify engine timing is set to specification-reset if necessary, Section 15. B. Place A/C-heat selector in the Off position and verify that all accessories (lamps, defrost, etc.) are Off. 1986 4-94 Carburetors, Fuel Charging Assemblies and Throttle Bodies Idle Mixture Setting Procedures Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air/Fuel Mixture > System Information > Technical Service Bulletins > Idle Fuel Mixture - Manual Revision > Page 3420 Figure 1 - In-Line Base Timing Connector NOTE: Remove PCV valve from grommet locate the crankcase closure hose and disconnect at the air cleaner end (allowing the PCV valve and closure hose to vent to underhood air during idle fuel mixture check). C. Verify that the idle speed control motor and the single wire connector near the distributor (sometimes called the In-Line Base timing connector, Figure 1) are connected electrically. With the transmission in Neutral, run the engine at approximately 2500 rpm for 15 seconds before each mixture check. If check is not completed within 60 seconds, repeat this cleanout Step. D. Return engine to idle and disconnect idle speed control motor from wiring harness. Disconnect single wire connector near the distributor (Fig. 1). With the engine idling at normal operating temperature, place the transmission selector in the position specified for the idle fuel mixture check. Gradually open the propane tool valve and watch for engine speed gain, on the tachometer. When the engine speed reaches a maximum and then begins to drop off, note the amount of speed gain. (Propane cartridge must be in vertical position). NOTE: If the engine speed will not drop off check the propane cartridge gas supply. If necessary repeat Steps C and D with a new propane cartridge gas supply. E. Compare measured speed gain to specified speed gain.* 1. If the measured speed gain is within specification, proceed to Step G. NOTE: The carburetor assembly is equipped with a tamper-resistant idle adjustment feature, the carburetor must be removed from the vehicle. Refer to Group 24, Powertrain Shop manual for removal of the above feature. NOTE: If it is determined that idle fuel mixture adjustment will be necessary, adjust the mixture according to the reset rpm specification. 2. If the measured speed gain is higher than the speed gain specification:* Turn the mixture screw counterclockwise (rich) and simultaneously repeat Steps C and D until the measured speed rise meets the reset rpm specification,* After final adjustment, proceed to Step F. 3. If the measured speed gain is lower than the speed gain specification:* Turn the mixture screw clockwise (lean) and simultaneously repeat Steps C and D until the measured speed rise meets the reset rpm specification.* After final adjustment, proceed to Step F. F. The carburetor fuel air adjustment must have the tamper-resistant feature reinstalled. Refer to appropriate carburetor assembly instructions in Shop Manual, Group 24. G. Reinstall PCV valve in grommet. Reconnect idle speed control motor and crankcase closure system, and the single wire connector near the distributor. H. Remove all test equipment. Reconnect all system components, reinstall air cleaner, and tighten the air cleaner wing nut(s) to specification, *Specified speed gain is 10 to 70 rpm, specified reset is 30 rpm. Pages 4-65 & 4-66 1987 Carburetors, Fuel Charging Assemblies and Throttle Bodies 4-65 Idle Mixture Setting Procedures Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air/Fuel Mixture > System Information > Technical Service Bulletins > Idle Fuel Mixture - Manual Revision > Page 3421 IDLE FUEL MIXTURE-PROPANE ENRICHMENT METHOD Propane Enrichment Procedures Are Not Applicable For The Following: ^ CFI Applications. ^ EFI Applications. ^ Truck Over 8500 GVW Applications. ^ 5.8L MCU Police and Trailer Tow Vehicles w/7200 Carburetors. 1987 4-66 Carburetors, Fuel Charging Assemblies and Throttle Bodies Idle Mixture Setting Procedures IDLE FUEL MIXTURE-PROPANE ENRICHMENT METHOD Passenger Car. 2.3L HSC w/1949-IV Truck, Under 8500 GVW: 5.8L w/418OC-4V. NOTE: This procedure is applicable to the above engines only. If CO and HC are not within specificatlon, perform appropriate electrical diagnostic procedure in Section 15. I. Vehicle Preparation: All Carburetors as noted above. A. Apply the parking brake, and block the wheels, Disconnect the automatic brake release, If so equipped, and plug the vacuum connection. B. Connect an analog tachometer, Rotunda 059-000010 or equivalent analog tachometer. C. If so equipped, ensure that the hot idle compensator is in a closed position and remains so throughout the test. Idle vehicle on kickdown step of fast idle cam for three to five minutes to ensure that HIC valve is closed. D. If so equipped, disconnect the fuel evaporative purge hose at the engine or the carburetor, (1.9L engines) and plug the connection. (Not applicable to 5.8L Truck engines). E. If so equipped, disconnect the fuel evaporative purge hose at the air cleaner and plug the nipple. (Not applicable 5.8L Truck engines.) F. Disconnect the flexible fresh air tube from the air cleaner duct or adaptor. Using propane enrichment Tool T75L-9600-A or equivalent, insert the tool hose approximately 3/4 of the way into the duct or fresh air tube. If necessary, secure the hose with tape. G. For vehicles equipped with Thermactor systems, revise the dump valve vacuum hoses as follows: 1. For dump valves with two vacuum fittings, disconnect and plug the hose(s). 2. For dump valves with one fitting or combination air bypass/air control valve, remove the hose at the dump valve and plug it. Connect a slave hose from the dump valve vacuum fitting to an intake manifold vacuum fitting. (Not applicable to 5.0L and 5.8L Truck engines with 2150A-2VFB). 3. For 5.8L 4180C-4V Truck Disconnect and Plug Vacuum Hose to Dump Valve. H. When the above Steps have been completed, proceed to Section II. Pages 4-69 & 4-70 1987 Carburetors, Fuel Charging Assemblies and Throttle Bodies 4-69 Idle Mixture Setting Procedures IDLE FUEL MIXTURE-PROPANE ENRICHMENT METHOD 2.0L TRUCK UNDER 8500 GVW w/Aisan Carburetor NOTE: This procedure is for 2.0L Truck engines only, it is not for trucks over 8500 GVW. Propane specifications are not listed for these applications. If CO and HC are not within specification, perform appropriate electrical diagnostic procedure, Section 15. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air/Fuel Mixture > System Information > Technical Service Bulletins > Idle Fuel Mixture - Manual Revision > Page 3422 I. Vehicle Preparation A. Apply the parking brake and block the wheels. B. Connect an analog tachometer, Rotunda 059-000010 or an equivalent analog tachometer. C. Disconnect the flexible fresh air tube from the air cleaner duct or adaptor. Using propane enrichment Tool T75L-9600-A or equivalent, insert the tool hose approximately 3/4 of the way into the duct or fresh air tube. If necessary, secure the hose with tape. D. Disconnect and plug the hose at the air bypass valve. E. Disconnect and plug the hose between the purge valve and the spacer at the purge valve. F. When the above Steps have been completed, proceed to Section II. II. Propane Enrichment Method (Except as Noted) NOTE: Leave all vacuum signal hoses attached to the air cleaner assembly when relocating the assembly to perform carburetor adjustments. The air cleaner assembly must be in place, however, when measuring engine speeds. CAUTION: Prolonged engine idling can result in catalyst overheating and excessive underbody temperatures. A. Verify engine timing is set to specification-reset if necessary, Section 15. B. Verify that the curb idle speed is being controlled to specification. Then, electrically disconnect idle speed control (ISC) motor from wiring harness. C. Place A/C-heat selector in the Off position and verify that lamps are Off. NOTE: Remove PCV valve from grommet, locate the crankcase closure hose and disconnect at the air cleaner end (allowing the PCV valve and closure hose to vent to underhood air during idle fuel mixture check). D. With the transmission in Neutral, run the engine at approximately 2500 rpm for 15 seconds before each mixture check. If check is not completed within 60 seconds, repeat this cleanout Step. 1987 4-70 Carburetors, Fuel Charging Assemblies and Throttle Bodies Idle Mixture Setting Procedures E. With the engine idling at normal operating temperature gradually open the propane tool valve and watch for engine speed gain, on the tachometer. When the engine speed reaches a maximum and then begins to drop off, note the amount of speed gain. (Propane cartridge must be in vertical position). NOTE: If the engine speed will not drop off check the propane cartridge gas supply. If necessary repeat Steps D & E with a new propane cartridge gas supply. F. Compare measured speed gain to specified speed gain.* 1. If the measured speed gain is within specification, proceed to Step H. NOTE: The carburetor assembly is equipped with a tamper-resistant idle adjustment feature, the carburetor must be removed from the vehicle. Refer to Shop Manual, Group 24 for removal of the above feature. NOTE: If it is determined that idle fuel mixture adjustment will be necessary, adjust the mixture according to the reset rpm specification. 2. If the measured speed gain is higher than the speed gain specification:* Turn the mixture screw counterclockwise (rich) and simultaneously repeat Steps D and E until the measured speed rise meets the reset rpm specification.* After final adjustment, proceed to Step G. 3. If the measured speed gain is lower than the speed gain specification:* Turn the mixture screw clockwise (lean) and simultaneously repeat Steps D and E until the measured speed rise meets the reset rpm specification.* After final adjustment, proceed to Step G. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air/Fuel Mixture > System Information > Technical Service Bulletins > Idle Fuel Mixture - Manual Revision > Page 3423 4. If there is no rpm rise and the minimum speed gain specification is "0" rpm, perform the following speed drop test: NOTE: Speed drop test information is specified with the artificial enrichment requirements whenever the minimum speed gain specification is "0" rpm.* a. While watching the tachometer, adjust the mixture screw 1/4 turn clockwise (lean). Note the drop in engine speed. b. If the measured speed drop is greater than "0" and less than or equal to 40 rpm, proceed to Step G. c. If the measured speed drop is more than 40 rpm, return the mixture screw to the position before adjustment. Proceed to Step G. d. If the measured speed drop is still "0" rpm repeat steps a, b, and c. G. The carburetor fuel air adjustment must have the tamper-resistant feature reinstalled, see Section III. *Refer to the Special Specifications Issue TSB Publications. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Technical Service Bulletins > Customer Interest for Accelerator Pedal: > 87538 > Mar > 87 > Engine - Lacks Power At Full Throttle Accelerator Pedal: Customer Interest Engine - Lacks Power At Full Throttle LACKS POWER - ACCELERATOR PEDAL HAS Article No. LIMITED TRAVEL 87-5-38 LIGHT TRUCK 1980-87 F SERIES, BRONCO ISSUE: Lack of power at wide open throttle may be caused by limited travel of the accelerator pedal. The current accelerator pedal may interfere with the floor carpet/mat when the driver demands wide open throttle. ACTION: To correct this, install a new design accelerator pedal, E7TZ-9725-A, which provides 3/8 inch additional clearance for travel. Refer to the following service procedure. 1. Check to see if the accelerator pedal interferes with the floor carpet/mat at wide open throttle. 2. If so, install the new design accelerator pedal, E7TZ-9725-A. Refer to the appropriate Light Truck Shop Manual. PART NUMBER PART NAME CLASS E7TZ-9725-A Accelerator Pedal B OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual OPERATION: 9725A TIME: 0.3 Hr. DLR. CODING: Basic Part No. 9725 - Code: 16 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Accelerator Pedal: > 87538 > Mar > 87 > Engine - Lacks Power At Full Throttle Accelerator Pedal: All Technical Service Bulletins Engine - Lacks Power At Full Throttle LACKS POWER - ACCELERATOR PEDAL HAS Article No. LIMITED TRAVEL 87-5-38 LIGHT TRUCK 1980-87 F SERIES, BRONCO ISSUE: Lack of power at wide open throttle may be caused by limited travel of the accelerator pedal. The current accelerator pedal may interfere with the floor carpet/mat when the driver demands wide open throttle. ACTION: To correct this, install a new design accelerator pedal, E7TZ-9725-A, which provides 3/8 inch additional clearance for travel. Refer to the following service procedure. 1. Check to see if the accelerator pedal interferes with the floor carpet/mat at wide open throttle. 2. If so, install the new design accelerator pedal, E7TZ-9725-A. Refer to the appropriate Light Truck Shop Manual. PART NUMBER PART NAME CLASS E7TZ-9725-A Accelerator Pedal B OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual OPERATION: 9725A TIME: 0.3 Hr. DLR. CODING: Basic Part No. 9725 - Code: 16 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Cleaner Element <--> [Air Filter Element] > Component Information > Technical Service Bulletins > Engine - Lack of Power/No Start Diagnosis Air Cleaner Element: Technical Service Bulletins Engine - Lack of Power/No Start Diagnosis Article No. 91-12-11 06/12/91 LACK OF POWER 7.5L, 5.8L, 5.0L, 4.9L - CATALYTIC CONVERTER DIAGNOSTIC TIPS LIGHT TRUCK: 1986-91 BRONCO, ECONOLINE, F-150-350 SERIES 1988-91 F SUPER DUTY, F47 ISSUE: Lack of power or a no start condition may be diagnosed as an exhaust restriction caused by a plugged catalytic converter. A plugged catalytic converter (internal deterioration) is usually caused by abnormal engine operation. ACTION: Diagnose the catalytic converter to confirm internal failure. Refer to the Catalyst and Exhaust System Diagnostic Section, in the Engine/Emissions Diagnostic Shop Manual and the following procedures for service details. 1. Lack of proper HEGO operation may cause, or be the result of a rich or lean fuel condition, which could cause additional heat in the catalyst. Perform self test KOEO and KOER, service any codes. NOTE: IF TWO DIGIT CODES 41, 42, 85 OR THREE DIGIT CODES 171, 172, 173, 179, 181, 182, 183 AND 565 ARE RECEIVED, CHECK FOR PROPER HEGO GROUND. If the HEGO ground is good, the following areas may be at fault: ^ Ignition Coil ^ Distributor Cap ^ Distributor Rotor ^ Fouled Spark Plug ^ Spark Plug Wires ^ Air Filter ^ Stuck Open Injector ^ Fuel Contamination Engine OIL ^ Manifold Leaks Intake/ Exhaust ^ Fuel Pressure ^ Poor Power Ground ^ Engine Not At Normal Operating Temperature ^ HEGO Sensor 2. Spark timing that is retarded from specification may increase exhaust gas temperature and shorten catalyst life. Refer to the following procedure for service details. a. Check spark timing. Check base timing with spout disconnected. Set base timing to the specification on the vehicle emission decal. b. Check computed timing with spout connected. NOTE: COMPUTED TIMING IS EQUAL TO BASE TIMING PLUS 20~ BTDC +/- 3~. 3. Misfiring spark plugs may cause an unburned fuel air mixture to pass through the catalyst, which could cause higher than normal catalyst temperatures. Refer to the following procedure for service details. a. Check secondary ignition, hook the vehicle up to an engine analyzer and check for a secondary ignition misfire. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Cleaner Element <--> [Air Filter Element] > Component Information > Technical Service Bulletins > Engine - Lack of Power/No Start Diagnosis > Page 3442 NOTE: SERVICE ANY ITEM THAT IS NOT PERFORMING AT PROPER SPECIFICATIONS BEFORE CONTINUING. 4. Fuel pressure that is too high may cause rich air fuel mixtures to pass through the catalyst which could cause higher than normal catalyst temperatures. Refer to the following procedure for service details. a. Check fuel pressure, install fuel pressure gauge, start and run the engine at idle. Fuel pressures between 28 and 34 PSI are typical (4.9L typically is 15 PSI higher). b. Disconnect the vacuum line going to the fuel pressure regulator. Fuel pressure typically jumps to 40 PSI +/- 3 PSI (4.9L typically is 15 PSI higher). Visually inspect vacuum line for raw fuel. NOTE: FUEL PRESSURES ABOVE THESE VALUES SHOULD BE CORRECTED. HOWEVER, THIS MAY NOT BE THE CAUSE OF THE CONCERN. SERVICE AS NECESSARY. 5. Throttle plates in the throttle body not returning to the proper closed position may cause excessive catalyst temperatures during downhill grades. Refer to the following procedure for service details. a. Visually inspect the throttle body and linkage for: ^ Binding or sticking throttle linkage. ^ Tight speed control linkage or cable. ^ Vacuum line interference. ^ Electrical harness interference. NOTE: AFTERMARKET GOVERNORS, THROTTLE LINKAGE AND CABLES ASSOCIATED WITH POWER TAKE-OFF UNITS, MAY ALSO INTERFERE WITH PROPER THROTTLE RETURN. SERVICE AS NECESSARY. 6. It is extremely important that all systems related to the engine and emission systems operate properly. a. Visually inspect the engine compartment to make sure all vacuum hoses and spark plug wires are properly routed and securely connected. b. Inspect all wiring harnesses and connectors for insulation damage, burned, overheated, loose or broken conditions. c. Verify proper operation of the thermactor system. Thermactor systems that fail to dump thermactor air to the atmosphere properly or at the correct time can cause high catalyst temperatures. d. Visually inspect thermactor system for damaged or kinked hoses and perform a function test on following components: air control valve, check valve, silencer, filter and the air bypass solenoid. e. Verify proper operation of the engine cooling system thermostat. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under Basic Warranty Coverage, Emissions Warranty Coverage OPERATION DESCRIPTION TIME 911211A Diagnostics - Perform 0.5 Hrs. KOEO And KOER Self Tests 911211B Timing - Check Or Adjust 0.5 Hrs. Spark Timing, Check Computed Timing And Check Secondary Ignition System With Engine Analyzer. 911211C Check - Fuel Pressure And 0.2 Hrs. Inspect Vacuum Line For Raw Fuel. 911211D Inspect - Throttle Body And 0.1 Hrs. Linkage. 911211E Inspect - Vacuum Hoses, 0.1 Hrs. Electrical Harnesses, Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Cleaner Element <--> [Air Filter Element] > Component Information > Technical Service Bulletins > Engine - Lack of Power/No Start Diagnosis > Page 3443 Connectors And Spark Plug Wires For Routing Damage. 911211F Thermactor System - 0.3 Hrs. Inspect For Proper Operation And Damaged Component. Includes Function Check Of Air Control Valve, Thermactor Air Bypass Solenoid, Check Valves, Silencer And Filter. 911211G Thermostat - Check For 0.2 Hrs. Proper Operation. DEALER CODING BASIC PART NO. CONDITION CODE 5E212 25 OASIS CODES: 403000, 603300, 614000 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Distributor Modulator Valve <--> [Altitude Compensator] > Component Information > Technical Service Bulletins > Vehicle - Altitude Compensator Kit Distributor Modulator Valve: Technical Service Bulletins Vehicle - Altitude Compensator Kit POOR PERFORMANCE - 5.8L AND 7.5L - NEW Article No. ALTITUDE COMPENSATOR KIT - VEHICLES 87-23-14 OVER 8500 GVW LIGHT TRUCK: 1983-85 E SERIES 1983-87 F SERIES ISSUE: Poor performance of vehicles operated at high altitudes of 4000 feet or above may be caused by an over-rich air/fuel mixture. The air density is lower at higher altitudes than it is at sea level resulting in the over-rich condition. ACTION: To correct this, install a new altitude compensator kit which compensates for the changing air density at high altitudes. The installation procedures are packaged inside the altitude compensator kits. Refer to the Altitude Compensator Kit application chart on this page for the correct service part number. PART NUMBER PART NAME CLASS E3UZ-9000-K Altitude Compensator Kit CG E3TZ-9000-E Altitude Compensator Kit CG E3TZ-9000-F Altitude Compensator Kit CG E3TZ-9000-G Altitude Compensator Kit CG OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION: SP872314A - 1983-85 E-250/350 (49S) 7.5L single thermactor TIME: 1.7 Hrs. OPERATION: SP872314B - 1985-87 F-250/350 (49S) 7.5L dual thermactor 1983-87 F-250/350 (Calif.) 7.5L single thermactor TIME: 1.0 Hr. OPERATION: SP872314C - 1983-85 F-250/350 (49S) 7.5L single thermactor 1985-87 F-250/350 (50S) 5.8L dual thermactor TIME: 0.9 Hr. DLR. CODING: Basic Part No. 9F701 - Code: 53 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Distributor Modulator Valve <--> [Altitude Compensator] > Component Information > Technical Service Bulletins > Vehicle - Altitude Compensator Kit > Page 3448 Distributor Modulator Valve: Technical Service Bulletins Altitude Compensation System - Shop Manual Revision Article No. 86-12-17 ALTITUDE COMPENSATION SYSTEM (5.8L) - SHOP MANUAL REVISION - UNDER 8,500 LBS. GVW LIGHT TRUCK 1984-86 E-SERIES, F-SERIES, BRONCO The description of the remote mounted altitude compensation system for the 5.8L engine was inadvertently omitted from the 1984 through 1986 Light Truck Engine Shop Manuals. Add the following altitude compensator description as a supplement to Section 24-26 of the above Shop Manuals. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Altitude Compensator Engines equipped to compensate for the lower atmospheric pressures at high elevations (4000 feet above sea level or higher) have a remote-mounted altitude compensator system. This system is used only on under 8500 lbs. GVW vehicles that have the optional "Altitude Package". Above 3400 feet, this altitude compensator bypasses the metering system to lean out the rich fuel/air ratios that occur. A defective altitude compensator that did not bypass air at high elevations would result in poor engine performance. Also, fuel economy would be low, and there might be black smoke from the exhaust. On the other hand, some defective altitude compensators might always bypass air, even at elevations near sea level. The resulting lean condition would cause poor engine performance and stalling at lower elevations. FIG. 1 - Remote Mounted Altitude Compensator The altitude compensator system is pictured in Figure 1. When the barometric pressure switch senses that the vehicle is operating at more than 3400 feet above sea level, it provides an electrical ground for the rest of the system. The vacuum switches and the vacuum solenoid valves function only when this electrical ground is present. The vacuum switches are used to sense manifold vacuum; and the vacuum solenoid valves, when open, bypass air to the engine in a staged function of manifold vacuum. Above 3400 feet, the idle solenoid valve is always open and bypassing air whenever the engine is running. The amount of air thus bypassed is limited by an orifice in the system. When the engine is at any speed except idle, an additional amount of air from the idle solenoid valve is bypassed through the off-idle vacuum switch. If the manifold vacuum drops below ten inches, the 10" vacuum switch engages. This provides a ground circuit that allows the 10" vacuum solenoid valve to open and bypass even more air. Likewise, if the manifold vacuum drops below five inches, the 5" vacuum switch and the two 5" vacuum solenoids operate to allow even more air to bypass. For information on the electrical schematic, refer to the Electrical and Vacuum Troubleshooting Manual, "5.8L 4-V Carburetor Circuits" section. Also, refer to the Engine Decal (located under the hood on top of the radiator shield) for the vacuum schematic. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Distributor Modulator Valve <--> [Altitude Compensator] > Component Information > Technical Service Bulletins > Vehicle - Altitude Compensator Kit > Page 3449 FIG. 2 - Altitude Compensator Installation The altitude compensator assembly is mounted to the passenger side fender apron (Figure 2). For Econoline applications, it is retained by two nuts. For F-Series and Bronco applications, it is retained by two nuts and also by a bracket at the battery hold-down clamp. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Distributor Modulator Valve <--> [Altitude Compensator] > Component Information > Technical Service Bulletins > Page 3450 Distributor Modulator Valve: Description and Operation This dual vacuum switch assembly (S1 normally CLOSED, and S2 normally CLOSED) is used in the 5.0L 4-V HO with manual transmission and the 5.8L 4-V to provide an air bleed to the carburetor for the high altitude calibration. S1 will open above 5.0 ±0.5 inches of vacuum, while S2 will open above 10.0 ±0.5 inches of vacuum. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Carburetor > Accelerator Pump > Component Information > Description and Operation Accelerator Pump: Description and Operation The Temperature Compensated (rate-sensitive) Pump, will allow delivery of a large pump capacity to facilitate cold engine requirements and a smaller pump capacity during warm engine operation. The amount of fuel delivered during warm engine operation is a function of the rate at which the accelerator pedal is opened (fast opening-low capacity/slow opening-higher capacity). The design incorporates a bypass bleed controlled by a vacuum operated valve. Normally, the input signal controlling the valve position is manifold vacuum switched by a PVS located in the engine coolant system. The valve is normally closed when no vacuum is applied allowing full pump capacity during the cold operation. With vacuum applied, the pump functions as a rate sensitive valve controlling the amount of fuel bypassed back to the fuel bowl and not delivered to the intake air stream. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Carburetor > Accelerator Pump > Component Information > Description and Operation > Page 3455 Accelerator Pump: Testing and Inspection LEAKING DIAPHRAGM: Allow engine coolant to stabilize to ambient temperature. Start engine and immediately check for vacuum at the Temperature Compensated Accelerator Pump TCAP valve. When the engine is cold, No vacuum should be present, (at the TCAP valve). Allow engine temperature to reach a stabilized value and check to ensure that a vacuum greater than 10 in-Hg. is present at the TCAP valve. If the vacuum signal to the TCAP valve is incorrect either in the hot or cold mode, check vacuum hoses, connections and the vacuum control valve. After a vacuum is verified, shut-off engine and connect a six inch section of clear tubing (5/32-inch ID) between the TCAP vacuum hose and the TCAP valve. If no fuel is flowing, remove clear tubing and reinstall vacuum hose to the TCAP valve, turn the engine Off. HOT/COLD FUNCTION: With engine Off, remove carburetor air horn and air horn gasket. If the engine is warm relieve pressure on fuel inlet needle by carefully depressing fuel bowl float, carefully remove float and needle assembly, remove enough fuel from the float bowl so that the TCAP bypass bleed hole (fuel bowl side of TCAP valve) is just at or above fuel level. Remove the vacuum hose from the TCAP valve, actuate accelerator pump - at a moderate to fast rate, observe fuel discharge out of TCAP bypass bleed hose. No fuel discharge should be observed from the bypass bleed. If fuel does discharge, replace valve. With a hand operated vacuum pump, apply a vacuum greater than 10 In.Hg. to the TCAP valve. Actuate the accelerator pump with a very quick action from idle to wide open throttle, fuel should be discharged from this bypass bleed. If fuel does not discharge, replace TCAP valve. Reinstall float and needle assembly, air horn and a new air horn gasket. Tighten screws securely. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Carburetor > Accelerator Pump > Component Information > Adjustments > Accelerator Pump Level Accelerator Pump: Adjustments Accelerator Pump Level Fig. 6 Checking accelerator pump lever clearance 1. Using a feeler gauge and with throttle plates wide open, there should be the specified clearance (minimum) between pump operating lever adjustment screw and pump arm when pump arm is depressed manually, Fig.6. 2. If adjustment is required, loosen lock nut and turn adjusting screw in to increase clearance and out to decrease clearance. One-half turn of screw is equal to approximately .015 inch. 3. When proper adjustment has been made, hold screw in position with a wrench and tighten lock nut. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Carburetor > Accelerator Pump > Component Information > Adjustments > Accelerator Pump Level > Page 3458 Accelerator Pump: Adjustments Accelerator Pump Stroke To satisfy the requirements in various climates, the pump discharge can be adjusted. The bottom hole (No. 2) in the pump cam and throttle lever provides the maximum pump discharge for extreme cold weather, and the top hole (No. 1) provides the minimum pump discharge for warm weather operation. If a change in the adjustment is required, make certain the proper hole in plastic pump cam, located behind throttle lever, is properly indexed with the numbered hole in the throttle lever before installing the retaining screw. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Carburetor > Bowl Vent Solenoid > Component Information > Locations Engine View Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Carburetor > Bowl Vent Solenoid > Component Information > Locations > Page 3462 Bowl Vent Solenoid: Description and Operation The Fuel Bowl Vent Solenoid Valve, Figure 1 is part of the Evaporative Emission Control System, and is a normally open valve located in the fuel bowl vent line. The vent solenoid valve closes off the fuel bowl vent line when the engine is running, and it returns to the normally open condition when the ignition switch is turned off. NOTE: if lean fuel mixture Is suspected as the cause of a problem, Inspect the bowl vent solenoid valve for proper closing during engine operation. If the valve leaks or does not close, the carburetor will give a leaner air/fuel mixture. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Carburetor > Bowl Vent Solenoid > Component Information > Locations > Page 3463 Bowl Vent Solenoid: Testing and Inspection Apply 9-14 volts DC to valve, and the valve should close, not allowing air to pass. If valve does not close, replace valve. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Carburetor > Carburetor Solenoid > Component Information > Description and Operation > Carburetor Feedback Solenoid - YFA Carburetor Solenoid: Description and Operation Carburetor Feedback Solenoid - YFA This solenoid assembly is an integral part of the YFA feedback carburetors In a feedback system, it operates as a pulse width modulated (dithering) solenoid, varying the air bled into the idle and main fuel metering circuits, in response to commands from the MCU or EEC, thereby varying the fuel/air ratio delivered to the engine. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Carburetor > Carburetor Solenoid > Component Information > Description and Operation > Carburetor Feedback Solenoid - YFA > Page 3468 Carburetor Solenoid: Description and Operation Carburetor Feedback Solenoid - 2150A Feedback Fuel Control utilizes a pulsing solenoid to introduce fresh air from the air cleaner into the idle and main system vacuum passages to lean the fuel and air mixture from the maximum rich condition (0% duty cycle - solenoid closed) to the maximum lean condition (100% duty cycle solenoid fully open). The solenoid operates under the control of the EEC-IV system. Also new to the 2150 carburetor is a throttle position sensor required by the EEC system. This new sensor was designed for the 2150 carburetor and was made non-adjustable to reduce production and warranty costs. To package the throttle position sensor and the feedback system changes were made to the booster assembly, main body, airhorn, throttle shaft and to certain choke linkage parts (fast idle cam, cam hub, cam rod, fast idle level & choke shield). Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Carburetor > Carburetor Solenoid > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures Carburetor Solenoid: Symptom Related Diagnostic Procedures After completing the MCU or EEC diagnostic procedure, and tracing the probable cause of the problem to the feedback solenoid, perform one or more of the following procedures: Feedback Carburetors - Rough Idle, Lean Drive 1. With the engine running at idle, retighten the solenoid mounting screws to 30 lb-in. If idle does not change, proceed to Step 2. 2. With the engine running at idle, apply a stethoscope or metal rod to the solenoid body and listen (or feel) for a 10 Hz constant pulse. If the pulse is not evident, or is erratic, replace the solenoid assembly and gasket. 3. With the engine running at idle, disconnect the solenoid lead. If the idle quality improves significantly with the solenoid disconnected, replace the solenoid assembly and gasket. NOTE: Since disconnecting the lead will appreciably richen the idle mixture, similar to the propane-gain technique, some degree of idle quality improvement and idle speed gain is to be expected, even with a properly operating solenoid. Feedback Carburetors - Running Rich, Poor Economy Use Step 2, above for diagnosis. NOTE: The 2.3L or 4.9L YFA 1-V Feedback Solenoid for the 1985 model year is not interchangeable with the 1981/82 4.9L solenoid. The former being designed for 38 ohm resistance, while the 1981/82 (4.9L) is 22 ohm. The Electronic Control Assembly (ECA) will be damaged if these units are interchanged. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Carburetor > Carburetor Solenoid > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3471 Carburetor Solenoid: Component Tests and General Diagnostics Duty Cycle Solenoid (FBCA) Diagnostic Routine NOTE: This procedure should be conducted only after completion of EEC IV diagnostic procedure when the resultant error codes included 41 or 42, and the appropriate Pinpoint Tests have been performed. To verify that the FBCA is functioning properly warm-up engine until the radiator hose is pressurized and hot. Turn ignition key to the Off position. Remove FBCA from carburetor, plug idle system feedback passage (top hole) in carburetor mainbody with a rubber plug, and restart engine. Observe FBCA for proper function. The rubber plunger in the actuator should be dithering open and closed If no dithering is observed immediately after start-up, replace FBCA. NOTE: Duty cycle dithering will be experienced only for a short period after engine start-up. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Carburetor > Choke Plate > Component Information > Adjustments Choke Plate: Adjustments Fig. 8 Choke plate pulldown adjustment. Except 1985 - 87 models w/electric choke EXCEPT. 1985 - 87 MODELS W/ELECTRIC CHOKE 1. Remove thermostat housing, gasket and retainer. 2. Insert a piece of wire, Fig. 8, into choke piston bore to move the piston down against the stop screw. Maintain light closing pressure on choke plate and measure the gap between the lower edge of the choke plate and air horn wall. 3. To adjust, remove the putty covering the adjustment screw and turn clockwise to decrease or counter-clockwise to increase gap setting. 4. Reinstall choke thermostatic housing, gasket and retainer. Do not tighten screws until Fast Idle Cam Set adjustment has been performed. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Carburetor > Choke Plate > Component Information > Adjustments > Page 3475 Fig. 9 Choke plate pulldown vacuum passage. 1985 - 87 models w/electric choke Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Carburetor > Choke Plate > Component Information > Adjustments > Page 3476 Fig. 10 Removing choke pulldown diaphragm adjusting screw cover. 1985 - 87 models w/ electric choke 1985 - 87 MODELS W/ELECTRIC CHOKE 1. Remove carburetor from vehicle and cover intake manifold. 2. Place carburetor on work stand suitable to allow access to pulldown diaphragm vacuum passage on underside of throttle body, Fig. 9. 3. Scribe alignment marks on choke cap and choke housing, then remove choke cap, gasket and retainer. 4. Temporarily install choke cap with standard choke cap gasket and align scribe marks, then rotate cap 90° counterclockwise and secure with one screw. 5. Ensuring that choke plate is in fully closed position, actuate choke pulldown motor using an outside vacuum source of at least 17 inches Hg. 6. Using drill gauge of specified size, check clearance between upper edge of choke plate and air horn wall. Gauge should fit in such a manner that it contacts air horn and choke plate but does not move plate. 7. If adjustment is necessary, carefully remove diaphragm adjustment screw cap using suitable tool, Fig. 10. 8. Using 5/64 inch Allen wrench, turn adjustment screw clockwise to decrease setting or counterclockwise to increase setting. Maintain a minimum of 17 inches Hg. to pulldown diaphragm during adjustment. Cycle vacuum from 0 to 17 inches Hg. to verify setting. 9. Apply suitable sealant to adjustment screw cavity and check fast idle cam adjustment. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Carburetor > Choke Pull-off > Component Information > Description and Operation Choke Pull-off: Description and Operation The one-port normally open valve assembly is designed with an atmospheric vent. The one vacuum port is connected to the atmospheric vent when the solenoid is de-energized. When the solenoid is energized, the atmospheric vent is closed. This valve assembly is used in the choke pulldown system. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Carburetor > Choke Pull-off > Component Information > Description and Operation > Page 3480 Choke Pull-off: Testing and Inspection The valve should allow air flow when the solenoid is deenergized. When the solenoid is energized, air flow is blocked. The solenoid resistance when measured at the terminals should be between 51 and 108 ohms. If the solenoid resistance is not within these values, replace the solenoid. NOTE: The valve can be expected to have a very small leakage when energized. This leakage is not measurable in the field and is not detrimental to valve function. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Carburetor > Choke Pull-off > Component Information > Description and Operation > Page 3481 Choke Pull-off: Adjustments Fig. 11 Dechoke adjustment 1. Hold throttle in wide open throttle position. 2. Apply a light closing pressure on the choke plate and measure the gap between the lower edge of the choke plate and air horn wall. 3. To adjust, bend the pawl on the fast idle lever, Fig. 11, forward to increase or backward to decrease the clearance. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Carburetor > Electric Assist Choke <--> [Choke Thermostat/Heater] > Component Information > Technical Service Bulletins > Vehicle - High Altitude Modification Electric Assist Choke: Technical Service Bulletins Vehicle - High Altitude Modification Article No. 86-15-16 ALTITUDE (5.8L (W)) - MODIFICATION OF SEA LEVEL CALIBRATION FOR ALTITUDE APPLICATION - VEHICLES WITH 4V CARBURETORS ONLY - OVER 8500 LBS. GVWR LIGHT TRUCK 1986 E SERIES, F SERIES CALIBRATION: 5-76J-R17 (Manual Transmission) WARNING: This modification is authorized only for the listed engines. Performing this modification on other engine calibrations is unauthorized and could create liability under applicable federal or local laws. Customers who may have relocated and/or continually operate the subject vehicles in high altitude (above 4,000 ft. alt.) may have the following procedure performed to improve performance. 1. Remove existing PCV valve and replace with new PCV valve (part number D90Z-6A666-A). 2. Advance initial ignition timing 6~ from nominal setting of 8~ BTDC to 14~ BTDC. Refer to 1986 Light Truck Shop Manual, Volume B, Section 23-01. 3. Increase choke pull down hard gauge setting to .193". Refer to 1986 Light Truck Shop Manual, Volume B, Section 24-26. 4. Remove existing choke cap and replace with new choke cap 47R-776-A (part number E5PZ-9848-B). 5. Reset hi-cam and curb idle speeds to specification (refer to Vehicle Emission Control Information Decal). Obtain a Vehicle Emission Control Information Update Decal (available at all Ford or Lincoln-Mercury dealers) and fill in the appropriate information as indicated. If the vehicle is returned to continuous sea level (below 4,000 ft. alt.) operation, the above procedure should be reversed and the Vehicle Emission Control Information Update Decal should be removed from the vehicle. PART NUMBER PART NAME CLASS D90Z-6A666-A PCV Valve A E5PZ-9848-B Choke Cap C OTHER APPLICABLE ARTICLES: 85-21-16 WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION: SP9514A86 TIME: 1.3 Hrs. DLR. CODING: Basic Part No. DRIVE - Code: N4, P6, T5 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Carburetor > Electric Assist Choke <--> [Choke Thermostat/Heater] > Component Information > Technical Service Bulletins > Page 3486 Electric Assist Choke: Locations At Carburetor Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Carburetor > Electric Assist Choke <--> [Choke Thermostat/Heater] > Component Information > Diagrams > Diagram Information and Instructions Electric Assist Choke: Diagram Information and Instructions Symbol Identification Wire Color Code Identification Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Carburetor > Electric Assist Choke <--> [Choke Thermostat/Heater] > Component Information > Diagrams > Diagram Information and Instructions > Page 3489 NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Carburetor > Electric Assist Choke <--> [Choke Thermostat/Heater] > Component Information > Diagrams > Diagram Information and Instructions > Page 3490 Electric Assist Choke: Electrical Diagrams Fig. 7 Carburetor Wiring Circuit. F250-350 Over 8,500 GVW Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Carburetor > Electric Assist Choke <--> [Choke Thermostat/Heater] > Component Information > Diagrams > Diagram Information and Instructions > Page 3491 Fig. 8 Carburetor Wiring Circuit. F150-250 Under 8,500 GVW Exc. California Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Carburetor > Electric Assist Choke <--> [Choke Thermostat/Heater] > Component Information > Diagrams > Page 3492 Electric Assist Choke: Description and Operation Fig. 45 Typical electric assist choke installation Most carbureted engine models are equipped with an electric assist choke. This device aids in reducing emissions of hydrocarbons (HC) and carbon monoxide (CO) during starting and warm-up (choke on) period. The electric assist choke is designed to give a more rapid choke opening at temperatures of about 54° to 74° F, or higher. It also provides a slower choke opening at temperatures below this point. The electric assist choke system does not change any carburetor service procedures and cannot be adjusted. If system is found out of calibration the heater control switch and/or choke unit must be replaced. The electric choke system, Fig. 45 consists of a choke cap, thermostatic spring, a bimetal temperature sensing disc (switch), and a ceramic positive temperature coefficient (PTC) heater. The choke is powered from terminal or tap of the alternator. Current is constantly supplied to the ambient temperature switch. The system is grounded through a ground strap connected to the carburetor body. At temperatures below approximately 60° F, the switch opens and no current is supplied to the ceramic heater located within the thermostatic spring. Normal thermostatic spring choking action then occurs. At temperatures above approximately 54°---74° F the temperature sensing switch closes and current is supplied to the ceramic heater. As the heater warms, it causes the thermostatic spring to pull the choke plates open within 1 - 1.25 minutes. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Carburetor > Electric Assist Choke <--> [Choke Thermostat/Heater] > Component Information > Diagrams > Page 3493 Electric Assist Choke: Testing and Inspection 1. Disconnect stator lead at connector leading from choke cap and connect a test light in series with stator lead and ground. 2. With engine running, test light should glow. 3. If light does not glow, repair or replace either the alternator or choke wire. 4. With engine running at normal operating temperature, place test light in series with choke terminal and alternator lead. If light does not glow, replace choke cap assembly. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Carburetor > Electric Assist Choke <--> [Choke Thermostat/Heater] > Component Information > Diagrams > Page 3494 Electric Assist Choke: Adjustments 1. Loosen thermostatic spring housing clamp retaining screws. 2. Rotate spring housing to align index mark on spring housing with center index mark on choke housing. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Carburetor > Throttle Plate - Carb. > Component Information > Adjustments Throttle Plate - Carb.: Adjustments Fig. 7 Secondary throttle plate adjustment With secondary throttle plates closed, rotate secondary throttle shaft lever stop screw counter-clockwise until the secondary throttle plates seat in the bores. Rotate adjusting screw clockwise until it contacts the secondary lever, Fig. 7. Turn stop screw an additional 1/4 turn on 1982 - 84 models or 3/8 turn on 1985 - 87 models. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Dashpot > Component Information > Adjustments Dashpot: Adjustments 1. With engine at normal operating temperature, apply 19 inches Hg vacuum to decel throttle modulator. 2. Loosen decel throttle modulator lock nut and rotate modulator to achieve 1800 RPM. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > Customer Interest: > 91813 > Apr > 91 > Engine - Rough Idle/Hesitation/Backfire/Stalling Fuel: Customer Interest Engine - Rough Idle/Hesitation/Backfire/Stalling Article No. 91-8-13 04/17/91 FUEL - USE OF UNLEADED GASOLINES - TIPS TO AVOID LEAN AIR - FUEL CONDITIONS FORD: 1985-86 LTD 1985-88 EXP 1985-91 CROWN VICTORIA, ESCORT, MUSTANG, TEMPO, THUNDERBIRD 1986-91 TAURUS 1988-91 FESTIVA 1989-91 PROBE LINCOLN-MERCURY: 1985-87 LYNX 1985-91 CAPRI, CONTINENTAL, COUGAR, GRAND MARQUIS, MARK VII, TOPAZ, TOWN CAR 1986-91 SABLE 1987-91 TRACER MERKUR: 1985-89 XR4TI 1988-89 SCORPIO LIGHT TRUCK: 1985-90 BRONCO II 1985-91 AEROSTAR, BRONCO, ECONOLINE, F-150-350 SERIES, RANGER 1989-91 F SUPER DUTY, F47, F53 1991 EXPLORER ISSUE: Rough idle, hesitation, poor throttle response, induction backfire and stalls during cold start/warm up may be caused by the poor volatility of some high octane premium grade unleaded fuels (91 octane or higher (R+M)/2). When compared to regular grade unleaded fuel (87 octane (R+M)/2), high octane premium grade unleaded fuel may cause long crank time. ACTION: Use a regular grade unleaded fuel in all vehicles, except where a premium unleaded fuel is recommended in the Owner Guide. If lean air-fuel type symptoms are experienced, determine the grade and brand of fuel used and offer the following service tips. ^ Advise those using a higher octane grade fuel to switch to a regular grade unleaded fuel. For those using a regular grade fuel, advise them to try another brand. ^ Do not advise using a higher octane unleaded fuel than is recommended for that specific engine. Ford engines are designed to perform best using a high quality regular grade unleaded fuel. ^ Only advise using a higher octane unleaded fuel to avoid potentially damaging spark knock or ping, but do so only after mechanical fixes are ineffective. NOTE: ALL UNLEADED GASOLINES USED SHOULD CONTAIN DETERGENT ADDITIVES THAT ARE ADVERTISED AS HAVING "KEEP CLEAN" OR "CLEAN UP" PERFORMANCE FOR BOTH INTAKE VALVES AND FUEL INJECTORS. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 404000 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 96107 > May > 96 > Fuel - California Reformulated Gasoline Fuel: All Technical Service Bulletins Fuel - California Reformulated Gasoline Article No. 96-10-7 05/06/96 FUEL - CALIFORNIA REFORMULATED GASOLINE (CARFG) - SERVICE TIP FORD: 1983-86 LTD 1983-88 EXP 1983-96 CROWN VICTORIA, ESCORT, MUSTANG, THUNDERBIRD 1985-94 TEMPO 1986-96 TAURUS 1989-96 PROBE 1995-96 CONTOUR LINCOLN-MERCURY: 1980-83 MARK VI 1983-88 LN7 1983-96 COUGAR, GRAND MARQUIS, TOWN CAR 1984-92 MARK VII 1985-94 TOPAZ 1986-96 SABLE 1991-96 TRACER 1993-96 CONTINENTAL, MARK VIII 1995-96 MYSTIQUE LIGHT TRUCK: 1983-96 BRONCO, ECONOLINE, F-150-350 SERIES, RANGER 1984-90 BRONCO II 1986-96 AEROSTAR 1987-96 F SUPER DUTY 1991-96 EXPLORER 1993-96 VILLAGER 1995-96 WINDSTAR ISSUE: California introduced CaRFG around March 1, 1996 and statewide it must be available at all service stations by June 1, 1996 to help reduce emissions and improve gasoline quality. It will replace the traditional gasoline sold in Northern California and improve the reformulated gasoline that has been sold in Southern California since January 1995. California Air Resources Board (CARB) projects smog forming emissions from motor vehicles to be reduced by about 15 percent. ACTION: The following text is provided to give some answers to some commonly asked questions by our customers. POSITION Ford Motor Company recommends the use of CaRFG as a cost effective means of reducing emissions to provide cleaner air. We have participated in vehicle and laboratory testing of CaRFG to make sure it is acceptable for our customers' use. There are no unusual vehicle performance concerns expected based upon these studies. The use of CaRFG will not affect Ford's new vehicle and/or emissions warranty. WHAT DOES CaRFG CONSIST OF? CaRFG consists of the same basic components as other gasolines, but it reduces pollution because of its cleaner burning components. Features are: ^ reduced aromatic hydrocarbons to form less smog emissions ^ added oxygenates to reduce emissions ^ decreases the amount of fuel evaporating from the vehicle ^ lowered sulfur content to provide more efficient operation of the vehicle's catalytic converter Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 96107 > May > 96 > Fuel - California Reformulated Gasoline > Page 3514 ^ reduced benzene by about one-half IS CaRFG MORE HAZARDOUS THAN CONVENTIONAL GASOLINES? CaRFG is a hazardous substance like conventional gasoline. Precautions should continue to be taken to avoid exposure to vapors or liquid when it is pumped or handled. It should never be siphoned or swallowed. HOW WILL CaRFG AFFECT VEHICLE PERFORMANCE? Properly blended CaRFG should have no adverse effect on vehicle performance or the durability of engine and fuel system components. Its basic properties are not significantly different than other cleaner burning gasolines that have been used in the U.S. for several years. If the vehicle is a certified California calibration 1996 or later model year, it was designed to operate on CaRFG gasoline. The vehicle will operate satisfactorily on gasolines in the other 49 states, but emission control system performance may be affected. Using gasolines other than CaRFG have substantially increased emissions from motor vehicles. WILL THE USE OF CaRFG AFFECT CALIFORNIA VEHICLE WARRANTY? No. The coverage of Ford's new vehicle warranty is not affected. In fact, Ford Owner Guides have consistently approved the use of properly blended reformulated gasolines containing oxygenates. Further information about properly fueling your vehicle is included in the Owner Guide. WILL FUEL ECONOMY BE AFFECTED? A very small reduction in fuel economy of less than one-half mile per gallon is possible if the customer was using gasoline without oxygenates. This is attributed to the lower energy content of oxygenates which have been in all Southern California gasolines since January of 1995 and in some gasolines since the 1970's. Many factors affect fuel economy like driving habits, vehicle maintenance, weather conditions, etc. Fuel economy can vary by more than a mile per gallon from one fill-up to the next with the same gasolines. For further details see TSB Article 95-12-2 for customer expectations regarding fuel economy. ARE SPECIAL ADDITIVES NECESSARY FOR CaRFG? No. It is not necessary to add anything to the vehicle fuel tank after the gasoline is purchased from the service station. California regulations require deposit control additives in CaRFG to minimize port fuel injector and intake valve deposits. WILL OLDER VEHICLES OPERATE SATISFACTORILY WITH THE NEW CaRFG? Older vehicles are expected to operate satisfactorily on CaRFG because vehicles have been operating on gasolines similar to CaRFG for a number of years. However, considerable testing indicates that older, high mileage vehicles are more susceptible to fuel system problems due to age and normal wear and tear regardless of whether they are operated on conventional or CaRFG gasolines. Owners of these older vehicles are encouraged to follow their vehicle manufacturer's recommendations regarding vehicle maintenance. WILL THE SMELL BE DIFFERENT THAN CONVENTIONAL GASOLINE? CaRFG is not expected to smell different than the gasoline most vehicles are currently using. If an unusual odor is noticed, it would probably be from oxygenates. Most service stations use vapor recovery systems to minimize the release of gasoline vapors while refueling. The use of CaRFG should result in little or no "rotten egg" smell from the exhaust because CaRFG has much lower sulfur than conventional gasoline. WAS CaRFG TESTED BEFORE INTRODUCTION? It was tested for over five million miles in more than 800 vehicles under the guidance of CARB including experts representing automobile manufacturers, gasoline suppliers, fleet operations and government. There was no increase in problems identified with the use of CaRFG. DOES CaRFG COST MORE? The price at the pump cannot be accurately predicted, although a modest increase is likely. The price of CaRFG is subject to the competitive forces in the marketplace. Many factors including production costs, supply and demand, weather, crude oil prices, and taxes affect gasoline prices. WHERE CAN I GET MORE INFORMATION ON CaRFG? Additional information within the state of California on CaRFG is available from the California Air Resources Board toll-free at 1-800-922-7349 (within California only). Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 96107 > May > 96 > Fuel - California Reformulated Gasoline > Page 3515 OTHER APPLICABLE ARTICLES: 95-12-2 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 404000, 623000 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 91813 > Apr > 91 > Engine - Rough Idle/Hesitation/Backfire/Stalling Fuel: All Technical Service Bulletins Engine - Rough Idle/Hesitation/Backfire/Stalling Article No. 91-8-13 04/17/91 FUEL - USE OF UNLEADED GASOLINES - TIPS TO AVOID LEAN AIR - FUEL CONDITIONS FORD: 1985-86 LTD 1985-88 EXP 1985-91 CROWN VICTORIA, ESCORT, MUSTANG, TEMPO, THUNDERBIRD 1986-91 TAURUS 1988-91 FESTIVA 1989-91 PROBE LINCOLN-MERCURY: 1985-87 LYNX 1985-91 CAPRI, CONTINENTAL, COUGAR, GRAND MARQUIS, MARK VII, TOPAZ, TOWN CAR 1986-91 SABLE 1987-91 TRACER MERKUR: 1985-89 XR4TI 1988-89 SCORPIO LIGHT TRUCK: 1985-90 BRONCO II 1985-91 AEROSTAR, BRONCO, ECONOLINE, F-150-350 SERIES, RANGER 1989-91 F SUPER DUTY, F47, F53 1991 EXPLORER ISSUE: Rough idle, hesitation, poor throttle response, induction backfire and stalls during cold start/warm up may be caused by the poor volatility of some high octane premium grade unleaded fuels (91 octane or higher (R+M)/2). When compared to regular grade unleaded fuel (87 octane (R+M)/2), high octane premium grade unleaded fuel may cause long crank time. ACTION: Use a regular grade unleaded fuel in all vehicles, except where a premium unleaded fuel is recommended in the Owner Guide. If lean air-fuel type symptoms are experienced, determine the grade and brand of fuel used and offer the following service tips. ^ Advise those using a higher octane grade fuel to switch to a regular grade unleaded fuel. For those using a regular grade fuel, advise them to try another brand. ^ Do not advise using a higher octane unleaded fuel than is recommended for that specific engine. Ford engines are designed to perform best using a high quality regular grade unleaded fuel. ^ Only advise using a higher octane unleaded fuel to avoid potentially damaging spark knock or ping, but do so only after mechanical fixes are ineffective. NOTE: ALL UNLEADED GASOLINES USED SHOULD CONTAIN DETERGENT ADDITIVES THAT ARE ADVERTISED AS HAVING "KEEP CLEAN" OR "CLEAN UP" PERFORMANCE FOR BOTH INTAKE VALVES AND FUEL INJECTORS. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 404000 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 87239 > Nov > 87 > Rotunda Gas Chek Kit - Requires Modification Fuel: All Technical Service Bulletins Rotunda Gas Chek Kit - Requires Modification Article No. FUEL SYSTEM - ROTUNDA "GAS-CHEK" KIT 87-23-9 TOOL MODIFICATION FORD: 1988 And Prior ALL CAR LINES LINCOLN-MERCURY: 1988 And Prior ALL CAR LINES LIGHT TRUCK: 1988 And Prior ALL LIGHT TRUCK LINES ISSUE: The Rotunda "Gas-Chek Kit" (Tool Number 113-00002) that you may have purchased prior to October, 1987 requires modification. The necessary components and new operating instructions will be shipped to you at no charge. This tool modification will provide greater accuracy when performing high fuel vapor pressure testing of gasoline. ACTION: To modify the Rotunda "Gas-Chek Kit", use the following service instructions. NOTE: This modification MUST be done because it will seriously affect the volatility tests. Figure 11 1. Remove adapter fitting attached to the 0-30 PSI gauge. CARE SHOULD BE TAKEN TO PREVENT DAMAGE TO GAUGE ASSEMBLY WHEN REMOVING FITTING. Throw away the adapter fitting, Figure 11. 2. Remove and throw away the aluminum vial, Figure 11. 3. Remove plastic thermos cup cap and throw away, Figure 11. 4. Remove the set of instructions from the lid of the Gas-Chek plastic storage box and throw them away. NOTE: USE ONLY THE NEW instruction booklet that is furnished in the modification kit. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 87239 > Nov > 87 > Rotunda Gas Chek Kit - Requires Modification > Page 3524 Figure 12 5. Using thread sealer or teflon tape on the threads of the PSI gauge, install gauge and tighten into new cover and air chamber, Figure 12. After installation is made, this assembly should not be disassembled. 6. Position small, plastic gasoline sample container and gas cup holder into gauge and vial cavity of die-cut, foam material for storage, Figure 12. 7. Care should be taken when storing unit to prevent damage which could then cause bad readings when checking gasoline vapor pressure. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 861321 > Jul > 86 > Fuel System - Gasoline Testing Kit Fuel: All Technical Service Bulletins Fuel System - Gasoline Testing Kit Article No. 86-13-21 GAS CHECK - GASOLINE TESTING KIT - VEHICLES WITH GASOLINE ENGINES FORD ALL CAR LINES LINCOLN-MERCURY ALL CAR LINES MERKUR 1985-86 XR4Ti LIGHT TRUCK ALL LIGHT TRUCK LINES Variations in gasoline quality and a general rise in fuel vapor pressures can cause driveability concerns such as vapor lock, loss of power, stalls and stumbles. The purpose of this article is to announce the availability of a fuel checking kit called Gas Check (Rotunda number 113-00002) as a part of the Rotunda tool and equipment program. The Gas Check kit can be used to measure fuel vapor pressure (RVP) and alcohol content. There is also a provision in the kit for detecting water in fuel tanks and the use of leaded fuels in vehicles. Refer to the Rotunda 1986 tool and equipment catalog (page B20) for details. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel: > 932410 > Nov > 93 > Instrument Cluster Warning Lights - Dimly Lit Oil Level Warning Indicator: All Technical Service Bulletins Instrument Cluster Warning Lights Dimly Lit Article No. 93-24-10 11/24/93 ^ LAMP - MALFUNCTION OF FOUR PIN LOW OIL LEVEL RELAY - VEHICLES BUILT AFTER 8/1/92 OR 1983-1993 VEHICLES THAT HAVE HAD SERVICE REPLACEMENT IGNITION SWITCHES AFTER 8/1/92 ^ LAMPS - INSTRUMENT CLUSTER WARNING LIGHTS DIMLY LIT - VEHICLES BUILT AFTER 8/1/92 OR 1983-1993 VEHICLES THAT HAVE HAD SERVICE REPLACEMENT IGNITION SWITCHES AFTER 8/1/92 FORD: 1983 FAIRMONT 1983-89 CROWN VICTORIA, ESCORT 1983-93 MUSTANG, THUNDERBIRD 1983-94 PROBE 1984-86 LTD 1984-94 TEMPO LINCOLN-MERCURY: 1983 LN7, ZEPHYR 1983-87 CONTINENTAL, LYNX 1983-89 GRAND MARQUIS, TOWN CAR 1983-93 COUGAR 1984-86 CAPRI, MARQUIS 1984-94 TOPAZ LIGHT TRUCK: 1983-91 BRONCO 1983-93 ECONOLINE, F-150-350 SERIES, RANGER 1986-91 AEROSTAR 1991-93 EXPLORER ISSUE: The instrument cluster warning light(s) may be dimly lit or there may be a malfunction of the four pin low oil relay on vehicles so equipped. This could be due to the ignition switch. ACTION: If the vehicle displays the subject symptoms and meets the following conditions, replace the ignition switch. Refer to the appropriate Car or Light Truck Service Manual (Section 13-04 for 1983-1990 Cars, Section 11-04 for 1991-1993 Cars and Section 13-05 for 1983-1990 Light Trucks, Section 11-05 for 1991-1993 Light Trucks) for removal and installation procedures. Refer to the Parts Block in this article for correct parts usage. CONDITIONS ^ The vehicle has 14401 wiring attached to the P2 terminal of the ignition switch. Refer to the wiring schematic and/or Electrical And Vacuum Troubleshooting Manual (EVTM) for the concern vehicle. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel: > 932410 > Nov > 93 > Instrument Cluster Warning Lights - Dimly Lit > Page 3534 ^ The vehicle is equipped with one of the ignition switches identified in the Ignition Switch Part Number Chart. NOTE: THE SERVICE PART NUMBERS FOR THE REPLACEMENT IGNITION SWITCHES WILL HAVE THE SAME PART NUMBERS AS THOSE REPLACED. THE NEW SWITCH HAS BEEN IMPROVED TO CORRECT THE SUBJECT ISSUE. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of The Bumper To Bumper For 1992/93 Models, Basic Warranty Coverage For All Other Models Except Lincolns. Major Component Warranty Coverage For Lincolns OPERATION DESCRIPTION TIME 932410A Replace Ignition Switch - 0.5 Hr. All Light and Compact Trucks DEALER CODING BASIC PART NO. CONDITION CODE 11572 X1 OASIS CODES: 201000, 201100, 206000 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel: > 932410 > Nov > 93 > Instrument Cluster Warning Lights - Dimly Lit > Page 3540 ^ The vehicle is equipped with one of the ignition switches identified in the Ignition Switch Part Number Chart. NOTE: THE SERVICE PART NUMBERS FOR THE REPLACEMENT IGNITION SWITCHES WILL HAVE THE SAME PART NUMBERS AS THOSE REPLACED. THE NEW SWITCH HAS BEEN IMPROVED TO CORRECT THE SUBJECT ISSUE. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of The Bumper To Bumper For 1992/93 Models, Basic Warranty Coverage For All Other Models Except Lincolns. Major Component Warranty Coverage For Lincolns OPERATION DESCRIPTION TIME 932410A Replace Ignition Switch - 0.5 Hr. All Light and Compact Trucks DEALER CODING BASIC PART NO. CONDITION CODE 11572 X1 OASIS CODES: 201000, 201100, 206000 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Technical Service Bulletins > Fuel Tank Filler Cap - New Design Available Fuel Filler Cap: Technical Service Bulletins Fuel Tank Filler Cap - New Design Available FUEL SYSTEM - HIGH FLOW "PRE-VENT" FULL TANK FILLER CAP Article No. 88-25-13 LIGHT TRUCK: 1983-88 ECONOLINE 1983-86 F-SERIES ISSUE: A new cam-lock high flow "Pre-vent" filler cap is available for service. The new filler cap encourages slower loosening for more gradual venting of fuel tank pressure. The "Pre-vent" filler cap has a black plastic cover. Trucks with exposed filler caps or trucks with filler caps covered by fuel filler doors can use the new filler cap. ACTION: Install a new high flow "Pre-vent" filler cap for service: ^ In areas that sell "winter grade" fuel in hot weather. ^ For owners who frequently overfill fuel tanks. ^ For owners concerned about normal venting of fuel tank pressure. FIGURE 4 The new filler cap meets or exceeds the performance of all other filler caps released by Ford Motor Company, Figure 4. NOTE: USE THE NEW FILLER CAP TO REPLACE FILLER CAPS LISTED IN TSB 87-15-13. PART NUMBER PART NAME CLASS E8TZ-9030-C Cap Assembly C ARTICLE SUPERSEDED: 87-15-13 WARRANTY STATUS: "INFORMATION ONLY" OASIS CODE: 4500 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Component Information > Service and Repair Fuel Filter: Service and Repair REMOVAL - Remove the air cleaner. - Hold the fuel filter inlet hex nut with a backup wrench and unscrew the fuel line tube nut from the fuel filter inlet. WARNING: Use care to prevent combustion from fuel spillage. - Unscrew the fuel inlet fitting. - Remove the gasket, filter and spring. - Discard the gasket and filter. INSTALLATION - Install the spring, new filter and gasket. - Hand start the fuel inlet fitting into the carburetor then, tighten to 30-35 Nm (22-26 lb-ft). Apply oil, ESE-M2C39-E or equivalent to the fuel tube nut threads and tube flare. - Hand start the fuel line tube nut into the fuel inlet fitting (approximately two threads). - Use a backup wrench on the fuel inlet fitting while tightening the fuel line tube nut to 20-24 Nm (15-18 lb-ft). - Start the engine and check for fuel leak. - Install the air cleaner. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > Customer Interest: > 881711 > Aug > 88 > Engine - Hesitation/Lack Of Power/Rough Idle Fuel Injector: Customer Interest Engine - Hesitation/Lack Of Power/Rough Idle FUEL INJECTORS - DIAGNOSTIC AND CLEANING TIPS Article No. 88-17-11 FORD: 1983-88 ESCORT, THUNDERBIRD 1984-88 EXP 1986-88 MUSTANG, TAURUS, CROWN VICTORIA 1988 TEMPO LINCOLN-MERCURY: 1983-86 LYNX 1983-88 COUGAR 1986 CAPRI 1986-88 SABLE, GRAND MARQUIS, MARK VII, CONTINENTAL, LINCOLN TOWN CAR 1988 TRACER, TOPAZ MERKUR: 1987-88 XR4Ti 1988 SCORPIO LIGHT TRUCK: 1985-88 RANGER, F-SERIES, BRONCO 1986-88 E-SERIES, AEROSTAR ISSUE: Port fuel injected vehicles that have cold hesitation, lack of power, rough engine idle or a surging condition at steady speeds may be caused by dirty fuel injectors. When no-detergent fuel is used, deposits form on the fuel metering surfaces of the fuel injectors. The deposits that form reduce the fuel flow resulting in a lean condition. ACTION: To correct this, follow normal diagnostics as shown in the Engine/Emissions Diagnosis Manual, Section 2. If you get to a step that instructs you to replace a fuel injector, FIRST try cleaning the injector with the Rotunda Tester/Cleaner, 113-00001. If the condition still exists after cleaning, the injectors should be flow tested to make sure they are functioning properly. If the flow test indicates lean injectors, a second cleaning may be necessary because of severe injector fouling. Refer to the diagnostic chart on page 69 of this TSB for step-by-step instructions. CAUTION: NEVER ATTEMPT TO FLOW TEST INJECTORS WITH THE CLEANING SOLUTION MIXTURE. THIS WILL PRODUCE FALSE TEST RESULTS. ONLY USE CLEAN GASOLINE. In cases where fouled injectors were the cause of the driveability concern, it should be recommended to the customer that a better quality gasoline be used. The Owner Guide, Maintenance Schedule and Operating Guide address the fuel quality issue. NOTE: IT IS VERY IMPORTANT THAT THE CORRECT CLEANING SOLVENT IS USED WITH THE ROTUNDA TESTER/CLEANER. THE CORRECT CLEANING SOLVENTS ARE: Power Flush Injector Fluid E6AZ-19579-C Carburetor and Combustion Chamber Cleaner D9AZ-19579-B DO NOT USE Injector and Fuel System Cleaner E6AZ-19579-A Rotunda Tester/Cleaner Equipment Update The following items are available for use with the Rotunda Tester/Cleaner: a. 3.8L ENGINE INJECTOR ADAPTER HARNESS 113-00005 To flow test injectors on the 1988 3.8L with EFI, a wire harness is available to allow a direct connection to the injector harness 8-pin connector. b. 2B SPAN TUBE 113-00003 To flow test the Tracer 1.6L, Light Truck 7.5L and 3.8L supercharged engine. CAUTION: NEVER LEAVE CLEANING SOLUTION IN THE ROTUNDA TESTER/CLEANER. ALWAYS DRAIN THE TANK AND LINES Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > Customer Interest: > 881711 > Aug > 88 > Engine - Hesitation/Lack Of Power/Rough Idle > Page 3556 COMPLETELY. PART NUMBER PART NAME CLASS E6AZ-19579-C Power Flush Injector B Cleaner D9AZ-19579-BA Carburetor and Combustion AM Chamber Cleaner OTHER APPLICABLE ARTICLES: 86-13-22 Supersedes 87-9-8 WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION: Refer to the Service Labor Tie Standards Manual DLR. CODING: Basic Part No. 9F593 Condition Code: 49 DIAGNOSTIC CHART Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 93114 > May > 93 > Engine - Rough Idle or Stumble Fuel Injector: All Technical Service Bulletins Engine - Rough Idle or Stumble Article No. 93-11-4 05/26/93 ^ FUEL INJECTORS - NON-DEPOSIT RESISTANT TYPE - DEPOSIT FORMATION ^ IDLE - ROUGH - LEAN FUEL FLOW CAUSED BY FUEL INJECTOR PINTLE DEPOSIT FORMATION ^ STUMBLE - LEAN FUEL FLOW CAUSED BY FUEL INJECTOR PINTLE DEPOSIT FORMATION FORD: 1988-90 TAURUS, TEMPO 1988-91 MUSTANG LINCOLN-MERCURY: 1988-89 CONTINENTAL 1988-90 SABLE, TOPAZ 1988-91 MARK VII LIGHT TRUCK: 1985-91 BRONCO, ECONOLINE, F-150-350 SERIES 1988-91 F-47, F-53 This TSB article is being republished in its entirety to correct the part number for the 7.5L engine injector assembly. ISSUE: A stumble or rough idle condition may be caused by lean fuel flow resulting from pintle deposit formation on non-deposit resistant fuel injectors. These non-deposit resistant fuel injectors are susceptible to pintle deposit formation. ACTION: If service is required, install deposit resistant injectors. These Deposit Resistant Injectors (DRI'S) are acceptable service replacements for non-deposit resistant injectors that exhibit lean fuel flow. Refer to the DRI Replacement Chart for correct parts usage. Parts Block NOTE: FUEL INJECTOR REPLACEMENT IS ONLY ALLOWED WHEN LEAN FLOW IS VERIFIED BY UTILIZING THE SERVICE BAY DIAGNOSTIC SYSTEM (SBDS) OR ROTUNDA FUEL INJECTOR CLEANER (113-0001). SUPERSEDES: 92-24-5 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 93114 > May > 93 > Engine - Rough Idle or Stumble > Page 3562 WARRANTY STATUS: Eligible Under Bumper To Bumper Warranty Coverage For 1991 Lincolns, Basic Warranty Coverage, Emissions Warranty Coverage LABOR OPERATION TIME DEALER CODING BASIC PART NO. CONDITION CODE 9F593 49 OASIS CODES: 404000, 608000, 608400, 611000, 611500 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 911211 > Jun > 91 > Engine - Lack of Power/No Start Diagnosis Fuel Injector: All Technical Service Bulletins Engine - Lack of Power/No Start Diagnosis Article No. 91-12-11 06/12/91 LACK OF POWER 7.5L, 5.8L, 5.0L, 4.9L - CATALYTIC CONVERTER DIAGNOSTIC TIPS LIGHT TRUCK: 1986-91 BRONCO, ECONOLINE, F-150-350 SERIES 1988-91 F SUPER DUTY, F47 ISSUE: Lack of power or a no start condition may be diagnosed as an exhaust restriction caused by a plugged catalytic converter. A plugged catalytic converter (internal deterioration) is usually caused by abnormal engine operation. ACTION: Diagnose the catalytic converter to confirm internal failure. Refer to the Catalyst and Exhaust System Diagnostic Section, in the Engine/Emissions Diagnostic Shop Manual and the following procedures for service details. 1. Lack of proper HEGO operation may cause, or be the result of a rich or lean fuel condition, which could cause additional heat in the catalyst. Perform self test KOEO and KOER, service any codes. NOTE: IF TWO DIGIT CODES 41, 42, 85 OR THREE DIGIT CODES 171, 172, 173, 179, 181, 182, 183 AND 565 ARE RECEIVED, CHECK FOR PROPER HEGO GROUND. If the HEGO ground is good, the following areas may be at fault: ^ Ignition Coil ^ Distributor Cap ^ Distributor Rotor ^ Fouled Spark Plug ^ Spark Plug Wires ^ Air Filter ^ Stuck Open Injector ^ Fuel Contamination Engine OIL ^ Manifold Leaks Intake/ Exhaust ^ Fuel Pressure ^ Poor Power Ground ^ Engine Not At Normal Operating Temperature ^ HEGO Sensor 2. Spark timing that is retarded from specification may increase exhaust gas temperature and shorten catalyst life. Refer to the following procedure for service details. a. Check spark timing. Check base timing with spout disconnected. Set base timing to the specification on the vehicle emission decal. b. Check computed timing with spout connected. NOTE: COMPUTED TIMING IS EQUAL TO BASE TIMING PLUS 20~ BTDC +/- 3~. 3. Misfiring spark plugs may cause an unburned fuel air mixture to pass through the catalyst, which could cause higher than normal catalyst temperatures. Refer to the following procedure for service details. a. Check secondary ignition, hook the vehicle up to an engine analyzer and check for a secondary ignition misfire. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 911211 > Jun > 91 > Engine - Lack of Power/No Start Diagnosis > Page 3567 NOTE: SERVICE ANY ITEM THAT IS NOT PERFORMING AT PROPER SPECIFICATIONS BEFORE CONTINUING. 4. Fuel pressure that is too high may cause rich air fuel mixtures to pass through the catalyst which could cause higher than normal catalyst temperatures. Refer to the following procedure for service details. a. Check fuel pressure, install fuel pressure gauge, start and run the engine at idle. Fuel pressures between 28 and 34 PSI are typical (4.9L typically is 15 PSI higher). b. Disconnect the vacuum line going to the fuel pressure regulator. Fuel pressure typically jumps to 40 PSI +/- 3 PSI (4.9L typically is 15 PSI higher). Visually inspect vacuum line for raw fuel. NOTE: FUEL PRESSURES ABOVE THESE VALUES SHOULD BE CORRECTED. HOWEVER, THIS MAY NOT BE THE CAUSE OF THE CONCERN. SERVICE AS NECESSARY. 5. Throttle plates in the throttle body not returning to the proper closed position may cause excessive catalyst temperatures during downhill grades. Refer to the following procedure for service details. a. Visually inspect the throttle body and linkage for: ^ Binding or sticking throttle linkage. ^ Tight speed control linkage or cable. ^ Vacuum line interference. ^ Electrical harness interference. NOTE: AFTERMARKET GOVERNORS, THROTTLE LINKAGE AND CABLES ASSOCIATED WITH POWER TAKE-OFF UNITS, MAY ALSO INTERFERE WITH PROPER THROTTLE RETURN. SERVICE AS NECESSARY. 6. It is extremely important that all systems related to the engine and emission systems operate properly. a. Visually inspect the engine compartment to make sure all vacuum hoses and spark plug wires are properly routed and securely connected. b. Inspect all wiring harnesses and connectors for insulation damage, burned, overheated, loose or broken conditions. c. Verify proper operation of the thermactor system. Thermactor systems that fail to dump thermactor air to the atmosphere properly or at the correct time can cause high catalyst temperatures. d. Visually inspect thermactor system for damaged or kinked hoses and perform a function test on following components: air control valve, check valve, silencer, filter and the air bypass solenoid. e. Verify proper operation of the engine cooling system thermostat. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under Basic Warranty Coverage, Emissions Warranty Coverage OPERATION DESCRIPTION TIME 911211A Diagnostics - Perform 0.5 Hrs. KOEO And KOER Self Tests 911211B Timing - Check Or Adjust 0.5 Hrs. Spark Timing, Check Computed Timing And Check Secondary Ignition System With Engine Analyzer. 911211C Check - Fuel Pressure And 0.2 Hrs. Inspect Vacuum Line For Raw Fuel. 911211D Inspect - Throttle Body And 0.1 Hrs. Linkage. 911211E Inspect - Vacuum Hoses, 0.1 Hrs. Electrical Harnesses, Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 911211 > Jun > 91 > Engine - Lack of Power/No Start Diagnosis > Page 3568 Connectors And Spark Plug Wires For Routing Damage. 911211F Thermactor System - 0.3 Hrs. Inspect For Proper Operation And Damaged Component. Includes Function Check Of Air Control Valve, Thermactor Air Bypass Solenoid, Check Valves, Silencer And Filter. 911211G Thermostat - Check For 0.2 Hrs. Proper Operation. DEALER CODING BASIC PART NO. CONDITION CODE 5E212 25 OASIS CODES: 403000, 603300, 614000 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 89153 > Jul > 89 > Fuel Injectors - Rotunda Injector Tester/Cleaner Fuel Injector: All Technical Service Bulletins Fuel Injectors - Rotunda Injector Tester/Cleaner INJECTOR TESTER/CLEANER-ROTUNDA MODEL 113-00001-MAINTENANCE REQUIREMENTS Article No. 89-15-3 FORD: 1984-89 ESCORT, EXP, TEMPO 1986-89 CROWN VICTORIA, MUSTANG, TAURUS, THUNDERBIRD LINCOLN-MERCURY: 1984-89 COUGAR 1984-87 LYNX 1984-89 TOPAZ 1986 CAPRI 1986-89 CONTINENTAL, GRAND MARQUIS, MARK VII, SABLE, TOWN CAR 1988-89 TRACER MERKUR: 1987-89 XR4TI 1988-89 SCORPIO LIGHT TRUCK: 1985-89 F-150, F-250, F-350, RANGER 1986-89 AEROSTAR, ECONOLINE ISSUE: Proper maintenance and good working condition of the Rotunda Injector Tester/Cleaner, 113-00001, is essential for reliable diagnosis and cleaning of multi-port fuel injectors. If the equipment is not properly maintained, premature failure can result and flowmeter contamination can occur. This can cause erroneous float readings and result in improper diagnosis. ACTION: Use the following injector tester/cleaner maintenance techniques and procedures to ensure proper operation of the equipment. 1. Always use a good quality, clean and filtered gasoline in the tester tank. 2. Never leave a mixture of injector power flush and gasoline in the tester after use. 3. Always rinse the tester out by circulating clean gasoline through the unit before storage. 4. Flush the unit with denatured alcohol at least once a month. a. Allow the fluid to recirculate several minutes, while switching the flowmeter selection valve from # 1 to # 2 several times. b. Discard the mixture and repeat the procedure. 5. Change the fuel filter every other month. 6. Always calibrate the flowmeters before testing. OTHER APPLICABLE ARTICLES: 88-17-11 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 680000, 4500 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 881711 > Aug > 88 > Engine - Hesitation/Lack Of Power/Rough Idle Fuel Injector: All Technical Service Bulletins Engine - Hesitation/Lack Of Power/Rough Idle FUEL INJECTORS - DIAGNOSTIC AND CLEANING TIPS Article No. 88-17-11 FORD: 1983-88 ESCORT, THUNDERBIRD 1984-88 EXP 1986-88 MUSTANG, TAURUS, CROWN VICTORIA 1988 TEMPO LINCOLN-MERCURY: 1983-86 LYNX 1983-88 COUGAR 1986 CAPRI 1986-88 SABLE, GRAND MARQUIS, MARK VII, CONTINENTAL, LINCOLN TOWN CAR 1988 TRACER, TOPAZ MERKUR: 1987-88 XR4Ti 1988 SCORPIO LIGHT TRUCK: 1985-88 RANGER, F-SERIES, BRONCO 1986-88 E-SERIES, AEROSTAR ISSUE: Port fuel injected vehicles that have cold hesitation, lack of power, rough engine idle or a surging condition at steady speeds may be caused by dirty fuel injectors. When no-detergent fuel is used, deposits form on the fuel metering surfaces of the fuel injectors. The deposits that form reduce the fuel flow resulting in a lean condition. ACTION: To correct this, follow normal diagnostics as shown in the Engine/Emissions Diagnosis Manual, Section 2. If you get to a step that instructs you to replace a fuel injector, FIRST try cleaning the injector with the Rotunda Tester/Cleaner, 113-00001. If the condition still exists after cleaning, the injectors should be flow tested to make sure they are functioning properly. If the flow test indicates lean injectors, a second cleaning may be necessary because of severe injector fouling. Refer to the diagnostic chart on page 69 of this TSB for step-by-step instructions. CAUTION: NEVER ATTEMPT TO FLOW TEST INJECTORS WITH THE CLEANING SOLUTION MIXTURE. THIS WILL PRODUCE FALSE TEST RESULTS. ONLY USE CLEAN GASOLINE. In cases where fouled injectors were the cause of the driveability concern, it should be recommended to the customer that a better quality gasoline be used. The Owner Guide, Maintenance Schedule and Operating Guide address the fuel quality issue. NOTE: IT IS VERY IMPORTANT THAT THE CORRECT CLEANING SOLVENT IS USED WITH THE ROTUNDA TESTER/CLEANER. THE CORRECT CLEANING SOLVENTS ARE: Power Flush Injector Fluid E6AZ-19579-C Carburetor and Combustion Chamber Cleaner D9AZ-19579-B DO NOT USE Injector and Fuel System Cleaner E6AZ-19579-A Rotunda Tester/Cleaner Equipment Update The following items are available for use with the Rotunda Tester/Cleaner: a. 3.8L ENGINE INJECTOR ADAPTER HARNESS 113-00005 To flow test injectors on the 1988 3.8L with EFI, a wire harness is available to allow a direct connection to the injector harness 8-pin connector. b. 2B SPAN TUBE 113-00003 To flow test the Tracer 1.6L, Light Truck 7.5L and 3.8L supercharged engine. CAUTION: NEVER LEAVE CLEANING SOLUTION IN THE ROTUNDA TESTER/CLEANER. ALWAYS DRAIN THE TANK AND LINES Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 881711 > Aug > 88 > Engine - Hesitation/Lack Of Power/Rough Idle > Page 3577 COMPLETELY. PART NUMBER PART NAME CLASS E6AZ-19579-C Power Flush Injector B Cleaner D9AZ-19579-BA Carburetor and Combustion AM Chamber Cleaner OTHER APPLICABLE ARTICLES: 86-13-22 Supersedes 87-9-8 WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION: Refer to the Service Labor Tie Standards Manual DLR. CODING: Basic Part No. 9F593 Condition Code: 49 DIAGNOSTIC CHART Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 87175 > Aug > 87 > Fuel System - Injector Tester/Cleaner Service Tips Fuel Injector: All Technical Service Bulletins Fuel System - Injector Tester/Cleaner Service Tips Article No. FUEL SYSTEM - INJECTOR TESTER/CLEANER 87-17-5 SERVICE TIPS FORD: 1983-88 ALL CAR LINES LINCOLN-MERCURY: 1983-88 ALL CAR LINES LIGHT TRUCK: 1983-88 ALL LIGHT TRUCK LINES ISSUE: A Fuel injector Tester/Cleaner has not been approved by Ford Motor Company for cleaning Central Fuel Injected (CFI) vehicles. ACTION: If a CFI system's fuel injector is contaminated, replace the injector using the appropriate shop manual procedure. NOTE: The unauthorized use of an lnjector Tester/Cleaner on CFI systems is not a reimbursable labor operation. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Injector: > 9167 > Mar > 91 > Rear Axle Hub Seal - Lubricant Leaks Wheel Seal: All Technical Service Bulletins Rear Axle Hub Seal - Lubricant Leaks Article No. 91-6-7 03/18/91 ^ AXLE - NEW HUB SEAL AND HUB SEAL REPLACER TOOL - VEHICLES WITH 10.25 INCH RING GEAR, FULL - FLOATING REAR AXLES ^ LEAKS - AXLE LUBE - 10.25 INCH RING GEAR, FULL - FLOATING REAR AXLES LIGHT TRUCK: 1985-91 F-250, F-350 ISSUE: A new hub seal and a hub seal replacer tool are now available for service. The new hub seal is designed to improve sealing when properly installed using the new hub seal replacer tool. ACTION: Install a new hub seal (FOTZ-1177-A) with the new hub seal replacer tool (T91T-1175-A). Refer to the following inspection list and service procedure for details. NOTE: DO NOT USE THE OLD HUB SEAL REPLACER TOOL (T85T-1175-AH). IT IS NOT DESIGNED TO INSTALL THE NEW SEAL. THE NEW HUB SEAL REPLACER TOOL IS AVAILABLE IN THE 1991 DEALER ESSENTIAL SERVICE TOOL KIT AND IS THE ONLY TOOL APPROVED TO INSTALL THE NEW SEAL. INSPECTION PRIOR TO SEAL INSTALLATION Prior to seal installation, make sure that the following items are checked and servicing action taken where indicated. ^ Inspect the outer diameter of the hub seal to be sure that it is dry and free of oil and grease. ^ Check the hub bore to be sure it is free of grease, dirt and debris. ^ Remove any nicks or burrs from the hub bore. ^ Inspect the inner and outer bearing for damage and replace as required. ^ Pack each hub bearing cone and roller with a bearing packing tool using XG-1-C grease. ^ Make sure that no residual grease from freshly greased bearings gets into the hub bore. ^ Prior to installing the hub assembly, clean the spindle thoroughly and inspect the seal and bearing journals for nicks and/or scratches. Remove nicks or scratches using crocus cloth or similar material. ^ Wipe spindle clean and lightly oil with clean axle lube or engine oil. Figure 1 REMOVAL & INSTALLATION PROCEDURE 1. Install the hub in a soft jawed vice. 2. Remove the hub seal as shown in Figure 1. CAUTION: CARE MUST BE TAKEN NOT TO DAMAGE THE HUB SEAL BORE WITH THE SEAL REMOVAL TOOL. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Injector: > 9167 > Mar > 91 > Rear Axle Hub Seal - Lubricant Leaks > Page 3587 Figure 2 3. Thoroughly clean and inspect the hub bore, Figure 2. CAUTION: MAKE SURE THE HUB BORE IS FREE OF DIRT, GREASE, BURRS OR NICKS. NOTE: HUB BEARINGS MUST BE PRELUBED WITH GREASE PRIOR TO INSTALLATION. USE XG-1-C GREASE OR EQUIVALENT. 4. Pack each bearing cone and roller assembly with a bearing packing tool. Figure 3 5. Install the seal in the hub with the Ford logo facing up, Figure 3. CAUTION: HUB SEAL MUST BE FREE OF DIRT OR GREASE. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Injector: > 9167 > Mar > 91 > Rear Axle Hub Seal - Lubricant Leaks > Page 3588 Figure 4 6. Install the hub oil seal on the hub seal installer tool, T91T-1175-A, Figure 4. Figure 5 7. Insert the tool with the seal squarely into the hub, Figure 5. Figure 6 8. Hold the tool straight. Strike the handle until the hub seal is fully seated (until tool strikes hub), Figure 6. CAUTION: INSTALL NEW SEAL IF SEAL IS MISALIGNED DURING OR AFTER INSTALLATION. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Injector: > 9167 > Mar > 91 > Rear Axle Hub Seal - Lubricant Leaks > Page 3589 It is extremely important that the 1991 F-Series Shop Manual procedures be followed when installing the hub assembly. CAUTION: THE SPECIFIED TORQUING AND BACKING OFF OF THE HUB NUT IS CRITICAL IN ORDER TO PERFORM THE REPAIR CORRECTLY. NOTE: ALWAYS TURN THE HUB WHILE TIGHTENING THE HUB NUT. ONCE THE SPECIFIED TORQUE 55-65 LB.FT., (75-88 N-m) IS ACHIEVED, RATCHETING BACK ON THE HUB NUT VARIES DEPENDING ON WHETHER THE HUB BEARINGS ARE NEW OR USED. BACK OFF 5 CLICKS FOR NEW BEARING AND 8 CLICKS FOR USED BEARINGS. Make sure hub nut wrench tool (T85T-4252-AH) is used as shown in the Shop Manual procedure. Consult The 1991 F-Series Light Truck Shop Manual, Section 05-02B, for service procedures and torque specifications. PART NUMBER PART NAME CLASS FOTZ-1177-A Hub Seal B XG-1-C Grease (14 oz. cartridge, Pkg. V 60) OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 509000 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Injector: > 862223 > Nov > 86 > Axle - Rear Axle Hub Seals Leak Wheel Seal: All Technical Service Bulletins Axle - Rear Axle Hub Seals Leak Article No. 86-22-23 AXLE (10.25") - REAR - HUB SEALS LEAK - VENT PLUGGED LIGHT TRUCK 1985-86 F-250/350 A plugged rear axle vent may cause water to be sucked in through the seals and grease to be pushed out. This happens when pressures rise and fall inside the axle during various driving conditions and temperatures. The purpose of the vent is to relieve those pressures. If the vent is plugged with mud or other foreign materials, the axle cannot "breathe". To eliminate this concern, perform the following procedure: Figure 17 1. Remove the vent from the axle (Figure 17). 2. Place the vent in a vise so as not to damage the threads. 3. Drill out the vent using a 3/16 inch drill bit. Clean all shavings from vent. 4. Install vent. 5. Make sure entire vent hose is clear of dirt and mud, etc. 6. Install hose. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION: SP4022A86 TIME: 0.5 Hr. DLR. CODING: Basic Part No. 4022 - Code: 55 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Injector: > 9167 > Mar > 91 > Rear Axle Hub Seal - Lubricant Leaks > Page 3599 Figure 2 3. Thoroughly clean and inspect the hub bore, Figure 2. CAUTION: MAKE SURE THE HUB BORE IS FREE OF DIRT, GREASE, BURRS OR NICKS. NOTE: HUB BEARINGS MUST BE PRELUBED WITH GREASE PRIOR TO INSTALLATION. USE XG-1-C GREASE OR EQUIVALENT. 4. Pack each bearing cone and roller assembly with a bearing packing tool. Figure 3 5. Install the seal in the hub with the Ford logo facing up, Figure 3. CAUTION: HUB SEAL MUST BE FREE OF DIRT OR GREASE. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Injector: > 9167 > Mar > 91 > Rear Axle Hub Seal - Lubricant Leaks > Page 3600 Figure 4 6. Install the hub oil seal on the hub seal installer tool, T91T-1175-A, Figure 4. Figure 5 7. Insert the tool with the seal squarely into the hub, Figure 5. Figure 6 8. Hold the tool straight. Strike the handle until the hub seal is fully seated (until tool strikes hub), Figure 6. CAUTION: INSTALL NEW SEAL IF SEAL IS MISALIGNED DURING OR AFTER INSTALLATION. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Injector: > 9167 > Mar > 91 > Rear Axle Hub Seal - Lubricant Leaks > Page 3601 It is extremely important that the 1991 F-Series Shop Manual procedures be followed when installing the hub assembly. CAUTION: THE SPECIFIED TORQUING AND BACKING OFF OF THE HUB NUT IS CRITICAL IN ORDER TO PERFORM THE REPAIR CORRECTLY. NOTE: ALWAYS TURN THE HUB WHILE TIGHTENING THE HUB NUT. ONCE THE SPECIFIED TORQUE 55-65 LB.FT., (75-88 N-m) IS ACHIEVED, RATCHETING BACK ON THE HUB NUT VARIES DEPENDING ON WHETHER THE HUB BEARINGS ARE NEW OR USED. BACK OFF 5 CLICKS FOR NEW BEARING AND 8 CLICKS FOR USED BEARINGS. Make sure hub nut wrench tool (T85T-4252-AH) is used as shown in the Shop Manual procedure. Consult The 1991 F-Series Light Truck Shop Manual, Section 05-02B, for service procedures and torque specifications. PART NUMBER PART NAME CLASS FOTZ-1177-A Hub Seal B XG-1-C Grease (14 oz. cartridge, Pkg. V 60) OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 509000 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Technical Service Bulletins > Recalls: > NHTSA87V139000 > Sep > 87 > Recall 87V139000: Fuel Line Coupling Retainer Clips Fuel Line Coupler: Recalls Recall 87V139000: Fuel Line Coupling Retainer Clips SPRING LOCK FUEL LINE COUPLING MAY NOT BE PROPERLY ENGAGED. COUPLING COULD DISENGAGE DUE TO FUEL PRESSURE, VIBRATION, AND ENGINE MOVEMENTS; THIS WOULD CAUSE LOSS OF FUEL WHICH, IN PRESENCE OF AN IGNITION SOURCE, CREATES A FIRE RISK. INSTALL RETAINER CLIPS OVER THE COUPLINGS TO PREVENT COUPLING SEPARATION AND FUEL LEAKAGE. SYSTEM: FUEL LINE COUPLING VEHICLE DESCRIPTION: PASSENGER CARS AND LIGHT TRUCKS EQUIPPED WITH FUELINJECTION. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Technical Service Bulletins > Customer Interest: > 861213 > Jun > 86 > Fuel Line Coupler - High Installation Effort Fuel Line Coupler: Customer Interest Fuel Line Coupler - High Installation Effort Article No. 86-12-13 FUEL SYSTEM - HIGH INSTALLATION EFFORTS OF SPRING LOCK FITTINGS AT ENGINE FUEL SUPPLY AND RETURN LINES VEHICLES WITH EFI LIGHT TRUCK 1986 E-SERIES, F-SERIES, BRONCO, RANGER, BRONCO II, AEROSTAR Figure 8 When installing the metal spring lock connections at the engine fuel rail, lubrication of the O-rings with clean engine oil will ease installation. (See Figure 8) OTHER APPLICABLE ARTICLES: 85-22-27 WARRANTY STATUS: "INFORMATION ONLY" Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Line Coupler: > NHTSA87V139000 > Sep > 87 > Recall 87V139000: Fuel Line Coupling Retainer Clips Fuel Line Coupler: All Technical Service Bulletins Recall 87V139000: Fuel Line Coupling Retainer Clips SPRING LOCK FUEL LINE COUPLING MAY NOT BE PROPERLY ENGAGED. COUPLING COULD DISENGAGE DUE TO FUEL PRESSURE, VIBRATION, AND ENGINE MOVEMENTS; THIS WOULD CAUSE LOSS OF FUEL WHICH, IN PRESENCE OF AN IGNITION SOURCE, CREATES A FIRE RISK. INSTALL RETAINER CLIPS OVER THE COUPLINGS TO PREVENT COUPLING SEPARATION AND FUEL LEAKAGE. SYSTEM: FUEL LINE COUPLING VEHICLE DESCRIPTION: PASSENGER CARS AND LIGHT TRUCKS EQUIPPED WITH FUELINJECTION. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Line Coupler: > 861213 > Jun > 86 > Fuel Line Coupler - High Installation Effort Fuel Line Coupler: All Technical Service Bulletins Fuel Line Coupler - High Installation Effort Article No. 86-12-13 FUEL SYSTEM - HIGH INSTALLATION EFFORTS OF SPRING LOCK FITTINGS AT ENGINE FUEL SUPPLY AND RETURN LINES VEHICLES WITH EFI LIGHT TRUCK 1986 E-SERIES, F-SERIES, BRONCO, RANGER, BRONCO II, AEROSTAR Figure 8 When installing the metal spring lock connections at the engine fuel rail, lubrication of the O-rings with clean engine oil will ease installation. (See Figure 8) OTHER APPLICABLE ARTICLES: 85-22-27 WARRANTY STATUS: "INFORMATION ONLY" Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Line Coupler: > 861213 > Jun > 86 > Fuel Line Coupler - High Installation Effort Fuel Line Coupler: All Technical Service Bulletins Fuel Line Coupler - High Installation Effort Article No. 86-12-13 FUEL SYSTEM - HIGH INSTALLATION EFFORTS OF SPRING LOCK FITTINGS AT ENGINE FUEL SUPPLY AND RETURN LINES VEHICLES WITH EFI LIGHT TRUCK 1986 E-SERIES, F-SERIES, BRONCO, RANGER, BRONCO II, AEROSTAR Figure 8 When installing the metal spring lock connections at the engine fuel rail, lubrication of the O-rings with clean engine oil will ease installation. (See Figure 8) OTHER APPLICABLE ARTICLES: 85-22-27 WARRANTY STATUS: "INFORMATION ONLY" Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Line Coupler: > NHTSA87V139000 > Sep > 87 > Recall 87V139000: Fuel Line Coupling Retainer Clips Fuel Line Coupler: All Technical Service Bulletins Recall 87V139000: Fuel Line Coupling Retainer Clips SPRING LOCK FUEL LINE COUPLING MAY NOT BE PROPERLY ENGAGED. COUPLING COULD DISENGAGE DUE TO FUEL PRESSURE, VIBRATION, AND ENGINE MOVEMENTS; THIS WOULD CAUSE LOSS OF FUEL WHICH, IN PRESENCE OF AN IGNITION SOURCE, CREATES A FIRE RISK. INSTALL RETAINER CLIPS OVER THE COUPLINGS TO PREVENT COUPLING SEPARATION AND FUEL LEAKAGE. SYSTEM: FUEL LINE COUPLING VEHICLE DESCRIPTION: PASSENGER CARS AND LIGHT TRUCKS EQUIPPED WITH FUELINJECTION. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > Technical Service Bulletins > By Symptom Fuel Pressure: By Symptom Technical Service Bulletin # 911211 Date: 910612 Engine - Lack of Power/No Start Diagnosis Article No. 91-12-11 06/12/91 LACK OF POWER 7.5L, 5.8L, 5.0L, 4.9L - CATALYTIC CONVERTER DIAGNOSTIC TIPS LIGHT TRUCK: 1986-91 BRONCO, ECONOLINE, F-150-350 SERIES 1988-91 F SUPER DUTY, F47 ISSUE: Lack of power or a no start condition may be diagnosed as an exhaust restriction caused by a plugged catalytic converter. A plugged catalytic converter (internal deterioration) is usually caused by abnormal engine operation. ACTION: Diagnose the catalytic converter to confirm internal failure. Refer to the Catalyst and Exhaust System Diagnostic Section, in the Engine/Emissions Diagnostic Shop Manual and the following procedures for service details. 1. Lack of proper HEGO operation may cause, or be the result of a rich or lean fuel condition, which could cause additional heat in the catalyst. Perform self test KOEO and KOER, service any codes. NOTE: IF TWO DIGIT CODES 41, 42, 85 OR THREE DIGIT CODES 171, 172, 173, 179, 181, 182, 183 AND 565 ARE RECEIVED, CHECK FOR PROPER HEGO GROUND. If the HEGO ground is good, the following areas may be at fault: ^ Ignition Coil ^ Distributor Cap ^ Distributor Rotor ^ Fouled Spark Plug ^ Spark Plug Wires ^ Air Filter ^ Stuck Open Injector ^ Fuel Contamination Engine OIL ^ Manifold Leaks Intake/ Exhaust ^ Fuel Pressure ^ Poor Power Ground ^ Engine Not At Normal Operating Temperature ^ HEGO Sensor 2. Spark timing that is retarded from specification may increase exhaust gas temperature and shorten catalyst life. Refer to the following procedure for service details. a. Check spark timing. Check base timing with spout disconnected. Set base timing to the specification on the vehicle emission decal. b. Check computed timing with spout connected. NOTE: COMPUTED TIMING IS EQUAL TO BASE TIMING PLUS 20~ BTDC +/- 3~. 3. Misfiring spark plugs may cause an unburned fuel air mixture to pass through the catalyst, which could cause higher than normal catalyst Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > Technical Service Bulletins > By Symptom > Page 3643 temperatures. Refer to the following procedure for service details. a. Check secondary ignition, hook the vehicle up to an engine analyzer and check for a secondary ignition misfire. NOTE: SERVICE ANY ITEM THAT IS NOT PERFORMING AT PROPER SPECIFICATIONS BEFORE CONTINUING. 4. Fuel pressure that is too high may cause rich air fuel mixtures to pass through the catalyst which could cause higher than normal catalyst temperatures. Refer to the following procedure for service details. a. Check fuel pressure, install fuel pressure gauge, start and run the engine at idle. Fuel pressures between 28 and 34 PSI are typical (4.9L typically is 15 PSI higher). b. Disconnect the vacuum line going to the fuel pressure regulator. Fuel pressure typically jumps to 40 PSI +/- 3 PSI (4.9L typically is 15 PSI higher). Visually inspect vacuum line for raw fuel. NOTE: FUEL PRESSURES ABOVE THESE VALUES SHOULD BE CORRECTED. HOWEVER, THIS MAY NOT BE THE CAUSE OF THE CONCERN. SERVICE AS NECESSARY. 5. Throttle plates in the throttle body not returning to the proper closed position may cause excessive catalyst temperatures during downhill grades. Refer to the following procedure for service details. a. Visually inspect the throttle body and linkage for: ^ Binding or sticking throttle linkage. ^ Tight speed control linkage or cable. ^ Vacuum line interference. ^ Electrical harness interference. NOTE: AFTERMARKET GOVERNORS, THROTTLE LINKAGE AND CABLES ASSOCIATED WITH POWER TAKE-OFF UNITS, MAY ALSO INTERFERE WITH PROPER THROTTLE RETURN. SERVICE AS NECESSARY. 6. It is extremely important that all systems related to the engine and emission systems operate properly. a. Visually inspect the engine compartment to make sure all vacuum hoses and spark plug wires are properly routed and securely connected. b. Inspect all wiring harnesses and connectors for insulation damage, burned, overheated, loose or broken conditions. c. Verify proper operation of the thermactor system. Thermactor systems that fail to dump thermactor air to the atmosphere properly or at the correct time can cause high catalyst temperatures. d. Visually inspect thermactor system for damaged or kinked hoses and perform a function test on following components: air control valve, check valve, silencer, filter and the air bypass solenoid. e. Verify proper operation of the engine cooling system thermostat. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under Basic Warranty Coverage, Emissions Warranty Coverage OPERATION DESCRIPTION TIME 911211A Diagnostics - Perform 0.5 Hrs. KOEO And KOER Self Tests 911211B Timing - Check Or Adjust 0.5 Hrs. Spark Timing, Check Computed Timing And Check Secondary Ignition System With Engine Analyzer. 911211C Check - Fuel Pressure And 0.2 Hrs. Inspect Vacuum Line For Raw Fuel. 911211D Inspect - Throttle Body And 0.1 Hrs. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > Technical Service Bulletins > By Symptom > Page 3644 Linkage. 911211E Inspect - Vacuum Hoses, 0.1 Hrs. Electrical Harnesses, Connectors And Spark Plug Wires For Routing Damage. 911211F Thermactor System - 0.3 Hrs. Inspect For Proper Operation And Damaged Component. Includes Function Check Of Air Control Valve, Thermactor Air Bypass Solenoid, Check Valves, Silencer And Filter. 911211G Thermostat - Check For 0.2 Hrs. Proper Operation. DEALER CODING BASIC PART NO. CONDITION CODE 5E212 25 OASIS CODES: 403000, 603300, 614000 Technical Service Bulletin # 911211 Date: 910612 Engine - Lack of Power/No Start Diagnosis Article No. 91-12-11 06/12/91 LACK OF POWER 7.5L, 5.8L, 5.0L, 4.9L - CATALYTIC CONVERTER DIAGNOSTIC TIPS LIGHT TRUCK: 1986-91 BRONCO, ECONOLINE, F-150-350 SERIES 1988-91 F SUPER DUTY, F47 ISSUE: Lack of power or a no start condition may be diagnosed as an exhaust restriction caused by a plugged catalytic converter. A plugged catalytic converter (internal deterioration) is usually caused by abnormal engine operation. ACTION: Diagnose the catalytic converter to confirm internal failure. Refer to the Catalyst and Exhaust System Diagnostic Section, in the Engine/Emissions Diagnostic Shop Manual and the following procedures for service details. 1. Lack of proper HEGO operation may cause, or be the result of a rich or lean fuel condition, which could cause additional heat in the catalyst. Perform self test KOEO and KOER, service any codes. NOTE: IF TWO DIGIT CODES 41, 42, 85 OR THREE DIGIT CODES 171, 172, 173, 179, 181, 182, 183 AND 565 ARE RECEIVED, CHECK FOR PROPER HEGO GROUND. If the HEGO ground is good, the following areas may be at fault: ^ Ignition Coil ^ Distributor Cap ^ Distributor Rotor ^ Fouled Spark Plug ^ Spark Plug Wires ^ Air Filter ^ Stuck Open Injector ^ Fuel Contamination Engine OIL ^ Manifold Leaks Intake/ Exhaust Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > Technical Service Bulletins > By Symptom > Page 3645 ^ Fuel Pressure ^ Poor Power Ground ^ Engine Not At Normal Operating Temperature ^ HEGO Sensor 2. Spark timing that is retarded from specification may increase exhaust gas temperature and shorten catalyst life. Refer to the following procedure for service details. a. Check spark timing. Check base timing with spout disconnected. Set base timing to the specification on the vehicle emission decal. b. Check computed timing with spout connected. NOTE: COMPUTED TIMING IS EQUAL TO BASE TIMING PLUS 20~ BTDC +/- 3~. 3. Misfiring spark plugs may cause an unburned fuel air mixture to pass through the catalyst, which could cause higher than normal catalyst temperatures. Refer to the following procedure for service details. a. Check secondary ignition, hook the vehicle up to an engine analyzer and check for a secondary ignition misfire. NOTE: SERVICE ANY ITEM THAT IS NOT PERFORMING AT PROPER SPECIFICATIONS BEFORE CONTINUING. 4. Fuel pressure that is too high may cause rich air fuel mixtures to pass through the catalyst which could cause higher than normal catalyst temperatures. Refer to the following procedure for service details. a. Check fuel pressure, install fuel pressure gauge, start and run the engine at idle. Fuel pressures between 28 and 34 PSI are typical (4.9L typically is 15 PSI higher). b. Disconnect the vacuum line going to the fuel pressure regulator. Fuel pressure typically jumps to 40 PSI +/- 3 PSI (4.9L typically is 15 PSI higher). Visually inspect vacuum line for raw fuel. NOTE: FUEL PRESSURES ABOVE THESE VALUES SHOULD BE CORRECTED. HOWEVER, THIS MAY NOT BE THE CAUSE OF THE CONCERN. SERVICE AS NECESSARY. 5. Throttle plates in the throttle body not returning to the proper closed position may cause excessive catalyst temperatures during downhill grades. Refer to the following procedure for service details. a. Visually inspect the throttle body and linkage for: ^ Binding or sticking throttle linkage. ^ Tight speed control linkage or cable. ^ Vacuum line interference. ^ Electrical harness interference. NOTE: AFTERMARKET GOVERNORS, THROTTLE LINKAGE AND CABLES ASSOCIATED WITH POWER TAKE-OFF UNITS, MAY ALSO INTERFERE WITH PROPER THROTTLE RETURN. SERVICE AS NECESSARY. 6. It is extremely important that all systems related to the engine and emission systems operate properly. a. Visually inspect the engine compartment to make sure all vacuum hoses and spark plug wires are properly routed and securely connected. b. Inspect all wiring harnesses and connectors for insulation damage, burned, overheated, loose or broken conditions. c. Verify proper operation of the thermactor system. Thermactor systems that fail to dump thermactor air to the atmosphere properly or at the correct time can cause high catalyst temperatures. d. Visually inspect thermactor system for damaged or kinked hoses and perform a function test on following components: air control valve, check valve, silencer, filter and the air bypass solenoid. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > Technical Service Bulletins > By Symptom > Page 3646 e. Verify proper operation of the engine cooling system thermostat. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under Basic Warranty Coverage, Emissions Warranty Coverage OPERATION DESCRIPTION TIME 911211A Diagnostics - Perform 0.5 Hrs. KOEO And KOER Self Tests 911211B Timing - Check Or Adjust 0.5 Hrs. Spark Timing, Check Computed Timing And Check Secondary Ignition System With Engine Analyzer. 911211C Check - Fuel Pressure And 0.2 Hrs. Inspect Vacuum Line For Raw Fuel. 911211D Inspect - Throttle Body And 0.1 Hrs. Linkage. 911211E Inspect - Vacuum Hoses, 0.1 Hrs. Electrical Harnesses, Connectors And Spark Plug Wires For Routing Damage. 911211F Thermactor System - 0.3 Hrs. Inspect For Proper Operation And Damaged Component. Includes Function Check Of Air Control Valve, Thermactor Air Bypass Solenoid, Check Valves, Silencer And Filter. 911211G Thermostat - Check For 0.2 Hrs. Proper Operation. DEALER CODING BASIC PART NO. CONDITION CODE 5E212 25 OASIS CODES: 403000, 603300, 614000 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Pressure: > 911211 > Jun > 91 > Engine - Lack of Power/No Start Diagnosis Fuel Pressure: All Technical Service Bulletins Engine - Lack of Power/No Start Diagnosis Article No. 91-12-11 06/12/91 LACK OF POWER 7.5L, 5.8L, 5.0L, 4.9L - CATALYTIC CONVERTER DIAGNOSTIC TIPS LIGHT TRUCK: 1986-91 BRONCO, ECONOLINE, F-150-350 SERIES 1988-91 F SUPER DUTY, F47 ISSUE: Lack of power or a no start condition may be diagnosed as an exhaust restriction caused by a plugged catalytic converter. A plugged catalytic converter (internal deterioration) is usually caused by abnormal engine operation. ACTION: Diagnose the catalytic converter to confirm internal failure. Refer to the Catalyst and Exhaust System Diagnostic Section, in the Engine/Emissions Diagnostic Shop Manual and the following procedures for service details. 1. Lack of proper HEGO operation may cause, or be the result of a rich or lean fuel condition, which could cause additional heat in the catalyst. Perform self test KOEO and KOER, service any codes. NOTE: IF TWO DIGIT CODES 41, 42, 85 OR THREE DIGIT CODES 171, 172, 173, 179, 181, 182, 183 AND 565 ARE RECEIVED, CHECK FOR PROPER HEGO GROUND. If the HEGO ground is good, the following areas may be at fault: ^ Ignition Coil ^ Distributor Cap ^ Distributor Rotor ^ Fouled Spark Plug ^ Spark Plug Wires ^ Air Filter ^ Stuck Open Injector ^ Fuel Contamination Engine OIL ^ Manifold Leaks Intake/ Exhaust ^ Fuel Pressure ^ Poor Power Ground ^ Engine Not At Normal Operating Temperature ^ HEGO Sensor 2. Spark timing that is retarded from specification may increase exhaust gas temperature and shorten catalyst life. Refer to the following procedure for service details. a. Check spark timing. Check base timing with spout disconnected. Set base timing to the specification on the vehicle emission decal. b. Check computed timing with spout connected. NOTE: COMPUTED TIMING IS EQUAL TO BASE TIMING PLUS 20~ BTDC +/- 3~. 3. Misfiring spark plugs may cause an unburned fuel air mixture to pass through the catalyst, which could cause higher than normal catalyst temperatures. Refer to the following procedure for service details. a. Check secondary ignition, hook the vehicle up to an engine analyzer and check for a secondary ignition misfire. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Pressure: > 911211 > Jun > 91 > Engine - Lack of Power/No Start Diagnosis > Page 3652 NOTE: SERVICE ANY ITEM THAT IS NOT PERFORMING AT PROPER SPECIFICATIONS BEFORE CONTINUING. 4. Fuel pressure that is too high may cause rich air fuel mixtures to pass through the catalyst which could cause higher than normal catalyst temperatures. Refer to the following procedure for service details. a. Check fuel pressure, install fuel pressure gauge, start and run the engine at idle. Fuel pressures between 28 and 34 PSI are typical (4.9L typically is 15 PSI higher). b. Disconnect the vacuum line going to the fuel pressure regulator. Fuel pressure typically jumps to 40 PSI +/- 3 PSI (4.9L typically is 15 PSI higher). Visually inspect vacuum line for raw fuel. NOTE: FUEL PRESSURES ABOVE THESE VALUES SHOULD BE CORRECTED. HOWEVER, THIS MAY NOT BE THE CAUSE OF THE CONCERN. SERVICE AS NECESSARY. 5. Throttle plates in the throttle body not returning to the proper closed position may cause excessive catalyst temperatures during downhill grades. Refer to the following procedure for service details. a. Visually inspect the throttle body and linkage for: ^ Binding or sticking throttle linkage. ^ Tight speed control linkage or cable. ^ Vacuum line interference. ^ Electrical harness interference. NOTE: AFTERMARKET GOVERNORS, THROTTLE LINKAGE AND CABLES ASSOCIATED WITH POWER TAKE-OFF UNITS, MAY ALSO INTERFERE WITH PROPER THROTTLE RETURN. SERVICE AS NECESSARY. 6. It is extremely important that all systems related to the engine and emission systems operate properly. a. Visually inspect the engine compartment to make sure all vacuum hoses and spark plug wires are properly routed and securely connected. b. Inspect all wiring harnesses and connectors for insulation damage, burned, overheated, loose or broken conditions. c. Verify proper operation of the thermactor system. Thermactor systems that fail to dump thermactor air to the atmosphere properly or at the correct time can cause high catalyst temperatures. d. Visually inspect thermactor system for damaged or kinked hoses and perform a function test on following components: air control valve, check valve, silencer, filter and the air bypass solenoid. e. Verify proper operation of the engine cooling system thermostat. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under Basic Warranty Coverage, Emissions Warranty Coverage OPERATION DESCRIPTION TIME 911211A Diagnostics - Perform 0.5 Hrs. KOEO And KOER Self Tests 911211B Timing - Check Or Adjust 0.5 Hrs. Spark Timing, Check Computed Timing And Check Secondary Ignition System With Engine Analyzer. 911211C Check - Fuel Pressure And 0.2 Hrs. Inspect Vacuum Line For Raw Fuel. 911211D Inspect - Throttle Body And 0.1 Hrs. Linkage. 911211E Inspect - Vacuum Hoses, 0.1 Hrs. Electrical Harnesses, Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Pressure: > 911211 > Jun > 91 > Engine - Lack of Power/No Start Diagnosis > Page 3653 Connectors And Spark Plug Wires For Routing Damage. 911211F Thermactor System - 0.3 Hrs. Inspect For Proper Operation And Damaged Component. Includes Function Check Of Air Control Valve, Thermactor Air Bypass Solenoid, Check Valves, Silencer And Filter. 911211G Thermostat - Check For 0.2 Hrs. Proper Operation. DEALER CODING BASIC PART NO. CONDITION CODE 5E212 25 OASIS CODES: 403000, 603300, 614000 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > Technical Service Bulletins > Page 3654 Fuel Pressure: Specifications FUEL PRESSURE Pump Pressure .................................................................................................................................... ...................................................................... 6 - 8 psi Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Test Fuel Pressure: Testing and Inspection Fuel Pressure Test NOTE: Perform Fuel System Capacity Test prior to performing Pressure Test. See: Fuel System Capacity Test PRESSURE TEST 1. Connect a suitable pressure gauge (0-15 PSI) to the carburetor end of the fuel line. WARNING: Use care to prevent combustion of spilled fuel. 2. Start the engine (it should be able to run for over 30 seconds on the fuel in the carburetor bowl) and read the pressure after 10 seconds. If pump pressure is too low or too high install a new fuel pump. Fuel Pump Pressure ............................................................................................................................ ................................................. 6.0-8.0 PSI 3. Reconnect fuel line at filter and install air cleaner. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Test > Page 3657 Fuel Pressure: Testing and Inspection Fuel System Capacity Test FUEL CAPACITY (VOLUME) TEST - Remove the carburetor air cleaner. - Slowly (fuel line is pressurized) disconnect the fuel line at the fuel filter. WARNING: Use care to prevent combustion of spilled fuel. - Place a suitable non-breakable container (1/2 liter or 1 pint minimum) at the end of the disconnected fuel line (a piece of hose may be needed on the fuel line end). - Disconnect high tension wire from coil. - Crank engine 10 seconds, the fuel pump should deliver 0.158 liters (1/3 pint) of fuel or more. - If fuel flow is to specification perform pressure test. See: Fuel Pressure Test - If fuel flow is low repeat procedure using a non-breakable container of gasoline connected to the fuel pump inlet. If fuel pressure is to specification, the problem is either a plugged in-tank filter, or a kinked or leaking fuel pump inlet hose. - If fuel flow is still below specification, replace fuel pump. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Technical Service Bulletins > Customer Interest for Fuel Pump Relay: > 90183 > Aug > 90 > Fuel Pump - Buzzing/Humming After Engine Shut Down Fuel Pump Relay: Customer Interest Fuel Pump - Buzzing/Humming After Engine Shut Down ^ NO START - 1.9L, 2.3L, 3.0L, 3.8L, 4.9L, 5.0L, 5.8L, 7.5L - LOW STATE OF BATTERY CHARGE ^ BATTERY - DISCHARGED - 1.9L, 2.3L, 3.0L, 3.8L, 4.9L, 5.0L, 5.8L, 7.5L ^ FUEL PUMP - NOISY - 1.9L, 2.3L, 3.0L, 3.8L, 4.9L, 5.0L, 5.8L, 7.5L ^ NOISE - "BUZZING" OR "HUMMING" FROM FUEL PUMP AFTER ENGINE IS TURNED OFF Article No. 90-18-3 FORD: 1983-90 CROWN VICTORIA, ESCORT, EXP, MUSTANG, TEMPO, THUNDERBIRD 1986 LTD 1986-90 TAURUS LINCOLN-MERCURY: 1983-87 LYNX 1983-90 CONTINENTAL, COUGAR, GRAND MARQUIS, MARK VII, TOPAZ, TOWN CAR 1985-86 CAPRI, MARQUIS 1986-90 SABLE LIGHT TRUCK: 1983-90 BRONCO II, BRONCO, ECONOLINE, F-150, F-250, F-350, RANGER 1988-90 F SUPER DUTY ISSUE: A "buzzing" or "humming" noise from the fuel pump may occur after the engine has been shut off. There may also be a no start condition or a discharged battery. These conditions are caused by a sticking fuel pump relay. ACTION: Install a new fuel pump relay. Refer to the following procedure for service details. 1. Check the fuel pump relay circuit for proper operation. Refer to the appropriate EVTM for troubleshooting details. 2. Install a new fuel pump relay, if the old one is defective. 3. Check the vehicle for proper operation. PART NUMBER PART NAME F19Z-9345-A Fuel Pump Relay Assy. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION DESCRIPTION TIME 901803A 1985-86 LTD/Marquis 0.6 Hr. (includes pinpoint test) 901803A 1990 Town Car (includes 0.4 Hr. pinpoint test) 901803A All Other Cars (includes 0.5 Hr. pinpoint test) 901803A All Trucks (includes pinpoint 0.5 Hr. test) DEALER CODING BASIC PART NO. CONDITION CODE 9345 09 OASIS CODES: 404000, 603300, 203000, 203100, 702000 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Pump Relay: > 90183 > Aug > 90 > Fuel Pump - Buzzing/Humming After Engine Shut Down Fuel Pump Relay: All Technical Service Bulletins Fuel Pump - Buzzing/Humming After Engine Shut Down ^ NO START - 1.9L, 2.3L, 3.0L, 3.8L, 4.9L, 5.0L, 5.8L, 7.5L - LOW STATE OF BATTERY CHARGE ^ BATTERY - DISCHARGED - 1.9L, 2.3L, 3.0L, 3.8L, 4.9L, 5.0L, 5.8L, 7.5L ^ FUEL PUMP - NOISY - 1.9L, 2.3L, 3.0L, 3.8L, 4.9L, 5.0L, 5.8L, 7.5L ^ NOISE - "BUZZING" OR "HUMMING" FROM FUEL PUMP AFTER ENGINE IS TURNED OFF Article No. 90-18-3 FORD: 1983-90 CROWN VICTORIA, ESCORT, EXP, MUSTANG, TEMPO, THUNDERBIRD 1986 LTD 1986-90 TAURUS LINCOLN-MERCURY: 1983-87 LYNX 1983-90 CONTINENTAL, COUGAR, GRAND MARQUIS, MARK VII, TOPAZ, TOWN CAR 1985-86 CAPRI, MARQUIS 1986-90 SABLE LIGHT TRUCK: 1983-90 BRONCO II, BRONCO, ECONOLINE, F-150, F-250, F-350, RANGER 1988-90 F SUPER DUTY ISSUE: A "buzzing" or "humming" noise from the fuel pump may occur after the engine has been shut off. There may also be a no start condition or a discharged battery. These conditions are caused by a sticking fuel pump relay. ACTION: Install a new fuel pump relay. Refer to the following procedure for service details. 1. Check the fuel pump relay circuit for proper operation. Refer to the appropriate EVTM for troubleshooting details. 2. Install a new fuel pump relay, if the old one is defective. 3. Check the vehicle for proper operation. PART NUMBER PART NAME F19Z-9345-A Fuel Pump Relay Assy. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION DESCRIPTION TIME 901803A 1985-86 LTD/Marquis 0.6 Hr. (includes pinpoint test) 901803A 1990 Town Car (includes 0.4 Hr. pinpoint test) 901803A All Other Cars (includes 0.5 Hr. pinpoint test) 901803A All Trucks (includes pinpoint 0.5 Hr. test) DEALER CODING BASIC PART NO. CONDITION CODE 9345 09 OASIS CODES: 404000, 603300, 203000, 203100, 702000 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Technical Service Bulletins > Page 3671 Fuel Pump Relay: Locations The EEC Power Relay is mounted to the Electronic Control Assembly in the rear center of the instrument panel. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions Fuel Pump Relay: Diagram Information and Instructions Symbol Identification Wire Color Code Identification Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3674 NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Technical Service Bulletins > Fuel System Spring Lock Fitting - Proper Assembly Fuel Return Line: Technical Service Bulletins Fuel System Spring Lock Fitting - Proper Assembly Article No. 85-22-27 FUEL SYSTEM - PROPER ASSEMBLY TECHNIQUE FOR SPRING LOCK FITTING AT ENGINE FUEL SUPPLY AND RETURN LINE CONNECTIONS LIGHT TRUCK 1986 RANGER, BRONCO II, AEROSTAR, BRONCO, E & F SERIES The following additional information supplements the spring lock fuel connection removal and installation procedures in the Light Truck Shop Manual, Section 24-50 for E & F Series, Bronco, Ranger, and Bronco II; and 9-06 for Aerostar. At initial assembly, a white plastic indicator ring is used to assure proper assembly of the spring lock fitting at the fuel supply line connection to the engine fuel rail, and at the engine fuel return line connection. Figure 24 - PROPER ASSEMBLY TECHNIQUE FOR SPRING LOCK FITTING AT ENGINE/FUEL LINE INTERFACE - ALL EFI ENGINES After each of these two fitting connections are assembled, the white plastic indicator ring remains (loose) on the fuel line (as shown in Figure 24). Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Technical Service Bulletins > Fuel System Spring Lock Fitting - Proper Assembly > Page 3679 When servicing these two spring lock fuel connections, and to assure proper reassembly of these connections, refer to the procedure outlined in Figure 24. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Technical Service Bulletins > Fuel System Spring Lock Fitting - Proper Assembly > Page 3680 Fuel Return Line: Technical Service Bulletins Fuel Line Spring Lock Coupling - Service Procedures FUEL LINE SPRING LOCK COUPLING - SUMMARY Article No. OF SERVICE PROCEDURES AND REVISED TOOLS 87-3-8 FORD 1986 LTD 1986-87 ESCORT, EXP, MUSTANG, TAURUS, THUNDERBIRD, FORD LINCOLN-MERCURY 1986 MARQUIS, CAPRI 1986-87 LYNX, SABLE, COUGAR, MERCURY, MARK VII, CONTINENTAL, LINCOLN TOWN CAR LIGHT TRUCK 1985-87 RANGER, BRONCO II, E-SERIES, F-SERIES, BRONCO ISSUE: This article summarizes the overall service procedure to be used for disconnecting and connecting the fuel line spring lock coupling. In addition, the service tools and service part O-rings have been recently revised. The service tools (available March, 1987) D87L-9280-A (3/8") and D87L-9280-B (1/2") used to disconnect the spring lock coupling will now fit around the rubber cover on the fuel line allowing an easier disconnect. The O-ring part numbers were changed to specify color. The fuel resistant O-rings 390846-S96 (3/8") and 390847-S96 (1/2") will be BROWN in color while the A/C refrigerant Orings will continue to be BLACK. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Technical Service Bulletins > Fuel System Spring Lock Fitting - Proper Assembly > Page 3681 Figure 5 ACTION: To properly disconnect and connect the fuel line spring coupling, use the illustrated service procedure on page 44 of this TSB, Figure 5. This illustration should also be used in place of the following 1985 through 1987 Car and Light Truck Shop Manual pages: 1985 Light Truck Shop Manual, Volume B, Section 24-05-16 / 24-05-17 1986 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Technical Service Bulletins > Fuel System Spring Lock Fitting - Proper Assembly > Page 3682 Car Shop Manual, Volume D, Section 24-50-11 Car Shop Manual, Volume E, Section 24-50-14 Taurus/Sable Shop Manual, Section 24-50-11 Ranger/Bronco II Shop Manual, Section 24-03-11 Aerostar Shop Maunal, Section 9-06-15 / 9-06-16 Light Truck Shop Manual, Volume B, Section 24-05-16 / 24-50-35 1987 Car Shop Manual, Volume D, Section 24-50-11 Car Shop Manual, Volume E, Section 24-50-17 Taurus/Sable Shop Manual, Section 24-50-12 Ranger/Bronco II Shop Manual, Section 24-03-10 / 24-05-10 Aerostar Shop Manual, Section 9-02-10 / 9-06-17 / 9-06-18 Light Truck Shop Manual, Volume B, Section 24-05-14 / 24-10-9 / 27-10-20 / 24-50-34 NOTE: The following items should be noted when service is required. ^ Use the specified tool or equivalent. ^ Inspect for missing or damaged O-rings. ^ Use the specified fuel resistant O-rings (BROWN). ^ Lubricate the O-ring with clean engine oil. ^ Check to make sure that the fitting is locked. PART NUMBER PART NAME CLASS 390846-S96 O-Ring 3/8" (Brown) S 390847-S96 O-Ring 1/2" (Brown) S OTHER APPLICABLE ARTICLES: Supersedes 86-12-17, 86-12-13 WARRANTY STATUS: "INFORMATION ONLY" Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Technical Service Bulletins > Fuel System Spring Lock Fitting - Proper Assembly > Page 3683 Fuel Return Line: Technical Service Bulletins Nylon Fuel Lines - Servicing Procedure Article No. 92-12-16 DATE: 06-03-92 FUEL LINES-NYLON-SERVICING PROCEDURE LIGHT TRUCK: 1985-92 F-150-350 SERIES 1986-90 BRONCO II 1986-92 AEROSTAR, BRONCO, ECONOLINE, RANGER 1988-92 F SUPER DUTY 1991-92 EXPLORER ISSUE: Metal fuel lines and connectors have been replaced with nylon lines and connectors on the subject vehicles. A procedure has been developed for servicing damaged nylon fuel lines. ACTION: If a nylon fuel line requires service, use the following procedure. FUEL SYSTEM SERVICE PROCEDURE FOR NYLON FUEL TUBES AND PUSH CONNECT FITTINGS FUEL LINES AND HOSES WARNING: FUEL SUPPLY LINES ON VEHICLES WITH FUEL INJECTED ENGINES WILL REMAIN PRESSURIZED FOR LONG PERIODS OF TIME AFTER ENGINE SHUT DOWN WHICH COULD RESULT IN PERSONAL INJURY. THE PRESSURE MUST BE RELIEVED, AS OUTLINED PER THE FUEL SYSTEM PRESSURE RELIEF PROCEDURE, BEFORE SERVICING THE FUEL SYSTEM. READ ALL CAUTIONARY NOTES PRIOR TO RELIEVING THE PRESSURIZED FUEL SYSTEM. FUEL TUBES - PLASTIC (NYLON) CAUTION: FORD APPROVED NYLON FUEL TUBING IS MADE FROM MATERIAL WHICH HAS BEEN TESTED AND PROVEN TO BE ACCEPTABLE FOR USE WITH COMMERCIALLY AVAILABLE FUELS. IT IS ALSO RESISTANT TO MOST ENVIRONMENTAL CONDITIONS. AVOID USING ALTERNATE TUBING MATERIALS. USE OF NON-APPROVED TUBING COULD POSE A HAZARD IN SERVICE. CAUTION: PLASTIC FUEL TUBES MUST NOT BE REPAIRED USING HOSE AND HOSE CLAMPS. PUSH CONNECT FITTINGS CANNOT BE REPAIRED EXCEPT TO REPLACE THE RETAINING CLIPS. IF THE PLASTIC TUBES OR PUSH CONNECT FITTINGS BECOME DAMAGED AND LEAK, APPROVED SERVICE PARTS MUST BE USED TO SERVICE THE FUEL LINES. MAJOR SERVICE OPERATIONS - FUEL LINES Vehicles equipped with nylon fuel tubes and push connect fittings have three (3) types of service that can be performed to the fuel lines... ^ Replacing nylon tubing (splicing nylon to nylon) ^ Replacing push connector fittings ^ Replacing damaged push connect tube ends. NOTE: FORMED SECTIONS (BENDS) OF NYLON FUEL LINES CANNOT BE REPAIRED USING STRAIGHT TUBING. STRAIGHT SERVICE TUBING WILL KINK IF BENT. FORMED NYLON FUEL LINE IS REOUIRED TO REPLACE THE DAMAGED SECTION. SPLICING NYLON TO NYLON 1. Relieve the fuel system pressure as outlined in the Service Manual. Read the previously cited Warning prior to relieving the pressurized fuel system. 2. Cut out the damaged section of tubing (straight non-formed sections only) and retain as a guide. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Technical Service Bulletins > Fuel System Spring Lock Fitting - Proper Assembly > Page 3684 3. Cut a section of nylon service tubing, type 11 or 12, of the same diameter and length as the damaged section of tubing. NOTE: TYPE 11 OR 12 NYLON SERVICE TUBING IS AVAILABLE IN 6.3MM (1/4"), 7.9MM (5/16") AND 9.5MM (3/8") DIAMETER SIZES. 4. Select the proper nylon barbed connector(s) for completing the splice... ^ 7.9mm (5/16") - Part Number (N806120-S) ^ 9.5mm (3/8") - Part Number (N806119-S) Two (2) in-line connectors are required for each splice. NOTE: TO MAKE INSERTION OF THE BARB CONNECTORS INTO THE NYLON LINE EASIER, THE TUBE END MAY BE SOAKED IN A CUP OF BOILING WATER FOR ONE (1) MINUTE BEFORE PUSHING THE BARB CONNECTOR INTO THE NYLON. USE ROTUNDA TOOL 134-000001 OR EQUIVALENT TO ASSIST IN ASSEMBLY. 5. Set up Rotunda Tool 134-000001 for in-line splice as shown in Figure 1. a. Select the proper inserts for the fuel line size and install into both sets of upper and lower block cavities. b. Connect the block cavity to the ratcheting rod of the Rotunda Tool with the slot in line with the slot in the ratcheting tool barrel c. Install both sets of upper and lower block cavities to the threaded rods of the ratcheting tool, Figure 1. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Technical Service Bulletins > Fuel System Spring Lock Fitting - Proper Assembly > Page 3685 d. Install one fuel line into the lower block cavity closest to the ratcheting end of the tool so that the extension of the fuel line is slightly greater than the barb length of the connector, Figure 2. e. Route the fuel line through the slot in the tool, Figure 2. f. Close the upper block cavity onto the lower block cavity and tighten the thumb screw securely. g. Place the replacement tubing in the forward lower block cavity and repeat Steps d and e. h. Place the barb connector between the ends of the lines to be spliced and ratchet the tool until the nylon line has covered all three (3) barbs of the connector on both ends. i. After completing the splice, unscrew the thumb screws and release the lines. Repeat Steps d through h on the opposite line end to complete the splice. 6. The completed fuel line splice is shown in Figure 3. 7. Install any remaining clips which were removed for this service. Check to be sure the fuel lines are secure in the original clips. 8. Start the engine and check for leaks. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Technical Service Bulletins > Fuel System Spring Lock Fitting - Proper Assembly > Page 3686 PART NUMBER PART NAME CLASS N806119-S Connector - Hose Push CG Connect (3/8") N806120-S Connector - Hose Push CG Connect (5/16") OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 404000, 490000 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Shut-off Solenoid > Fuel Shut-off Solenoid Relay > Component Information > Locations Fuel Shut-off Solenoid Relay: Locations LH Side Of Dash Panel In Engine Compartment, On LH Side Of Dash Panel Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Technical Service Bulletins > Recalls: > 89S76 > Mar > 90 > Recall - Fuel Filter And Fuel Line Replacement Technical Service Bulletin # 89S76 Date: 900328 Recall - Fuel Filter And Fuel Line Replacement 89S76 SAFETY RECALL Certain 1986-1989 Gasoline Powered F-Series Pick-Up & Chassis Cab Trks. & Broncos for Replacement of the Fuel Filter & Fuel Line from the High Pressure Frame-Mounted Fuel Pump to the Engine. Supersedes & Replaces Safety Recall 88S57 Dealer Letter Attachment I ^ Administrative Information Attachment II ^ Labor Allowances ^ Parts Ordering Information ^ Purge of Dealership Parts Stock Attachment III ^ Technical Information Customer Notification Letter Dealer Letter March 28, 1990 To: Ford of Canada Dealers in Midwestern and Western Regions and the Yukon Territory Attention: Dealer Principal, Dealer Service Manager, Dealer Parts Manager Subject: Subject Recall 89S76 - Recall of Certain 1986 through 1989 Gasoline Powered F-Series Pick-Up and Chassis Cab Trucks and Bronco's for Replacement of the Fuel Filter and Fuel Line from the High Pressure Frame-Mounted Fuel Pump to the Engine. This Recall Supersedes and Replaces Safety Recall 88S57 In CARES / OASIS YES Dealer Listings YES Recall Time Limitation None Parts Return NO NOTE: Please read and circulate this bulletin to your service personnel so that they may become familiar with this recall and be able to respond to owner inquiries. Special Note: Safety Recall 89S76 supersedes and replaces Safety Recall 88S57. If you are presented with a vehicle that does not have 88S57 completed, do not perform that recall on it; instead perform Safety Recall 89S76 on that vehicle. Due to parts supply, owner mailings will be phased. Dealers should not delay completion of Safety Recall 89S76 on an involved vehicle because the owner has not received a recall notification. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Technical Service Bulletins > Recalls: > 89S76 > Mar > 90 > Recall - Fuel Filter And Fuel Line Replacement > Page 3699 Affected Vehicles: All 1986-1/2, 1987, 1988 and 1989 Model Year gasoline powered F-Series Pickup Trucks including Chassis Cabs, and Bronco vehicles with EFI engines sold or operated in Mid-West and Western Regions and the Yukon Territory. Vehicles involved were produced from February 1, 1986, through to the end of the 1989 model year. Reason For Recall: Field investigation has determined that repairs specified in Recall 88S57 were not completely effective in preventing the condition of pinhole leaks forming in the U-shaped fuel tube ("Jumper Tube") connecting the on-frame fuel pump to the fuel filter. Correction: To prevent this condition from re-occurring, the U-shaped fuel tube, the frame mounted filter and the fuel delivery tube from the filter to the engine will be replaced with a steel braided electrically conductive fuel line from the high pressure frame-mounted fuel pump to the engine. A fuel filter cartridge will also be installed in the fuel reservoir. Purge Of Dealership Parts Stock: Service Part Sold to Customer or Installed on a Vehicle Review all service and parts sales records to determine if you have installed or sold any of the following parts: Tube Assembly (Fuel Pump to Fuel Filter) E6TZ-9C330-A E9TZ-9C330-A E7TZ-9C330-A E9TZ-9C330-B Tube Assembly (Fuel Engine Supply & Return) E6TZ-9J323-G E7TZ-9J338-J E7TZ-9J338-B E9TZ-9J338-B E7TZ-9J338-C E9TZ-9J338-D E7TZ-9J338-H E9TZ-9J338-P Contact all owners whose vehicles have had such service replacements or who have purchased such parts. Dealers should arrange a service date with vehicle owners/part purchasers for replacement of the respective fuel tube assemblies. Dealers should also provide a copy of the owner letter to owners/part purchasers. Vehicle Owners are advised in the owner letter to immediately contact their dealer if they had purchased any fuel line assemblies. Dealers should determine from the part numbers provided if the assemblies should be replaced. Tube assemblies as identified above must be replaced. If the part was installed on a vehicle arrange a service date to have it replaced. Company Contacts : (For dealer use only) CONCERN NATURE CONTACT ACTIVITY Technical Technical Assistance Hotline for your Region Claiming Procedures Warranty Claims Hotline for your Region Owner Relations Owner Relations Hotline for your Region General Administrative Brian Moroz - Recall Administrator ^ Telephone (416) 845-2511 - Ext 1495 ^ Facsimile (416) 845-7069 Attachments Attachment I ^ Administrative Information Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Technical Service Bulletins > Recalls: > 89S76 > Mar > 90 > Recall - Fuel Filter And Fuel Line Replacement > Page 3700 Attachment II ^ Labor Allowances ^ Parts Ordering Allowances ^ Purge Of Dealership Parts Stock ^ Technical information ATTACHMENT III ^ Technical information Attachment I - Administrative Information CARES / OASIS You must use CARES or OASIS to determine if a vehicle is eligible for this recall or involved in another recall. Tell owners of any other recalls that may be uncompleted. Complete all recalls during a single visit by the owner. Promptly Correct ^ Affected units on the enclosed list. ^ Other eligible vehicles which are brought to your dealership. NOTE: Correct all involved vehicles in dealer stock before delivery to owners. Dealer-Owner Contact/Action Immediately contact any owner of an affected vehicle whose name does not appear on the enclosed list and arrange a service date. Give the owner a copy of the owner letter. Dealership Responsibilities Dealers are responsible to perform this recall service promptly following tender of the vehicle by the owner. It is important that you promptly report to the "National Owner Relations Office" at Oakville any instance in which an owner will not allow you to complete this recall because of objections in scheduling or for any other reason. Reimbursement For Recall Completion And Claims Preparation Instructions ^ Claims must be submitted for all completed units. ^ Claim reimbursement through the Direct Warranty entry (DWE) system using the RECALLS screen. Use the RECALLS screen only (PF3 Recall Entry/Retrieval on the DWE Menu screen). If the claim number contains more than six digits, enter only the last six digits. NOTE: Use a Form 6125-2 or authorized computer generated claim form as an internal repair order to support DWE Entry through the RECALLS screen. Ensure that only the RECALLS screen is used when inputting completion and reimbursement information. ^ The few dealers who do not have DWE capability must mail the second copy of a completed Form 1864 to Warranty Claims Processing at Oakville for reimbursement. Forms submitted must show all parts used and their cost, the parts handling allowance, and be imprinted, dated and signed by authorized dealership personnel. ^ All claims must show 89S76 in the recall box. Attachment II - Labor and Parts Information LABOR ALLOWANCES LABOR TIME LABOR CODE Install new fuel line from the high-pressure 1.5 Hrs. B frame-mounted fuel pump to the engine and install filter in frame mounted reservoir Administrative allowance 0.1 Hrs. NOTE: The 0.1 hour Administrative Allowance must be added to the total labor time before inputting. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Technical Service Bulletins > Recalls: > 89S76 > Mar > 90 > Recall - Fuel Filter And Fuel Line Replacement > Page 3701 Parts Ordering Information Parts will not be direct shipped for this recall. Order your parts through your Servicing Parts Distribution Centre. PART NUMBER DESCRIPTION QUANTITY USAGE E6TZ--9A337-C Fuel Line Assembly 1 All Chassis Cab with EFI engines (VIN positions 5, 6, 7 = F37, F38, F47 or F53) E6TZ--9A337-A Fuel Line Assembly 1 Non-Chassis Cab with 4.9L or 5.0L engine (VIN position 8 = Y or N) E6TZ--9A337-B Fuel Line Assembly 1 Non-Chassis Cab with 5.8L or 7.5L engine (VIN position 8 = H or G) E6TZ--9416-A Fitting - Adapter 1 All affected units Fuel Pump Quick Connect 95874-S Tie Strap (USP of 6 pieces All affected units 10 pieces) N620480-S100 Nut M6 (USP of 8 1 piece All affected units pieces) N800558-S100 Clip (USP of 2 1 piece All affected units pieces) FG-848-A Fuel Filter 1 All affected units E6TZ-9374-A Gasket (Copper 1 piece All affected units Washer) - Fuel Pump (USP of 10 pieces) Purge of Dealership Parts Stock I - Service Part Sold to Customer or Installed on a Vehicle Review all service and parts sales records to determine if you have installed or sold any of the following parts: Tube Assembly (Fuel Pump to Fuel Filter) E6TZ-9C330-A E9TZ-9C330-A E7TZ-9C330-A E9TZ-9C330-B Tube Assembly (Fuel Engine Supply & Return) E6TZ-9J323-G E7TZ-9J338-J E7TZ-9J338-B E9TZ-9J338-B E7TZ-9J338-C E9TZ-9J338-D E7TZ-9J338-H E9TZ-9J338-P Contact all owners whose vehicles have had such service replacements or who have purchased such parts. Dealers should arrange a service date with vehicle owners/part purchasers for replacement of the respective fuel tube assemblies. Dealers should also provide a copy of the owner letter to owners/part purchasers. Vehicle Owners are advised in the owner letter to immediately contact their dealer if they had purchased any fuel line assemblies. Dealers should determine from the part numbers provided if the assemblies should be replaced. Tube assemblies as identified above must be replaced. If the part was installed on a vehicle arrange a service date to have it replaced. II - Service Stock Within Dealership Dealers are requested to purge all fuel tube assemblies as identified below. Dealers can return the purged stock for credit to the Warranty Parts Evaluation Centre. Purge the part numbers listed below: Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Technical Service Bulletins > Recalls: > 89S76 > Mar > 90 > Recall - Fuel Filter And Fuel Line Replacement > Page 3702 SERVICE PART NUMBER DESCRIPTION E6TZ-9C330-A Tube Assembly (Fuel Pump to Fuel Filter) E7TZ-9C330-A Tube Assembly (Fuel Pump to Fuel Filter) E9TZ-9C330-A Tube Assembly (Fuel Pump to Fuel Filter) E9TZ-9C330-B Tube Assembly (Fuel Pump to Fuel Filter) E6TZ-9J323-G Tube Assembly (Fuel Engine Supply) E7TZ-9J338-B Tube Assembly (Fuel Engine Supply & Return) E7TZ-9J338-C Tube Assembly (Fuel Engine Supply & Return) E7TZ-9J338-H Tube Assembly (Fuel Engine Supply & Return) E7TZ-9J338-J Tube Assembly (Fuel Engine Supply & Return) E9TZ-9J338-B Tube Assembly (Fuel Engine Supply & Return) E9TZ-9J338-D Tube Assembly (Fuel Engine Supply & Return) E9TZ-9J338-P Tube Assembly (Fuel Engine Supply & Return) All service stock within dealerships must be returned with a completed Form 6125-2 annotated "RETURNED PER INSTRUCTIONS IN SAFETY RECALL 89S76". Show the appropriate causal part number for the replacing part in the Causal Part No. box and E79 in the Condition Code box. Attachment III - Technical Information Technical Instructions The new stainless steel reinforced Teflon(R) fuel line replaces both the short "jumper" fuel line from the high-pressure frame-mounted fuel pump to the filter and the long fuel line from the filter to the fuel rail on the engine. The existing In-Line Fuel Filter will be removed and discarded. A canister-type Fuel Filter will be added to the existing fuel reservoir on the frame rail behind the high pressure pump. EFI Engines CAUTION Fuel supply lines on 4.9L EFI, 5.0L EFI, 5.8L EFI and 7.5L EFI engines will remain pressurized for some period of time after the engine is shut off. This pressure must be relieved before servicing of the fuel system. Before opening the fuel system on vehicles with EFI engines, relieve fuel pressure as follows: 1. Locate and disconnect the electrical connection to either the fuel pump relay, the inertia switch or the in-line high pressure fuel pump. 2. Crank engine for approximately ten seconds. NOTE: Engine may start and run for a short time. If so, crank engine an additional five seconds after engine stalls. 3. Connect the electrical connector that was disconnected in Step 1. 4. Disconnect battery ground cable. 5. Raise vehicle on hoist. Refer to the appropriate model year Volume F Pre-Delivery Shop Manual, Section 50-04, Hoisting and Jacking. Canister-Type Fuel Filter Installation CAUTION If the fuel filter canister is being serviced with the rear of the truck higher than the front, or if the tank is pressurized, fuel leakage or siphoning from the tank fuel lines could occur. To prevent this condition, maintain the vehicle front end at or above the level of the rear of vehicle. Also, relieve tank pressure by loosening the fuel fill cap. Cap should be retightened after pressure is relieved. If vehicle is warm, install the fuel filter before the pressure rebuilds. 1. Remove the reservoir shield on 4 x 4 vehicles by removing either three or four screws (depending on vehicle). On 4 x 4 vehicles it may be necessary to disconnect the rear of the front driveshaft to allow for tool clearance. NOTE: To maintain driveshaft balance, mark the rear slip yoke in relation to the transfer case yoke for correct positioning during reinstallation. Then remove the nuts and U-bolts (bolts for F350 transfer case) that connect the front driveshaft to the rear slip yoke of the transfer case. 2. Unscrew the lower canister of the reservoir using a flexible strap type oil filter wrench, and slide canister out from frame rail. NOTE: Fuel canister will be full of fuel. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Technical Service Bulletins > Recalls: > 89S76 > Mar > 90 > Recall - Fuel Filter And Fuel Line Replacement > Page 3703 3. Empty fuel from the fuel canister. Remove and discard the O-ring. 4. Remove the stand pipe from the reservoir by pulling it down sharply. Discard the stand pipe. Refer to Figures 1 and 2. 5. Install grommet (supplied with filter) into top of filter cartridge, then install the fuel filter cartridge into fuel canister. 6. Position new O-ring so that it is seated in the O-ring groove of the canister. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Technical Service Bulletins > Recalls: > 89S76 > Mar > 90 > Recall - Fuel Filter And Fuel Line Replacement > Page 3704 7. While keeping canister level, so as not to dislodge O-ring, position canister to bottom of reservoir housing and tighten loosely by hand. It may be necessary to loosen reservoir-to-frame mounting bolts to access the canister. Using a flexible strap type oil filter wrench, complete filter canister tightening by turning canister about one-sixth of a turn past initial O-ring compression. NOTE: The rubber grommet on the filter will automatically seat on the piloted stud of the upper housing as the canister is tightened. REMINDER: If reservoir-to-frame mounting bolts were loosened in above step, re-tighten. Fuel Line Replacement CAUTION Fuel lines may still contain fuel. Use caution when disconnecting. 1. Refer to Figure 3. Remove the three bolts holding the fuel filter bracket to the frame. Retain one bolt for subsequent use. 2. Disconnect "Push Connect" fitting at the high pressure pump outlet nipple by removing hairpin clip and twisting the line while pulling on it. 3. Using a 16 mm wrench for the fitting and a 14 mm wrench (on the boss of the fuel pump) for backup, unscrew outlet nipple from the front of the high pressure fuel pump. Discard nipple and copper sealing washer. 4. Install new copper washer (E6TZ-9374-A) on the new fuel pump nipple (E6TZ-9416-A). Screw this new nipple into the pump. Torque to 12-16 N.m (9-12 lbs.ft.), while keeping a 14 mm wrench (on the boss of the fuel pump) for backup. 5. Select the appropriate new fuel line as per "Parts Ordering Information". Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Technical Service Bulletins > Recalls: > 89S76 > Mar > 90 > Recall - Fuel Filter And Fuel Line Replacement > Page 3705 6. Remove red shipping plug on fuel pump outlet connector of the fuel line if present. Leave white shipping plug on for protection. Install the end of the fuel line with the small bell-shaped connector to the new fuel pump outlet nipple. Push on to nipple until distinct click is heard or felt. Pull on line to test for and confirm retention. Engage the retainer clip to line and nipple by firmly pushing down on the clip. (Reference Figure 7). NOTE: If fuel line removal is required use tool T90T-9550-B to release connector. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Technical Service Bulletins > Recalls: > 89S76 > Mar > 90 > Recall - Fuel Filter And Fuel Line Replacement > Page 3706 7. Route fuel line forward inside frame rail, following routing of fuel return line. Install clip N800558-S100 to retain fuel lines, by bolting to lower front bolt hole in frame, that was previously used for the fuel filter bracket. Refer to Figures 1, 2, and 5. Use bolt from Step 1. and nut N620480-S100 Torque to 8-12 N.m (6-9 lbs. ft.) Ensure fuel line is pressed against frame rail web to clear automatic transmission shift linkage. 8. Disconnect the fuel supply line at the engine fuel rail as follows: ^ lift the tethered retaining clip off the coupling connection. Move it aside, leaving it hanging by its tether (Refer Figure 6). Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Technical Service Bulletins > Recalls: > 89S76 > Mar > 90 > Recall - Fuel Filter And Fuel Line Replacement > Page 3707 ^ disconnect the fuel line spring lock coupling, using the proper special service tool. Refer to Figure 4. 9. 5.0L or 4.9L engines equipped vehicles. Remove the complete fuel supply line, filter and jumper fuel line as an assembly. Mutilate and scrap. 10. 5.8L or 7.5L engine equipped vehicles. Use a pair of diagonal side cutters to cut both ends of the fuel supply line flush with the foil insulation wrapping. This leaves the wrapped section of the original supply line in place, which is not to be disturbed. Use caution to avoid damaging fuel return line. Mutilate and scrap the ends of fuel lines, fuel filter and bracket and "jumper" fuel line. 11. Remove white shipping cap and connect fuel line to engine fuel rail. Refer to Figure 4. Install retainer clip previously removed in Step 8. Refer to Figure 6. 12. (5.0L or 4.9L) Strap new fuel line to existing fuel return line using tie straps 95874-S at 8" (20 cm) intervals. Refer to Figures 2 and 5. Cut off excess tie strap length. 13. (5.8L or 7.5L) Strap new fuel line to existing fuel line insulation bundle as shown in Figure 1. Locate tie straps 95874-S at 8" (20 cm) intervals. Ensure heat shield is installed as shown in Figure 1. Use additional strap to secure fuel line to shield. Cut off excess tie strap length. Slight excess fuel line length is allowed to form a "hump" at the upper end of the fuel line near the engine. 14. Lower vehicle. 15. Reconnect battery ground cable. 16. Cycle ignition key to "ON" position 5 times at 2 second intervals to prime the fuel system. Inspect reservoir, pump nipple and fuel line connections for leaks (correct as required). 17. Start engine and reinspect the fuel system for leaks. (Correct as required). 18. (4 X 4 only) Reinstall fuel reservoir shield. Torque attaching bolts to 16-20 N.m. (12-15 lbs. ft.) Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Technical Service Bulletins > Recalls: > 89S76 > Mar > 90 > Recall - Fuel Filter And Fuel Line Replacement > Page 3708 19. (4 x 4 only) Reinstall driveshaft, if removed, making sure markings on rear slip yoke and transfer casing yoke line up so as to maintain driveshaft balance. 20. Mutilate and scrap all removed parts. Owner Letter April, 1990 Owner Name 123 Main Street Anytown PR ANA NAN This notice is sent to you in accordance with the requirements of the Motor Vehicle Safety Act of Canada. Ford Motor Company of Canada, Limited (Ford) has determined that certain 1986, 1987, 1988 and 1989 model F-150/250/350 Trucks and Broncos sold in specific areas of Canada where severe winter weather is experienced contain a fuel tube that may develop a leak. Our records indicate that you own the 19xx (F-150/250/350 Truck, Bronco) bearing the following serial number: Safety Defect: A short fuel tube located beneath the cab of the vehicle, on the driver's side, could develop a pin hole in the tubing wall. If this condition occurs fuel will leak and a fire could result. Repair: At no cost to you, your dealer will replace the fuel filter and the fuel line from the fuel pump to the engine with a steel braided fuel line and install a fuel filter in the fuel reservoir. How Long Will It Take? The time needed to repair your vehicle is less than two hours. However, due to service scheduling times, your dealer may need your vehicle for one full day. You Need To: Call your dealer without delay and ask for a service date. Your dealer has the service and part ordering information needed to repair your vehicle. If your dealer does not have the parts in stock, they can be ordered before scheduling your service date. Parts would be expected to arrive within a week. When you bring your vehicle in, show the dealer this letter. If you lose the letter, your dealer will still do the work, free of charge. Have You Purchased Any Fuel Line Service Parts? Immediately contact your dealer if you have purchased any fuel line assemblies for your vehicle. Provide the dealer the part numbers of the parts purchased. Your dealer will advise you of what actions, if any, you should take. Changed Name, Address Or Sold The Vehicle? If you have changed your name, address, or sold the vehicle, please fill out the enclosed prepaid postcard and mail it to us. If you cannot get this service performed please contact the "National Owner Relations Office", or the nearest Ford of Canada Regional Office. The addresses and telephone numbers for these offices are shown in your vehicle's Owner Guide. Any Ford or Lincoln-Mercury dealer can also give you this information. Please identify your vehicle's serial number in any correspondence. We regret the inconvenience this service may cause you, but we want you to have the work done for your safety and satisfaction with your Ford-built vehicle. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Supply Line: > 921216 > Jun > 92 > Nylon Fuel Lines - Servicing Procedure Fuel Supply Line: All Technical Service Bulletins Nylon Fuel Lines - Servicing Procedure Article No. 92-12-16 DATE: 06-03-92 FUEL LINES-NYLON-SERVICING PROCEDURE LIGHT TRUCK: 1985-92 F-150-350 SERIES 1986-90 BRONCO II 1986-92 AEROSTAR, BRONCO, ECONOLINE, RANGER 1988-92 F SUPER DUTY 1991-92 EXPLORER ISSUE: Metal fuel lines and connectors have been replaced with nylon lines and connectors on the subject vehicles. A procedure has been developed for servicing damaged nylon fuel lines. ACTION: If a nylon fuel line requires service, use the following procedure. FUEL SYSTEM SERVICE PROCEDURE FOR NYLON FUEL TUBES AND PUSH CONNECT FITTINGS FUEL LINES AND HOSES WARNING: FUEL SUPPLY LINES ON VEHICLES WITH FUEL INJECTED ENGINES WILL REMAIN PRESSURIZED FOR LONG PERIODS OF TIME AFTER ENGINE SHUT DOWN WHICH COULD RESULT IN PERSONAL INJURY. THE PRESSURE MUST BE RELIEVED, AS OUTLINED PER THE FUEL SYSTEM PRESSURE RELIEF PROCEDURE, BEFORE SERVICING THE FUEL SYSTEM. READ ALL CAUTIONARY NOTES PRIOR TO RELIEVING THE PRESSURIZED FUEL SYSTEM. FUEL TUBES - PLASTIC (NYLON) CAUTION: FORD APPROVED NYLON FUEL TUBING IS MADE FROM MATERIAL WHICH HAS BEEN TESTED AND PROVEN TO BE ACCEPTABLE FOR USE WITH COMMERCIALLY AVAILABLE FUELS. IT IS ALSO RESISTANT TO MOST ENVIRONMENTAL CONDITIONS. AVOID USING ALTERNATE TUBING MATERIALS. USE OF NON-APPROVED TUBING COULD POSE A HAZARD IN SERVICE. CAUTION: PLASTIC FUEL TUBES MUST NOT BE REPAIRED USING HOSE AND HOSE CLAMPS. PUSH CONNECT FITTINGS CANNOT BE REPAIRED EXCEPT TO REPLACE THE RETAINING CLIPS. IF THE PLASTIC TUBES OR PUSH CONNECT FITTINGS BECOME DAMAGED AND LEAK, APPROVED SERVICE PARTS MUST BE USED TO SERVICE THE FUEL LINES. MAJOR SERVICE OPERATIONS - FUEL LINES Vehicles equipped with nylon fuel tubes and push connect fittings have three (3) types of service that can be performed to the fuel lines... ^ Replacing nylon tubing (splicing nylon to nylon) ^ Replacing push connector fittings ^ Replacing damaged push connect tube ends. NOTE: FORMED SECTIONS (BENDS) OF NYLON FUEL LINES CANNOT BE REPAIRED USING STRAIGHT TUBING. STRAIGHT SERVICE TUBING WILL KINK IF BENT. FORMED NYLON FUEL LINE IS REOUIRED TO REPLACE THE DAMAGED SECTION. SPLICING NYLON TO NYLON 1. Relieve the fuel system pressure as outlined in the Service Manual. Read the previously cited Warning prior to relieving the pressurized fuel system. 2. Cut out the damaged section of tubing (straight non-formed sections only) and retain as a guide. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Supply Line: > 921216 > Jun > 92 > Nylon Fuel Lines - Servicing Procedure > Page 3714 3. Cut a section of nylon service tubing, type 11 or 12, of the same diameter and length as the damaged section of tubing. NOTE: TYPE 11 OR 12 NYLON SERVICE TUBING IS AVAILABLE IN 6.3MM (1/4"), 7.9MM (5/16") AND 9.5MM (3/8") DIAMETER SIZES. 4. Select the proper nylon barbed connector(s) for completing the splice... ^ 7.9mm (5/16") - Part Number (N806120-S) ^ 9.5mm (3/8") - Part Number (N806119-S) Two (2) in-line connectors are required for each splice. NOTE: TO MAKE INSERTION OF THE BARB CONNECTORS INTO THE NYLON LINE EASIER, THE TUBE END MAY BE SOAKED IN A CUP OF BOILING WATER FOR ONE (1) MINUTE BEFORE PUSHING THE BARB CONNECTOR INTO THE NYLON. USE ROTUNDA TOOL 134-000001 OR EQUIVALENT TO ASSIST IN ASSEMBLY. 5. Set up Rotunda Tool 134-000001 for in-line splice as shown in Figure 1. a. Select the proper inserts for the fuel line size and install into both sets of upper and lower block cavities. b. Connect the block cavity to the ratcheting rod of the Rotunda Tool with the slot in line with the slot in the ratcheting tool barrel c. Install both sets of upper and lower block cavities to the threaded rods of the ratcheting tool, Figure 1. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Supply Line: > 921216 > Jun > 92 > Nylon Fuel Lines - Servicing Procedure > Page 3715 d. Install one fuel line into the lower block cavity closest to the ratcheting end of the tool so that the extension of the fuel line is slightly greater than the barb length of the connector, Figure 2. e. Route the fuel line through the slot in the tool, Figure 2. f. Close the upper block cavity onto the lower block cavity and tighten the thumb screw securely. g. Place the replacement tubing in the forward lower block cavity and repeat Steps d and e. h. Place the barb connector between the ends of the lines to be spliced and ratchet the tool until the nylon line has covered all three (3) barbs of the connector on both ends. i. After completing the splice, unscrew the thumb screws and release the lines. Repeat Steps d through h on the opposite line end to complete the splice. 6. The completed fuel line splice is shown in Figure 3. 7. Install any remaining clips which were removed for this service. Check to be sure the fuel lines are secure in the original clips. 8. Start the engine and check for leaks. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Supply Line: > 921216 > Jun > 92 > Nylon Fuel Lines - Servicing Procedure > Page 3716 PART NUMBER PART NAME CLASS N806119-S Connector - Hose Push CG Connect (3/8") N806120-S Connector - Hose Push CG Connect (5/16") OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 404000, 490000 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Supply Line: > 89S76 > Mar > 90 > Recall - Fuel Filter And Fuel Line Replacement Technical Service Bulletin # 89S76 Date: 900328 Recall - Fuel Filter And Fuel Line Replacement 89S76 SAFETY RECALL Certain 1986-1989 Gasoline Powered F-Series Pick-Up & Chassis Cab Trks. & Broncos for Replacement of the Fuel Filter & Fuel Line from the High Pressure Frame-Mounted Fuel Pump to the Engine. Supersedes & Replaces Safety Recall 88S57 Dealer Letter Attachment I ^ Administrative Information Attachment II ^ Labor Allowances ^ Parts Ordering Information ^ Purge of Dealership Parts Stock Attachment III ^ Technical Information Customer Notification Letter Dealer Letter March 28, 1990 To: Ford of Canada Dealers in Midwestern and Western Regions and the Yukon Territory Attention: Dealer Principal, Dealer Service Manager, Dealer Parts Manager Subject: Subject Recall 89S76 - Recall of Certain 1986 through 1989 Gasoline Powered F-Series Pick-Up and Chassis Cab Trucks and Bronco's for Replacement of the Fuel Filter and Fuel Line from the High Pressure Frame-Mounted Fuel Pump to the Engine. This Recall Supersedes and Replaces Safety Recall 88S57 In CARES / OASIS YES Dealer Listings YES Recall Time Limitation None Parts Return NO NOTE: Please read and circulate this bulletin to your service personnel so that they may become familiar with this recall and be able to respond to owner inquiries. Special Note: Safety Recall 89S76 supersedes and replaces Safety Recall 88S57. If you are presented with a vehicle that does not have 88S57 completed, do not perform that recall on it; instead perform Safety Recall 89S76 on that vehicle. Due to parts supply, owner mailings will be phased. Dealers should not delay completion of Safety Recall 89S76 on an involved vehicle because the owner has not received a recall notification. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Supply Line: > 89S76 > Mar > 90 > Recall - Fuel Filter And Fuel Line Replacement > Page 3721 Affected Vehicles: All 1986-1/2, 1987, 1988 and 1989 Model Year gasoline powered F-Series Pickup Trucks including Chassis Cabs, and Bronco vehicles with EFI engines sold or operated in Mid-West and Western Regions and the Yukon Territory. Vehicles involved were produced from February 1, 1986, through to the end of the 1989 model year. Reason For Recall: Field investigation has determined that repairs specified in Recall 88S57 were not completely effective in preventing the condition of pinhole leaks forming in the U-shaped fuel tube ("Jumper Tube") connecting the on-frame fuel pump to the fuel filter. Correction: To prevent this condition from re-occurring, the U-shaped fuel tube, the frame mounted filter and the fuel delivery tube from the filter to the engine will be replaced with a steel braided electrically conductive fuel line from the high pressure frame-mounted fuel pump to the engine. A fuel filter cartridge will also be installed in the fuel reservoir. Purge Of Dealership Parts Stock: Service Part Sold to Customer or Installed on a Vehicle Review all service and parts sales records to determine if you have installed or sold any of the following parts: Tube Assembly (Fuel Pump to Fuel Filter) E6TZ-9C330-A E9TZ-9C330-A E7TZ-9C330-A E9TZ-9C330-B Tube Assembly (Fuel Engine Supply & Return) E6TZ-9J323-G E7TZ-9J338-J E7TZ-9J338-B E9TZ-9J338-B E7TZ-9J338-C E9TZ-9J338-D E7TZ-9J338-H E9TZ-9J338-P Contact all owners whose vehicles have had such service replacements or who have purchased such parts. Dealers should arrange a service date with vehicle owners/part purchasers for replacement of the respective fuel tube assemblies. Dealers should also provide a copy of the owner letter to owners/part purchasers. Vehicle Owners are advised in the owner letter to immediately contact their dealer if they had purchased any fuel line assemblies. Dealers should determine from the part numbers provided if the assemblies should be replaced. Tube assemblies as identified above must be replaced. If the part was installed on a vehicle arrange a service date to have it replaced. Company Contacts : (For dealer use only) CONCERN NATURE CONTACT ACTIVITY Technical Technical Assistance Hotline for your Region Claiming Procedures Warranty Claims Hotline for your Region Owner Relations Owner Relations Hotline for your Region General Administrative Brian Moroz - Recall Administrator ^ Telephone (416) 845-2511 - Ext 1495 ^ Facsimile (416) 845-7069 Attachments Attachment I ^ Administrative Information Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Supply Line: > 89S76 > Mar > 90 > Recall - Fuel Filter And Fuel Line Replacement > Page 3722 Attachment II ^ Labor Allowances ^ Parts Ordering Allowances ^ Purge Of Dealership Parts Stock ^ Technical information ATTACHMENT III ^ Technical information Attachment I - Administrative Information CARES / OASIS You must use CARES or OASIS to determine if a vehicle is eligible for this recall or involved in another recall. Tell owners of any other recalls that may be uncompleted. Complete all recalls during a single visit by the owner. Promptly Correct ^ Affected units on the enclosed list. ^ Other eligible vehicles which are brought to your dealership. NOTE: Correct all involved vehicles in dealer stock before delivery to owners. Dealer-Owner Contact/Action Immediately contact any owner of an affected vehicle whose name does not appear on the enclosed list and arrange a service date. Give the owner a copy of the owner letter. Dealership Responsibilities Dealers are responsible to perform this recall service promptly following tender of the vehicle by the owner. It is important that you promptly report to the "National Owner Relations Office" at Oakville any instance in which an owner will not allow you to complete this recall because of objections in scheduling or for any other reason. Reimbursement For Recall Completion And Claims Preparation Instructions ^ Claims must be submitted for all completed units. ^ Claim reimbursement through the Direct Warranty entry (DWE) system using the RECALLS screen. Use the RECALLS screen only (PF3 Recall Entry/Retrieval on the DWE Menu screen). If the claim number contains more than six digits, enter only the last six digits. NOTE: Use a Form 6125-2 or authorized computer generated claim form as an internal repair order to support DWE Entry through the RECALLS screen. Ensure that only the RECALLS screen is used when inputting completion and reimbursement information. ^ The few dealers who do not have DWE capability must mail the second copy of a completed Form 1864 to Warranty Claims Processing at Oakville for reimbursement. Forms submitted must show all parts used and their cost, the parts handling allowance, and be imprinted, dated and signed by authorized dealership personnel. ^ All claims must show 89S76 in the recall box. Attachment II - Labor and Parts Information LABOR ALLOWANCES LABOR TIME LABOR CODE Install new fuel line from the high-pressure 1.5 Hrs. B frame-mounted fuel pump to the engine and install filter in frame mounted reservoir Administrative allowance 0.1 Hrs. NOTE: The 0.1 hour Administrative Allowance must be added to the total labor time before inputting. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Supply Line: > 89S76 > Mar > 90 > Recall - Fuel Filter And Fuel Line Replacement > Page 3723 Parts Ordering Information Parts will not be direct shipped for this recall. Order your parts through your Servicing Parts Distribution Centre. PART NUMBER DESCRIPTION QUANTITY USAGE E6TZ--9A337-C Fuel Line Assembly 1 All Chassis Cab with EFI engines (VIN positions 5, 6, 7 = F37, F38, F47 or F53) E6TZ--9A337-A Fuel Line Assembly 1 Non-Chassis Cab with 4.9L or 5.0L engine (VIN position 8 = Y or N) E6TZ--9A337-B Fuel Line Assembly 1 Non-Chassis Cab with 5.8L or 7.5L engine (VIN position 8 = H or G) E6TZ--9416-A Fitting - Adapter 1 All affected units Fuel Pump Quick Connect 95874-S Tie Strap (USP of 6 pieces All affected units 10 pieces) N620480-S100 Nut M6 (USP of 8 1 piece All affected units pieces) N800558-S100 Clip (USP of 2 1 piece All affected units pieces) FG-848-A Fuel Filter 1 All affected units E6TZ-9374-A Gasket (Copper 1 piece All affected units Washer) - Fuel Pump (USP of 10 pieces) Purge of Dealership Parts Stock I - Service Part Sold to Customer or Installed on a Vehicle Review all service and parts sales records to determine if you have installed or sold any of the following parts: Tube Assembly (Fuel Pump to Fuel Filter) E6TZ-9C330-A E9TZ-9C330-A E7TZ-9C330-A E9TZ-9C330-B Tube Assembly (Fuel Engine Supply & Return) E6TZ-9J323-G E7TZ-9J338-J E7TZ-9J338-B E9TZ-9J338-B E7TZ-9J338-C E9TZ-9J338-D E7TZ-9J338-H E9TZ-9J338-P Contact all owners whose vehicles have had such service replacements or who have purchased such parts. Dealers should arrange a service date with vehicle owners/part purchasers for replacement of the respective fuel tube assemblies. Dealers should also provide a copy of the owner letter to owners/part purchasers. Vehicle Owners are advised in the owner letter to immediately contact their dealer if they had purchased any fuel line assemblies. Dealers should determine from the part numbers provided if the assemblies should be replaced. Tube assemblies as identified above must be replaced. If the part was installed on a vehicle arrange a service date to have it replaced. II - Service Stock Within Dealership Dealers are requested to purge all fuel tube assemblies as identified below. Dealers can return the purged stock for credit to the Warranty Parts Evaluation Centre. Purge the part numbers listed below: Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Supply Line: > 89S76 > Mar > 90 > Recall - Fuel Filter And Fuel Line Replacement > Page 3724 SERVICE PART NUMBER DESCRIPTION E6TZ-9C330-A Tube Assembly (Fuel Pump to Fuel Filter) E7TZ-9C330-A Tube Assembly (Fuel Pump to Fuel Filter) E9TZ-9C330-A Tube Assembly (Fuel Pump to Fuel Filter) E9TZ-9C330-B Tube Assembly (Fuel Pump to Fuel Filter) E6TZ-9J323-G Tube Assembly (Fuel Engine Supply) E7TZ-9J338-B Tube Assembly (Fuel Engine Supply & Return) E7TZ-9J338-C Tube Assembly (Fuel Engine Supply & Return) E7TZ-9J338-H Tube Assembly (Fuel Engine Supply & Return) E7TZ-9J338-J Tube Assembly (Fuel Engine Supply & Return) E9TZ-9J338-B Tube Assembly (Fuel Engine Supply & Return) E9TZ-9J338-D Tube Assembly (Fuel Engine Supply & Return) E9TZ-9J338-P Tube Assembly (Fuel Engine Supply & Return) All service stock within dealerships must be returned with a completed Form 6125-2 annotated "RETURNED PER INSTRUCTIONS IN SAFETY RECALL 89S76". Show the appropriate causal part number for the replacing part in the Causal Part No. box and E79 in the Condition Code box. Attachment III - Technical Information Technical Instructions The new stainless steel reinforced Teflon(R) fuel line replaces both the short "jumper" fuel line from the high-pressure frame-mounted fuel pump to the filter and the long fuel line from the filter to the fuel rail on the engine. The existing In-Line Fuel Filter will be removed and discarded. A canister-type Fuel Filter will be added to the existing fuel reservoir on the frame rail behind the high pressure pump. EFI Engines CAUTION Fuel supply lines on 4.9L EFI, 5.0L EFI, 5.8L EFI and 7.5L EFI engines will remain pressurized for some period of time after the engine is shut off. This pressure must be relieved before servicing of the fuel system. Before opening the fuel system on vehicles with EFI engines, relieve fuel pressure as follows: 1. Locate and disconnect the electrical connection to either the fuel pump relay, the inertia switch or the in-line high pressure fuel pump. 2. Crank engine for approximately ten seconds. NOTE: Engine may start and run for a short time. If so, crank engine an additional five seconds after engine stalls. 3. Connect the electrical connector that was disconnected in Step 1. 4. Disconnect battery ground cable. 5. Raise vehicle on hoist. Refer to the appropriate model year Volume F Pre-Delivery Shop Manual, Section 50-04, Hoisting and Jacking. Canister-Type Fuel Filter Installation CAUTION If the fuel filter canister is being serviced with the rear of the truck higher than the front, or if the tank is pressurized, fuel leakage or siphoning from the tank fuel lines could occur. To prevent this condition, maintain the vehicle front end at or above the level of the rear of vehicle. Also, relieve tank pressure by loosening the fuel fill cap. Cap should be retightened after pressure is relieved. If vehicle is warm, install the fuel filter before the pressure rebuilds. 1. Remove the reservoir shield on 4 x 4 vehicles by removing either three or four screws (depending on vehicle). On 4 x 4 vehicles it may be necessary to disconnect the rear of the front driveshaft to allow for tool clearance. NOTE: To maintain driveshaft balance, mark the rear slip yoke in relation to the transfer case yoke for correct positioning during reinstallation. Then remove the nuts and U-bolts (bolts for F350 transfer case) that connect the front driveshaft to the rear slip yoke of the transfer case. 2. Unscrew the lower canister of the reservoir using a flexible strap type oil filter wrench, and slide canister out from frame rail. NOTE: Fuel canister will be full of fuel. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Supply Line: > 89S76 > Mar > 90 > Recall - Fuel Filter And Fuel Line Replacement > Page 3725 3. Empty fuel from the fuel canister. Remove and discard the O-ring. 4. Remove the stand pipe from the reservoir by pulling it down sharply. Discard the stand pipe. Refer to Figures 1 and 2. 5. Install grommet (supplied with filter) into top of filter cartridge, then install the fuel filter cartridge into fuel canister. 6. Position new O-ring so that it is seated in the O-ring groove of the canister. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Supply Line: > 89S76 > Mar > 90 > Recall - Fuel Filter And Fuel Line Replacement > Page 3726 7. While keeping canister level, so as not to dislodge O-ring, position canister to bottom of reservoir housing and tighten loosely by hand. It may be necessary to loosen reservoir-to-frame mounting bolts to access the canister. Using a flexible strap type oil filter wrench, complete filter canister tightening by turning canister about one-sixth of a turn past initial O-ring compression. NOTE: The rubber grommet on the filter will automatically seat on the piloted stud of the upper housing as the canister is tightened. REMINDER: If reservoir-to-frame mounting bolts were loosened in above step, re-tighten. Fuel Line Replacement CAUTION Fuel lines may still contain fuel. Use caution when disconnecting. 1. Refer to Figure 3. Remove the three bolts holding the fuel filter bracket to the frame. Retain one bolt for subsequent use. 2. Disconnect "Push Connect" fitting at the high pressure pump outlet nipple by removing hairpin clip and twisting the line while pulling on it. 3. Using a 16 mm wrench for the fitting and a 14 mm wrench (on the boss of the fuel pump) for backup, unscrew outlet nipple from the front of the high pressure fuel pump. Discard nipple and copper sealing washer. 4. Install new copper washer (E6TZ-9374-A) on the new fuel pump nipple (E6TZ-9416-A). Screw this new nipple into the pump. Torque to 12-16 N.m (9-12 lbs.ft.), while keeping a 14 mm wrench (on the boss of the fuel pump) for backup. 5. Select the appropriate new fuel line as per "Parts Ordering Information". Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Supply Line: > 89S76 > Mar > 90 > Recall - Fuel Filter And Fuel Line Replacement > Page 3727 6. Remove red shipping plug on fuel pump outlet connector of the fuel line if present. Leave white shipping plug on for protection. Install the end of the fuel line with the small bell-shaped connector to the new fuel pump outlet nipple. Push on to nipple until distinct click is heard or felt. Pull on line to test for and confirm retention. Engage the retainer clip to line and nipple by firmly pushing down on the clip. (Reference Figure 7). NOTE: If fuel line removal is required use tool T90T-9550-B to release connector. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Supply Line: > 89S76 > Mar > 90 > Recall - Fuel Filter And Fuel Line Replacement > Page 3728 7. Route fuel line forward inside frame rail, following routing of fuel return line. Install clip N800558-S100 to retain fuel lines, by bolting to lower front bolt hole in frame, that was previously used for the fuel filter bracket. Refer to Figures 1, 2, and 5. Use bolt from Step 1. and nut N620480-S100 Torque to 8-12 N.m (6-9 lbs. ft.) Ensure fuel line is pressed against frame rail web to clear automatic transmission shift linkage. 8. Disconnect the fuel supply line at the engine fuel rail as follows: ^ lift the tethered retaining clip off the coupling connection. Move it aside, leaving it hanging by its tether (Refer Figure 6). Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Supply Line: > 89S76 > Mar > 90 > Recall - Fuel Filter And Fuel Line Replacement > Page 3729 ^ disconnect the fuel line spring lock coupling, using the proper special service tool. Refer to Figure 4. 9. 5.0L or 4.9L engines equipped vehicles. Remove the complete fuel supply line, filter and jumper fuel line as an assembly. Mutilate and scrap. 10. 5.8L or 7.5L engine equipped vehicles. Use a pair of diagonal side cutters to cut both ends of the fuel supply line flush with the foil insulation wrapping. This leaves the wrapped section of the original supply line in place, which is not to be disturbed. Use caution to avoid damaging fuel return line. Mutilate and scrap the ends of fuel lines, fuel filter and bracket and "jumper" fuel line. 11. Remove white shipping cap and connect fuel line to engine fuel rail. Refer to Figure 4. Install retainer clip previously removed in Step 8. Refer to Figure 6. 12. (5.0L or 4.9L) Strap new fuel line to existing fuel return line using tie straps 95874-S at 8" (20 cm) intervals. Refer to Figures 2 and 5. Cut off excess tie strap length. 13. (5.8L or 7.5L) Strap new fuel line to existing fuel line insulation bundle as shown in Figure 1. Locate tie straps 95874-S at 8" (20 cm) intervals. Ensure heat shield is installed as shown in Figure 1. Use additional strap to secure fuel line to shield. Cut off excess tie strap length. Slight excess fuel line length is allowed to form a "hump" at the upper end of the fuel line near the engine. 14. Lower vehicle. 15. Reconnect battery ground cable. 16. Cycle ignition key to "ON" position 5 times at 2 second intervals to prime the fuel system. Inspect reservoir, pump nipple and fuel line connections for leaks (correct as required). 17. Start engine and reinspect the fuel system for leaks. (Correct as required). 18. (4 X 4 only) Reinstall fuel reservoir shield. Torque attaching bolts to 16-20 N.m. (12-15 lbs. ft.) Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Supply Line: > 89S76 > Mar > 90 > Recall - Fuel Filter And Fuel Line Replacement > Page 3730 19. (4 x 4 only) Reinstall driveshaft, if removed, making sure markings on rear slip yoke and transfer casing yoke line up so as to maintain driveshaft balance. 20. Mutilate and scrap all removed parts. Owner Letter April, 1990 Owner Name 123 Main Street Anytown PR ANA NAN This notice is sent to you in accordance with the requirements of the Motor Vehicle Safety Act of Canada. Ford Motor Company of Canada, Limited (Ford) has determined that certain 1986, 1987, 1988 and 1989 model F-150/250/350 Trucks and Broncos sold in specific areas of Canada where severe winter weather is experienced contain a fuel tube that may develop a leak. Our records indicate that you own the 19xx (F-150/250/350 Truck, Bronco) bearing the following serial number: Safety Defect: A short fuel tube located beneath the cab of the vehicle, on the driver's side, could develop a pin hole in the tubing wall. If this condition occurs fuel will leak and a fire could result. Repair: At no cost to you, your dealer will replace the fuel filter and the fuel line from the fuel pump to the engine with a steel braided fuel line and install a fuel filter in the fuel reservoir. How Long Will It Take? The time needed to repair your vehicle is less than two hours. However, due to service scheduling times, your dealer may need your vehicle for one full day. You Need To: Call your dealer without delay and ask for a service date. Your dealer has the service and part ordering information needed to repair your vehicle. If your dealer does not have the parts in stock, they can be ordered before scheduling your service date. Parts would be expected to arrive within a week. When you bring your vehicle in, show the dealer this letter. If you lose the letter, your dealer will still do the work, free of charge. Have You Purchased Any Fuel Line Service Parts? Immediately contact your dealer if you have purchased any fuel line assemblies for your vehicle. Provide the dealer the part numbers of the parts purchased. Your dealer will advise you of what actions, if any, you should take. Changed Name, Address Or Sold The Vehicle? If you have changed your name, address, or sold the vehicle, please fill out the enclosed prepaid postcard and mail it to us. If you cannot get this service performed please contact the "National Owner Relations Office", or the nearest Ford of Canada Regional Office. The addresses and telephone numbers for these offices are shown in your vehicle's Owner Guide. Any Ford or Lincoln-Mercury dealer can also give you this information. Please identify your vehicle's serial number in any correspondence. We regret the inconvenience this service may cause you, but we want you to have the work done for your safety and satisfaction with your Ford-built vehicle. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Supply Line: > 8738 > Feb > 87 > Fuel Line Spring Lock Coupling - Service Procedures Fuel Supply Line: All Technical Service Bulletins Fuel Line Spring Lock Coupling - Service Procedures FUEL LINE SPRING LOCK COUPLING - SUMMARY Article No. OF SERVICE PROCEDURES AND REVISED TOOLS 87-3-8 FORD 1986 LTD 1986-87 ESCORT, EXP, MUSTANG, TAURUS, THUNDERBIRD, FORD LINCOLN-MERCURY 1986 MARQUIS, CAPRI 1986-87 LYNX, SABLE, COUGAR, MERCURY, MARK VII, CONTINENTAL, LINCOLN TOWN CAR LIGHT TRUCK 1985-87 RANGER, BRONCO II, E-SERIES, F-SERIES, BRONCO ISSUE: This article summarizes the overall service procedure to be used for disconnecting and connecting the fuel line spring lock coupling. In addition, the service tools and service part O-rings have been recently revised. The service tools (available March, 1987) D87L-9280-A (3/8") and D87L-9280-B (1/2") used to disconnect the spring lock coupling will now fit around the rubber cover on the fuel line allowing an easier disconnect. The O-ring part numbers were changed to specify color. The fuel resistant O-rings 390846-S96 (3/8") and 390847-S96 (1/2") will be BROWN in color while the A/C refrigerant Orings will continue to be BLACK. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Supply Line: > 8738 > Feb > 87 > Fuel Line Spring Lock Coupling - Service Procedures > Page 3735 Figure 5 ACTION: To properly disconnect and connect the fuel line spring coupling, use the illustrated service procedure on page 44 of this TSB, Figure 5. This illustration should also be used in place of the following 1985 through 1987 Car and Light Truck Shop Manual pages: 1985 Light Truck Shop Manual, Volume B, Section 24-05-16 / 24-05-17 1986 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Supply Line: > 8738 > Feb > 87 > Fuel Line Spring Lock Coupling - Service Procedures > Page 3736 Car Shop Manual, Volume D, Section 24-50-11 Car Shop Manual, Volume E, Section 24-50-14 Taurus/Sable Shop Manual, Section 24-50-11 Ranger/Bronco II Shop Manual, Section 24-03-11 Aerostar Shop Maunal, Section 9-06-15 / 9-06-16 Light Truck Shop Manual, Volume B, Section 24-05-16 / 24-50-35 1987 Car Shop Manual, Volume D, Section 24-50-11 Car Shop Manual, Volume E, Section 24-50-17 Taurus/Sable Shop Manual, Section 24-50-12 Ranger/Bronco II Shop Manual, Section 24-03-10 / 24-05-10 Aerostar Shop Manual, Section 9-02-10 / 9-06-17 / 9-06-18 Light Truck Shop Manual, Volume B, Section 24-05-14 / 24-10-9 / 27-10-20 / 24-50-34 NOTE: The following items should be noted when service is required. ^ Use the specified tool or equivalent. ^ Inspect for missing or damaged O-rings. ^ Use the specified fuel resistant O-rings (BROWN). ^ Lubricate the O-ring with clean engine oil. ^ Check to make sure that the fitting is locked. PART NUMBER PART NAME CLASS 390846-S96 O-Ring 3/8" (Brown) S 390847-S96 O-Ring 1/2" (Brown) S OTHER APPLICABLE ARTICLES: Supersedes 86-12-17, 86-12-13 WARRANTY STATUS: "INFORMATION ONLY" Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Supply Line: > 852227 > Nov > 85 > Fuel System Spring Lock Fitting - Proper Assembly Fuel Supply Line: All Technical Service Bulletins Fuel System Spring Lock Fitting - Proper Assembly Article No. 85-22-27 FUEL SYSTEM - PROPER ASSEMBLY TECHNIQUE FOR SPRING LOCK FITTING AT ENGINE FUEL SUPPLY AND RETURN LINE CONNECTIONS LIGHT TRUCK 1986 RANGER, BRONCO II, AEROSTAR, BRONCO, E & F SERIES The following additional information supplements the spring lock fuel connection removal and installation procedures in the Light Truck Shop Manual, Section 24-50 for E & F Series, Bronco, Ranger, and Bronco II; and 9-06 for Aerostar. At initial assembly, a white plastic indicator ring is used to assure proper assembly of the spring lock fitting at the fuel supply line connection to the engine fuel rail, and at the engine fuel return line connection. Figure 24 - PROPER ASSEMBLY TECHNIQUE FOR SPRING LOCK FITTING AT ENGINE/FUEL LINE INTERFACE - ALL EFI ENGINES After each of these two fitting connections are assembled, the white plastic indicator ring remains (loose) on the fuel line (as shown in Figure 24). Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Supply Line: > 852227 > Nov > 85 > Fuel System Spring Lock Fitting - Proper Assembly > Page 3741 When servicing these two spring lock fuel connections, and to assure proper reassembly of these connections, refer to the procedure outlined in Figure 24. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Supply Line: > 921216 > Jun > 92 > Nylon Fuel Lines - Servicing Procedure Fuel Supply Line: All Technical Service Bulletins Nylon Fuel Lines - Servicing Procedure Article No. 92-12-16 DATE: 06-03-92 FUEL LINES-NYLON-SERVICING PROCEDURE LIGHT TRUCK: 1985-92 F-150-350 SERIES 1986-90 BRONCO II 1986-92 AEROSTAR, BRONCO, ECONOLINE, RANGER 1988-92 F SUPER DUTY 1991-92 EXPLORER ISSUE: Metal fuel lines and connectors have been replaced with nylon lines and connectors on the subject vehicles. A procedure has been developed for servicing damaged nylon fuel lines. ACTION: If a nylon fuel line requires service, use the following procedure. FUEL SYSTEM SERVICE PROCEDURE FOR NYLON FUEL TUBES AND PUSH CONNECT FITTINGS FUEL LINES AND HOSES WARNING: FUEL SUPPLY LINES ON VEHICLES WITH FUEL INJECTED ENGINES WILL REMAIN PRESSURIZED FOR LONG PERIODS OF TIME AFTER ENGINE SHUT DOWN WHICH COULD RESULT IN PERSONAL INJURY. THE PRESSURE MUST BE RELIEVED, AS OUTLINED PER THE FUEL SYSTEM PRESSURE RELIEF PROCEDURE, BEFORE SERVICING THE FUEL SYSTEM. READ ALL CAUTIONARY NOTES PRIOR TO RELIEVING THE PRESSURIZED FUEL SYSTEM. FUEL TUBES - PLASTIC (NYLON) CAUTION: FORD APPROVED NYLON FUEL TUBING IS MADE FROM MATERIAL WHICH HAS BEEN TESTED AND PROVEN TO BE ACCEPTABLE FOR USE WITH COMMERCIALLY AVAILABLE FUELS. IT IS ALSO RESISTANT TO MOST ENVIRONMENTAL CONDITIONS. AVOID USING ALTERNATE TUBING MATERIALS. USE OF NON-APPROVED TUBING COULD POSE A HAZARD IN SERVICE. CAUTION: PLASTIC FUEL TUBES MUST NOT BE REPAIRED USING HOSE AND HOSE CLAMPS. PUSH CONNECT FITTINGS CANNOT BE REPAIRED EXCEPT TO REPLACE THE RETAINING CLIPS. IF THE PLASTIC TUBES OR PUSH CONNECT FITTINGS BECOME DAMAGED AND LEAK, APPROVED SERVICE PARTS MUST BE USED TO SERVICE THE FUEL LINES. MAJOR SERVICE OPERATIONS - FUEL LINES Vehicles equipped with nylon fuel tubes and push connect fittings have three (3) types of service that can be performed to the fuel lines... ^ Replacing nylon tubing (splicing nylon to nylon) ^ Replacing push connector fittings ^ Replacing damaged push connect tube ends. NOTE: FORMED SECTIONS (BENDS) OF NYLON FUEL LINES CANNOT BE REPAIRED USING STRAIGHT TUBING. STRAIGHT SERVICE TUBING WILL KINK IF BENT. FORMED NYLON FUEL LINE IS REOUIRED TO REPLACE THE DAMAGED SECTION. SPLICING NYLON TO NYLON 1. Relieve the fuel system pressure as outlined in the Service Manual. Read the previously cited Warning prior to relieving the pressurized fuel system. 2. Cut out the damaged section of tubing (straight non-formed sections only) and retain as a guide. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Supply Line: > 921216 > Jun > 92 > Nylon Fuel Lines - Servicing Procedure > Page 3747 3. Cut a section of nylon service tubing, type 11 or 12, of the same diameter and length as the damaged section of tubing. NOTE: TYPE 11 OR 12 NYLON SERVICE TUBING IS AVAILABLE IN 6.3MM (1/4"), 7.9MM (5/16") AND 9.5MM (3/8") DIAMETER SIZES. 4. Select the proper nylon barbed connector(s) for completing the splice... ^ 7.9mm (5/16") - Part Number (N806120-S) ^ 9.5mm (3/8") - Part Number (N806119-S) Two (2) in-line connectors are required for each splice. NOTE: TO MAKE INSERTION OF THE BARB CONNECTORS INTO THE NYLON LINE EASIER, THE TUBE END MAY BE SOAKED IN A CUP OF BOILING WATER FOR ONE (1) MINUTE BEFORE PUSHING THE BARB CONNECTOR INTO THE NYLON. USE ROTUNDA TOOL 134-000001 OR EQUIVALENT TO ASSIST IN ASSEMBLY. 5. Set up Rotunda Tool 134-000001 for in-line splice as shown in Figure 1. a. Select the proper inserts for the fuel line size and install into both sets of upper and lower block cavities. b. Connect the block cavity to the ratcheting rod of the Rotunda Tool with the slot in line with the slot in the ratcheting tool barrel c. Install both sets of upper and lower block cavities to the threaded rods of the ratcheting tool, Figure 1. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Supply Line: > 921216 > Jun > 92 > Nylon Fuel Lines - Servicing Procedure > Page 3748 d. Install one fuel line into the lower block cavity closest to the ratcheting end of the tool so that the extension of the fuel line is slightly greater than the barb length of the connector, Figure 2. e. Route the fuel line through the slot in the tool, Figure 2. f. Close the upper block cavity onto the lower block cavity and tighten the thumb screw securely. g. Place the replacement tubing in the forward lower block cavity and repeat Steps d and e. h. Place the barb connector between the ends of the lines to be spliced and ratchet the tool until the nylon line has covered all three (3) barbs of the connector on both ends. i. After completing the splice, unscrew the thumb screws and release the lines. Repeat Steps d through h on the opposite line end to complete the splice. 6. The completed fuel line splice is shown in Figure 3. 7. Install any remaining clips which were removed for this service. Check to be sure the fuel lines are secure in the original clips. 8. Start the engine and check for leaks. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Supply Line: > 921216 > Jun > 92 > Nylon Fuel Lines - Servicing Procedure > Page 3749 PART NUMBER PART NAME CLASS N806119-S Connector - Hose Push CG Connect (3/8") N806120-S Connector - Hose Push CG Connect (5/16") OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 404000, 490000 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Supply Line: > 8738 > Feb > 87 > Fuel Line Spring Lock Coupling - Service Procedures Fuel Supply Line: All Technical Service Bulletins Fuel Line Spring Lock Coupling - Service Procedures FUEL LINE SPRING LOCK COUPLING - SUMMARY Article No. OF SERVICE PROCEDURES AND REVISED TOOLS 87-3-8 FORD 1986 LTD 1986-87 ESCORT, EXP, MUSTANG, TAURUS, THUNDERBIRD, FORD LINCOLN-MERCURY 1986 MARQUIS, CAPRI 1986-87 LYNX, SABLE, COUGAR, MERCURY, MARK VII, CONTINENTAL, LINCOLN TOWN CAR LIGHT TRUCK 1985-87 RANGER, BRONCO II, E-SERIES, F-SERIES, BRONCO ISSUE: This article summarizes the overall service procedure to be used for disconnecting and connecting the fuel line spring lock coupling. In addition, the service tools and service part O-rings have been recently revised. The service tools (available March, 1987) D87L-9280-A (3/8") and D87L-9280-B (1/2") used to disconnect the spring lock coupling will now fit around the rubber cover on the fuel line allowing an easier disconnect. The O-ring part numbers were changed to specify color. The fuel resistant O-rings 390846-S96 (3/8") and 390847-S96 (1/2") will be BROWN in color while the A/C refrigerant Orings will continue to be BLACK. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Supply Line: > 8738 > Feb > 87 > Fuel Line Spring Lock Coupling - Service Procedures > Page 3754 Figure 5 ACTION: To properly disconnect and connect the fuel line spring coupling, use the illustrated service procedure on page 44 of this TSB, Figure 5. This illustration should also be used in place of the following 1985 through 1987 Car and Light Truck Shop Manual pages: 1985 Light Truck Shop Manual, Volume B, Section 24-05-16 / 24-05-17 1986 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Supply Line: > 8738 > Feb > 87 > Fuel Line Spring Lock Coupling - Service Procedures > Page 3755 Car Shop Manual, Volume D, Section 24-50-11 Car Shop Manual, Volume E, Section 24-50-14 Taurus/Sable Shop Manual, Section 24-50-11 Ranger/Bronco II Shop Manual, Section 24-03-11 Aerostar Shop Maunal, Section 9-06-15 / 9-06-16 Light Truck Shop Manual, Volume B, Section 24-05-16 / 24-50-35 1987 Car Shop Manual, Volume D, Section 24-50-11 Car Shop Manual, Volume E, Section 24-50-17 Taurus/Sable Shop Manual, Section 24-50-12 Ranger/Bronco II Shop Manual, Section 24-03-10 / 24-05-10 Aerostar Shop Manual, Section 9-02-10 / 9-06-17 / 9-06-18 Light Truck Shop Manual, Volume B, Section 24-05-14 / 24-10-9 / 27-10-20 / 24-50-34 NOTE: The following items should be noted when service is required. ^ Use the specified tool or equivalent. ^ Inspect for missing or damaged O-rings. ^ Use the specified fuel resistant O-rings (BROWN). ^ Lubricate the O-ring with clean engine oil. ^ Check to make sure that the fitting is locked. PART NUMBER PART NAME CLASS 390846-S96 O-Ring 3/8" (Brown) S 390847-S96 O-Ring 1/2" (Brown) S OTHER APPLICABLE ARTICLES: Supersedes 86-12-17, 86-12-13 WARRANTY STATUS: "INFORMATION ONLY" Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Supply Line: > 852227 > Nov > 85 > Fuel System Spring Lock Fitting - Proper Assembly Fuel Supply Line: All Technical Service Bulletins Fuel System Spring Lock Fitting - Proper Assembly Article No. 85-22-27 FUEL SYSTEM - PROPER ASSEMBLY TECHNIQUE FOR SPRING LOCK FITTING AT ENGINE FUEL SUPPLY AND RETURN LINE CONNECTIONS LIGHT TRUCK 1986 RANGER, BRONCO II, AEROSTAR, BRONCO, E & F SERIES The following additional information supplements the spring lock fuel connection removal and installation procedures in the Light Truck Shop Manual, Section 24-50 for E & F Series, Bronco, Ranger, and Bronco II; and 9-06 for Aerostar. At initial assembly, a white plastic indicator ring is used to assure proper assembly of the spring lock fitting at the fuel supply line connection to the engine fuel rail, and at the engine fuel return line connection. Figure 24 - PROPER ASSEMBLY TECHNIQUE FOR SPRING LOCK FITTING AT ENGINE/FUEL LINE INTERFACE - ALL EFI ENGINES After each of these two fitting connections are assembled, the white plastic indicator ring remains (loose) on the fuel line (as shown in Figure 24). Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Supply Line: > 852227 > Nov > 85 > Fuel System Spring Lock Fitting - Proper Assembly > Page 3760 When servicing these two spring lock fuel connections, and to assure proper reassembly of these connections, refer to the procedure outlined in Figure 24. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest: > 87717 > Apr > 87 > Fuel Gauge - Always Reads Full Fuel Gauge Sender: Customer Interest Fuel Gauge - Always Reads Full GAUGE - FUEL - ALWAYS READS "FULL" - Article No. 7.5L - MIDSHIP FUEL TANK 87-7-17 LIGHTTRUCK: 1985-86 F-250/350 Figure 15 - Article 87-7-17 ISSUE: A fuel gauge that always reads "full" may be caused by the float on the electric fuel pump sender catching on the internal fuel fill pipe inside the midship fuel tank. See Figure 15. ACTION: To correct this, install a new design fuel pump sender assembly, E5TZ- 9H307-L, with revised float travel that will not contact the internal fill pipe. PART NUMBER PART NAME CLASS E5TZ-9H307-L Sender and Fuel Pump A Assembly OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual OPERATION: SP870717A TIME: 0.9 Hr. DLR. CODING: Basic Part No. 9H307 - Code: 09 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 89146 > Jul > 89 > Fuel Tank Sending Unit - Connector Replacement Fuel Gauge Sender: All Technical Service Bulletins Fuel Tank Sending Unit - Connector Replacement FUEL SYSTEM-FUEL TANK SENDING UNIT-WIRE HARNESS CONNECTOR REPLACEMENT WIRING-FUEL TANK SENDING UNIT-CONNECTOR REPLACEMENT Article No. 89-14-6 FORD: 1985-89 CROWN VICTORIA, ESCORT 1985-88 EXP 1985-89 MUSTANG, TEMPO, THUNDERBIRD 1986-89 TAURUS LINCOLN-MERCURY: 1985-89 CONTINENTAL, COUGAR, GRAND MARQUIS 1985-87 LYNX 1985-89 MARK VII, TOPAZ, TOWN CAR 1986-89 SABLE LIGHT TRUCK: 1985-89 BRONCO II, ECONOLINE, F-150, F-250, F-350, RANGER Figure 1 ISSUE: Damaged fuel tank sending unit connectors can be serviced by splicing in a new wire harness connector. The new connector can be obtained by ordering the fuel tank sending unit wire harness and cutting off the connector. ACTION: Splice the new fuel tank sending unit connector to the existing wire harness. Refer to the following procedure for service details. 1. Disconnect the battery ground. 2. Cut the connector from the new harness. 3. Leave 6-8 inches of wiring lead on the connector. 4. Remove the old connector from the fuel tank sending unit. 5. Cut the connector off the vehicle's wire harness about 6-8 inches from the old connector. 6. Match the wire colors. 7. Install the new connector. Use a "Duraseal" butt splice connector, Figure 1. 8. Using a heat gun, seal the splice. CAUTION: DO NOT USE AN OPEN FLAME. 9. Connect the battery ground. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 89146 > Jul > 89 > Fuel Tank Sending Unit - Connector Replacement > Page 3775 10. Check the operation of the fuel gauge. PART NUMBER PART NAME CLASS E9FZ-9A400-A Wire Harness - Fuel Pump C OTHER APPLICABLE ARTICLES: 86-3-11 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 2300, 2310, 2400, 2770, 4500 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 87717 > Apr > 87 > Fuel Gauge - Always Reads Full Fuel Gauge Sender: All Technical Service Bulletins Fuel Gauge - Always Reads Full GAUGE - FUEL - ALWAYS READS "FULL" - Article No. 7.5L - MIDSHIP FUEL TANK 87-7-17 LIGHTTRUCK: 1985-86 F-250/350 Figure 15 - Article 87-7-17 ISSUE: A fuel gauge that always reads "full" may be caused by the float on the electric fuel pump sender catching on the internal fuel fill pipe inside the midship fuel tank. See Figure 15. ACTION: To correct this, install a new design fuel pump sender assembly, E5TZ- 9H307-L, with revised float travel that will not contact the internal fill pipe. PART NUMBER PART NAME CLASS E5TZ-9H307-L Sender and Fuel Pump A Assembly OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual OPERATION: SP870717A TIME: 0.9 Hr. DLR. CODING: Basic Part No. 9H307 - Code: 09 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 86163 > Aug > 86 > Fuel Pump/Sender - Erratic Operation Prevention Fuel Gauge Sender: All Technical Service Bulletins Fuel Pump/Sender - Erratic Operation Prevention Article No. 86-16-3 FUEL SYSTEM - FUEL PUMP/SENDER-APPLICATION OF GREASE TO ELECTRICAL TERMINALS FORD 1985-86 ESCORT, EXP, TEMPO, MUSTANG, LTD, THUNDERBIRD LINCOLN-MERCURY 1985-86 LYNX, TOPAZ, CAPRI, MARQUIS, COUGAR, MARK VII, CONTINENTAL LIGHT TRUCK 1985-86 RANGER, BRONCO II, AEROSTAR, BRONCO, E SERIES, F SERIES To prevent erratic operation of the fuel gauge or the in-tank fuel pump, a generous application of electrical grease should be applied to the terminals of the fuel pump/sender when service is required. The electrical grease will prevent corrosion and reduce the chance of a repeat repair. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge Sender: > 89146 > Jul > 89 > Fuel Tank Sending Unit - Connector Replacement Fuel Gauge Sender: All Technical Service Bulletins Fuel Tank Sending Unit - Connector Replacement FUEL SYSTEM-FUEL TANK SENDING UNIT-WIRE HARNESS CONNECTOR REPLACEMENT WIRING-FUEL TANK SENDING UNIT-CONNECTOR REPLACEMENT Article No. 89-14-6 FORD: 1985-89 CROWN VICTORIA, ESCORT 1985-88 EXP 1985-89 MUSTANG, TEMPO, THUNDERBIRD 1986-89 TAURUS LINCOLN-MERCURY: 1985-89 CONTINENTAL, COUGAR, GRAND MARQUIS 1985-87 LYNX 1985-89 MARK VII, TOPAZ, TOWN CAR 1986-89 SABLE LIGHT TRUCK: 1985-89 BRONCO II, ECONOLINE, F-150, F-250, F-350, RANGER Figure 1 ISSUE: Damaged fuel tank sending unit connectors can be serviced by splicing in a new wire harness connector. The new connector can be obtained by ordering the fuel tank sending unit wire harness and cutting off the connector. ACTION: Splice the new fuel tank sending unit connector to the existing wire harness. Refer to the following procedure for service details. 1. Disconnect the battery ground. 2. Cut the connector from the new harness. 3. Leave 6-8 inches of wiring lead on the connector. 4. Remove the old connector from the fuel tank sending unit. 5. Cut the connector off the vehicle's wire harness about 6-8 inches from the old connector. 6. Match the wire colors. 7. Install the new connector. Use a "Duraseal" butt splice connector, Figure 1. 8. Using a heat gun, seal the splice. CAUTION: DO NOT USE AN OPEN FLAME. 9. Connect the battery ground. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge Sender: > 89146 > Jul > 89 > Fuel Tank Sending Unit - Connector Replacement > Page 3789 10. Check the operation of the fuel gauge. PART NUMBER PART NAME CLASS E9FZ-9A400-A Wire Harness - Fuel Pump C OTHER APPLICABLE ARTICLES: 86-3-11 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 2300, 2310, 2400, 2770, 4500 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge Sender: > 86163 > Aug > 86 > Fuel Pump/Sender - Erratic Operation Prevention Fuel Gauge Sender: All Technical Service Bulletins Fuel Pump/Sender - Erratic Operation Prevention Article No. 86-16-3 FUEL SYSTEM - FUEL PUMP/SENDER-APPLICATION OF GREASE TO ELECTRICAL TERMINALS FORD 1985-86 ESCORT, EXP, TEMPO, MUSTANG, LTD, THUNDERBIRD LINCOLN-MERCURY 1985-86 LYNX, TOPAZ, CAPRI, MARQUIS, COUGAR, MARK VII, CONTINENTAL LIGHT TRUCK 1985-86 RANGER, BRONCO II, AEROSTAR, BRONCO, E SERIES, F SERIES To prevent erratic operation of the fuel gauge or the in-tank fuel pump, a generous application of electrical grease should be applied to the terminals of the fuel pump/sender when service is required. The electrical grease will prevent corrosion and reduce the chance of a repeat repair. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Page 3794 Fuel Gauge Sender: Locations Top Of Fuel Tank Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Page 3795 Fuel Gauge Sender: Description and Operation DESCRIPTION AND OPERATION FUEL LEVEL INDICATING SYSTEM The fuel indicating system is a bimetal-resistance type system. It consists of an instrument voltage regulator, fuel indicator (gauge) mounted in the instrument cluster and a sender located in the fuel tank, INSTRUMENT VOLTAGE REGULATOR The instrument voltage regulator (IVR) used with the fuel indicator (gauge) controls and maintains an average pulsating voltage of 5.0 volts at the gauge terminals. FUEL INDICATOR (GAUGE) The fuel indicator gauge pointer is attached to a wire wound bimetal strip which when heated by the flow of electrical current controlled by the sender unit, produoes the appropriate indication. Fuel Indicating System Using A Bimetal Gauge - Typical FUEL SENDER The fuel sender consists of a variable screened resistor made up of a ceramic substrate. It is controlled by the action of an attached float in the fuel tank. When the fuel level is low, resistance in the sender is high and allows only a low current to flow through the indicator (gauge) windings, causing the pointer to move a short distance. When the fuel level is high, the resistance in the sender is low and allows a higher current flow and a greater heating effect causing the pointer to move a greater distance. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Page 3796 Fuel Gauge Sender: Testing and Inspection DIAGNOSIS AND TESTING WARNING: DO NOT REMOVE THE NIPPLE ON THE END OF THE FUEL RETURN LINE. IT IS THERE TO PREVENT FUEL FROM DRAINING OUT OF THE TANK IN THE EVENT OF A ROLLOVER. NOTE: On vehicles equipped with diesel engines and dual fuel tanks, refer to the diagnosis guide in this Section before proceeding with the calibration testing. CAUTION: DO NOT INTERCHANGE SENDING UNITS BETWEEN GASOLINE-AND DIESEL-POWERED VEHICLES. DOING SO MAY CAUSE SEVERE ENGINE AND FUEL SYSTEM DAMAGE. CALIBRATION TEST (USING ROTUNDA TESTER MODEL 021-00034) Fuel Indicating System Test With Rotunda Tester Model 21-0015 Or Equivalent The Rotunda Instrument Gauge System Tester Model 021-00034 or equivalent is used to diagnose problems in all fuel indicating systems using the bimetal fuel indicator gauge and instrument voltage regulator (IVR). Prior to performing fuel system test the following tester checks should be made. 1. Set tester switch at IVR CHECK position. 2. Attach tester ground wire to the negative (-) terminal of 12-volt battery and touch one of the tester terminals marked with an arrow to the positive (+) battery terminal. 3. If the IVR check lamp does not come on, return tester for service or replacement. TEST SET-UP Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Page 3797 CAUTION: DURING IN-VEHICLE TESTS, Do NOT LET TESTER TERMINAL STUDS DESIGNATED BY ARROWS COME IN CONTACT WITH VEHICLE GROUND. THE FUEL GAUGE WILL BE SHORTED TO GROUND, PREVENTING AN ACCURATE TEST AND POSSIBLY DAMAGING THE IVR OR GAUGE. 1. Disconnect connector from fuel sender and hook onto the matching terminals on the tester (Fig. 4). 2. Turn vehicle ignition switch to ACC position. FUNCTIONAL TEST NOTE: The IVR also supplies a common regulated voltage for the temperature gauge indicating system and oil gauge indicating system (when applicable); therefore, the IVR can only be damaged if the other gauges exhibit similar problems (fluctuating movement or high or low indications at the upper calibration band). The IVR has little effect on the lower calibration band of the indicator. 1. Set test switch to IVR check position. 2. If IVR check lamp flashes on and off, the IVR and wiring are functional. Proceed to calibration check. 3. If IVR check lamp is on steady, check IVR ground screw. If ground screw is secure, replace IVR 4. If IVR check lamp does not come on, check for open circuit in gauge and/or circuit wiring. CALIBRATION CHECK With the tester switch in either the HIGH or LOW position, the center line of the gauge pointer should be within the "F" or "E" white band of the graphics for the fuel test function as shown on the tester. If the center line of the pointer registers in the white bands, the fuel indicating system is operating properly and replacement of the fuel sender is necessary. If the pointer center line falls outside the "E" white band, replace the fuel gauge. If the pointer center line falls outside the "F" white band, replace the IVR and retest. If still outside the upper white band, replace the fuel gauge reinstall the original IVR and retest for calibration. CALIBRATION TEST (WITHOUT TESTER) If only the fuel gauge is inoperative or appears to be out of calibration, a calibration test can be conducted on the vehicle fuel gauge system. The calibration test checks the fuel gauge and IVR simultaneously. The required test equipment consists of a 10 ohm resistor and a 73 ohm resistor. Disconnect the wiring connector at the sender unit. Connect one of the resistors between the lead wire terminal and ground, and turn the ignition switch to the ON or ACC position With the 10 ohm resistor, the gauge should indicate a full-scale reading. With the 73 ohm resistor, the gauge should read at the E graduation mark. Without any resistor (open circuit) the gauge reading should be the same as with the ignition switch in the OFF position. If reading is OK, replace wire connection to sender. If the gauge pointer does not move and stays below the E mark, check for an open circuit in the wiring assembly, the gauge windings, or the instrument cluster printed circuit. If the gauge pointer moves without any resistor connected, check for a short circuit in the lead to the sender unit. If the gauge reads out of calibration, replace IVR and retest. If still out of calibration, replace the gauge. GAUGE BENCH TEST FOR OPEN WINDINGS To test the gauge for open windings, remove the gauge from the vehicle. Connect the gauge to an ohmmeter and read the resistance. An upward movement of the needle from 10 to 14 ohms is normal, because the current increases the temperature of the gauge coil (windings). If the ohmmeter reads below 10 ohms or above 14 ohms, replace the gauge. FUEL TANK DAMAGE If fuel indicating system components are functioning properly and inaccurate indications continue, check the fuel tank for damage which may have changed the fuel sender mounting angle and/or damaged the fuel sender. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Selector Switch > Component Information > Locations > Fuel Tank Selector Switch Fuel Tank Selector Switch: Locations Fuel Tank Selector Switch On Instrument Panel Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Selector Switch > Component Information > Locations > Fuel Tank Selector Switch > Page 3802 Fuel Tank Selector Switch: Locations Fuel Tank Selector Relay LH Corner Of Dash Panel Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Selector Switch > Component Information > Diagrams > Diagram Information and Instructions Fuel Tank Selector Switch: Diagram Information and Instructions Symbol Identification Wire Color Code Identification Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Selector Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3805 NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Selector Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3806 Fuel Tank Selector Switch: Electrical Diagrams Fig. 26 Fuel Tank Selector & Gauges Wiring Circuit. Models W/6-300 (4.9L) & V8-351 (5.8L) Engines With 8,500 GVW Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Selector Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3807 Fig. 27 Fuel Tank Selector & Gauges Wiring Circuit. F150-350 W/V8-351 (5.8L) & V8-460 (7.5L) Engines & Dual Tanks (Less Electric Fuel Pumps) Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Switching Valve > Component Information > Technical Service Bulletins > Fuel Tank Switching Valve - Service Tips Fuel Tank Switching Valve: Technical Service Bulletins Fuel Tank Switching Valve - Service Tips Article No. 91-7-11 04/05/91 ^ FUEL SYSTEM - DUAL FUNCTION RESERVOIR - ALL EFI ENGINES WITH DUAL FUEL TANKS - SERVICE TIPS ^ LEAKS - GASOLINE SPILLAGE - DUAL FUNCTION RESERVOIR - ALL EFI ENGINES WITH DUAL FUEL TANKS LIGHT TRUCK: 1986-89 F-150-350 SERIES 1988-91 ECONOLINE ISSUE: Some fuel spillage may occur while servicing the dual function reservoir when the fuel lines are disconnected. This happens because the dual fuel tank switching valve does not completely shut off the fuel supply. ACTION: To minimize the possibility of fuel spillage when servicing the dual function reservoir (DFR), use the following service procedure. 1. Remove the six (6) plastic fuel line retaining clips from the original dual function reservoir. Do not remove the DFR from the frame at this time. 2. Remove one fuel line at a time and immediately reinstall on the corresponding port of the replacement DFR (F1UZ-9B263-A). a. Install one new plastic fuel line retaining clip (N802241-S). b. Make sure that it is properly seated. 3. Repeat Step # 2 for the remaining fuel lines. 4. Remove the original DFR from the frame rail. NOTE: SEND THE ORIGINAL DUAL FUNCTION RESERVOIR TO THE WARRANTY PARTS RETURN CENTER, 1285 S. MILL ST., PLYMOUTH, MI 48170. 5. Install the new DFR, with all fuel lines and retaining clips attached, to the frame rail. 6. Start the engine and check for fuel leaks. 7. Switch the fuel tanks and repeat the leak check. PART NUMBER PART NAME CLASS N802241-S Fuel Line Retaining Clip (Pkg. BG of 14) F1UZ-9B263-A Dual Function Reservoir B OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION DESCRIPTION TIME 910711A Install Dual Function 0.5 Hr. Reservoir DEALER CODING BASIC PART NO. CONDITION CODE 9B263 73 OASIS CODES: 404000 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Switching Valve > Component Information > Technical Service Bulletins > Page 3812 Fuel Tank Switching Valve: Locations Behind Cab, On LH Frame Member Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Switching Valve > Component Information > Diagrams > Diagram Information and Instructions Fuel Tank Switching Valve: Diagram Information and Instructions Symbol Identification Wire Color Code Identification Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Switching Valve > Component Information > Diagrams > Diagram Information and Instructions > Page 3815 NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Switching Valve > Component Information > Diagrams > Diagram Information and Instructions > Page 3816 Fuel Tank Switching Valve: Electrical Diagrams Fig. 26 Fuel Tank Selector & Gauges Wiring Circuit. Models W/6-300 (4.9L) & V8-351 (5.8L) Engines With 8,500 GVW Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Switching Valve > Component Information > Diagrams > Diagram Information and Instructions > Page 3817 Fig. 27 Fuel Tank Selector & Gauges Wiring Circuit. F150-350 W/V8-351 (5.8L) & V8-460 (7.5L) Engines & Dual Tanks (Less Electric Fuel Pumps) Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank Unit > Component Information > Technical Service Bulletins > Customer Interest for Fuel Tank Unit: > 87717 > Apr > 87 > Fuel Gauge Always Reads Full Fuel Tank Unit: Customer Interest Fuel Gauge - Always Reads Full GAUGE - FUEL - ALWAYS READS "FULL" - Article No. 7.5L - MIDSHIP FUEL TANK 87-7-17 LIGHTTRUCK: 1985-86 F-250/350 Figure 15 - Article 87-7-17 ISSUE: A fuel gauge that always reads "full" may be caused by the float on the electric fuel pump sender catching on the internal fuel fill pipe inside the midship fuel tank. See Figure 15. ACTION: To correct this, install a new design fuel pump sender assembly, E5TZ- 9H307-L, with revised float travel that will not contact the internal fill pipe. PART NUMBER PART NAME CLASS E5TZ-9H307-L Sender and Fuel Pump A Assembly OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual OPERATION: SP870717A TIME: 0.9 Hr. DLR. CODING: Basic Part No. 9H307 - Code: 09 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank Unit > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Tank Unit: > 87717 > Apr > 87 > Fuel Gauge - Always Reads Full Fuel Tank Unit: All Technical Service Bulletins Fuel Gauge - Always Reads Full GAUGE - FUEL - ALWAYS READS "FULL" - Article No. 7.5L - MIDSHIP FUEL TANK 87-7-17 LIGHTTRUCK: 1985-86 F-250/350 Figure 15 - Article 87-7-17 ISSUE: A fuel gauge that always reads "full" may be caused by the float on the electric fuel pump sender catching on the internal fuel fill pipe inside the midship fuel tank. See Figure 15. ACTION: To correct this, install a new design fuel pump sender assembly, E5TZ- 9H307-L, with revised float travel that will not contact the internal fill pipe. PART NUMBER PART NAME CLASS E5TZ-9H307-L Sender and Fuel Pump A Assembly OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual OPERATION: SP870717A TIME: 0.9 Hr. DLR. CODING: Basic Part No. 9H307 - Code: 09 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Technical Service Bulletins > Customer Interest for Idle Speed/Throttle Actuator Electronic: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up Technical Service Bulletin # 91257 Date: 911213 Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up Article No. 91-25-7 12/13/91 ^ HARD COLD START - DURING INITIAL START-UP, IDLE OR DECEL - EFI ENGINES SLUDGE IN THROTTLE BODY AND/OR IDLE AIR BY-PASS VALVE ^ HESITATION/STALLS - DURING INITIAL START-UP, IDLE OR DECEL - EFI ENGINES SLUDGE IN THROTTLE BODY AND/OR IDLE AIR BY-PASS VALVE FORD: 1983-87 EXP 1983-91 ESCORT 1984-90 MUSTANG, THUNDERBIRD 1986-90 TAURUS 1986-91 CROWN VICTORIA 1988-90 TEMPO LINCOLN-MERCURY: 1983-85 LN7 1983-87 LYNX 1984-88 CAPRI 1984-90 COUGAR 1986-90 CONTINENTAL, MARK VII, SABLE 1986-91 GRAND MARQUIS, TOWN CAR 1988-90 TOPAZ 1991 TRACER LIGHT TRUCK: 1985-90 BRONCO II, BRONCO 1985-91 ECONOLINE, F-150-350 SERIES 1985-92 RANGER 1986-91 AEROSTAR 1991 EXPLORER ISSUE: Hard cold starts, hesitation and stalls on initial start-up or during idle or decel may be caused by sludge in the throttle body and/or idle by-pass valve. Sludge deposits or oil film on the throttle body bore and plate or the idle air by-pass valve may cause one or more of the following conditions. ^ Hard Cold Start ^ Stall On Initial Start-Up ^ Stall During Idle ^ Stall During Decel ^ Rough Idle ^ Rolling Idle ^ Hesitation During Acceleration ACTION: A new idle air by-pass service kit (F2PZ-9F939-A) is now available for service use to correct sludge contamination concerns of the throttle bore and plate only. It eliminates the need to clean the majority of past model throttle body applications. Cleaning is not required on sludge tolerant throttle body designs released for 1991 and newer model years. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Technical Service Bulletins > Customer Interest for Idle Speed/Throttle Actuator Electronic: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3839 Figure 1 Install an idle air by-pass service kit (F2PZ-9F939-A) as applicable to provide a permanent correction for symptoms caused by throttle body sludge deposits. Refer to the instruction sheet included in the kit for installation details. Refer to Figure 1 for a specific application list of EFI (port fuel Injection) engines involved in this TSB article. The idle air by-pass service kit (F2PZ-9F939-A) includes the following items. ^ One (1) Idle Adjust Spacer ^ Two (2) Gaskets Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Technical Service Bulletins > Customer Interest for Idle Speed/Throttle Actuator Electronic: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3840 ^ Two (2) Attaching Bolts ^ One (1) "Attention" Sticker ^ One (1) Instruction Sheet Figure 2 Refer to Figure 2 for a pictorial of the kits components. NOTE: EFFECTIVE WITH THIS TSB, THROTTLE BODY CLEANING IS NO LONGER COVERED UNDER 5/50 EMISSIONS WARRANTY, UNLESS AS SPECIFIED IN THE FOLLOWING APPLICATION CHARTS. FAILURE TO FOLLOW THE CORRECT PROCEDURE MAY RESULT IN THE CLAIM BEING DISALLOWED. The idle air adjust spacer incorporates sludge tolerant design features that eliminate throttle body sludge related conditions. Once installed, throttle body cleaning is not allowed and periodic adjustment of the throttle body is not required. Procedures, Warranty and Labor CHECKS TO MAKE PRIOR TO SERVICE KIT INSTALLATION Confirm that the following items are not causing the idle quality concern before proceeding with the service kit installation. ^ Contamination within the idle air by-pass solenoid ^ Lack of fuel system control (excessively rich or lean) ^ Ignition timing change ^ Incorrect or malfunctioning EGR system ^ Incorrect or malfunctioning cooling system ^ Vacuum leaks (air intake manifold, vacuum hoses, vacuum reservoirs, power brake booster where applicable) ^ EEC diagnostics have been performed and vehicle malfunction indicated service output codes have been resolved and cleared. If any of the areas listed above are found to be at fault, correct them before proceeding with the service kit installation. Idle Speed Adjustment Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Technical Service Bulletins > Customer Interest for Idle Speed/Throttle Actuator Electronic: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3841 WARNING: BEFORE PROCEEDING WITH THE IDLE SPEED ADJUSTMENT, VERIFY THAT THE FOLLOWING ITEMS ARE TAKEN CARE OF PROPERLY. ^ The transmission is in PARK or Neutral. ^ The parking brake is applied. ^ The wheels are properly blocked. ^ The engine is at operating temperature. ^ The heater, A/C, cooling fan and other accessories are OFF. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Technical Service Bulletins > Customer Interest for Idle Speed/Throttle Actuator Electronic: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3842 Figure 3 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Technical Service Bulletins > Customer Interest for Idle Speed/Throttle Actuator Electronic: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3843 Figure 4 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Technical Service Bulletins > Customer Interest for Idle Speed/Throttle Actuator Electronic: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3844 Figure 5 The EFI throttle body idle speed adjustment procedures for the various model year passenger cars and light trucks are outlined in step-by-step procedures featured in Figures 3, 4 and 5. Select the appropriate procedure for the vehicle involved and adjust the throttle body idle RPM accordingly, after service kit installation. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Technical Service Bulletins > Customer Interest for Idle Speed/Throttle Actuator Electronic: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3845 Figure 6 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Technical Service Bulletins > Customer Interest for Idle Speed/Throttle Actuator Electronic: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3846 Figure 7 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Technical Service Bulletins > Customer Interest for Idle Speed/Throttle Actuator Electronic: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3847 Figure 8 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Technical Service Bulletins > Customer Interest for Idle Speed/Throttle Actuator Electronic: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3848 Figure 9 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Technical Service Bulletins > Customer Interest for Idle Speed/Throttle Actuator Electronic: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3849 Figure 10 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Technical Service Bulletins > Customer Interest for Idle Speed/Throttle Actuator Electronic: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3850 Figure 11 THROTTLE BODY AND IDLE AIR BY-PASS SOLENOID SERVICE PROCEDURE Detailed application charts for throttle body and idle air by-pass solenoid service procedures by engine VIN # /engine displacement/vehicle application and model year are shown in Figures 6 through 11. Refer to these charts to see if the service kit is to be installed and which service cleaning procedure, if any, is to be used. SERVICE CLEANING PROCEDURES The following items should be noted prior to beginning the service cleaning procedure. ^ Confirm that the correct service cleaning procedure is identified in the Application Charts, Figures 6-11, for the vehicle/engine combination being Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Technical Service Bulletins > Customer Interest for Idle Speed/Throttle Actuator Electronic: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3851 serviced. ^ Do not clean throttle bodies identified to accept service kit (F2PZ-9F939-A), IDLE AIR ADJUST SPACER. ^ Use a 1" (25.4 mm) to 1-1/2" (38.1 mm) wire stemmed horse hair or nylon bottle cleaner type brush. ^ Use rubber gloves and eye protection. ^ Do not clean throttle bodies identified with a yellow/black "ATTENTION" label. ^ Do not clean "Black" plastic air by-pass valves. Refer to TSB 89-13-8 for service details. ^ Do not run vehicles with air flow meters when the air duct is removed. ^ Do not use carburetor cleaner as a cleaning solvent. Use Carburetor Tune-up Cleaner (D9AZ-19579-AA). Procedure # 1 THROTTLE BODY AND IDLE AIR BY-PASS VALVE CLEANING CAUTION: DO NOT RUN VEHICLES EQUIPPED WITH AIR FLOW METERS DURING THE CLEANING PROCEDURE. IF THERE IS A YELLOW/BLACK "ATTENTION" LABEL ON THE THROTTLE BODY ADVISING NOT TO CLEAN, OR IF THE VEHICLE IS IDENTIFIED AS ACCEPTING SERVICE KIT (F2PZ-9F939-A), USE PROCEDURE # 2 FOR IDLE AIR BY-PASS VALVE CLEANING ONLY. 1. Plug the actuator into the connector in the Rotunda Cleaner/Tester, Tool 113-00009. 2. Remove the air duct to the throttle body inlet. 3. Disoonnect the idle air by-pass valve signal lead. 4. Attach the actuator harness plug to the idle air by-pass valve. 5. Start the actuator and then start the engine. Do not start engines that have air flow meters. 6. Spray just enough Carburetor Tune-up Cleaner (D9AZ-19579-AA) into the throttle bore to wet the bore and throttle plate. 7. Spray the Carburetor Tune-up Cleaner for about five (5) seconds into the idle air by-pass valve inlet passage while the actuator is operating. 8. Stop the engine and actuator. Let everything soak for fifteen (15) minutes. 9. After a fifteen (15) minute soak, saturate the cleaning brush with solvent and scrub between the throttle body bore and plate while holding the throttle wide open. NOTE: IT IS NECESSARY TO APPLY SOME PRESSURE ON THE BRUSH WHILE SCRUBBING. 10. Repeat saturating the brush and scrubbing for one (1) to two (2) minutes, making sure to reach into the corners where the throttle shaft meets the bore wall. 11. Start the actuator and the start the engine. Do not start engines that have air flow meters. 12. Spray Carburetor Tune-up Cleaner into the throttle bore for up to one (1) minute to wash away residue. Do not spray for longer than six (6) continuous seconds on engines that have air flow meters and are not running. 13. Spray Carburetor Tune-up Cleaner into the idle by-pass valve passage leading to the inlet of the valve for up to one (1) minute. Do not spray for longer than six (6) continuous seconds on engines that have air flow meters and are not running. 14. Stop actuator and stop engine, if running. NOTE: MAKE SURE THE THROTTLE PLATES OPERATE FREELY AND CLOSE PROPERLY. 15. Reinstall the air duct. 16. Start and run the engine for about one (1) minute to dry out the solvent residue. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Technical Service Bulletins > Customer Interest for Idle Speed/Throttle Actuator Electronic: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3852 17. Operate the actuator to make sure the solvent is purged from the idle by-pass valve. 18. Disconnect the actuator from the idle air by-pass valve. 19. Reattach the control signal lead to the air by-pass valve. 20. Check engine for normal operation. It may be necessary to reset the idle speed due to a previous adjustment for an idle concern. (Refer to the respective Powertrain/Emissions Diagnosis Service Manual, Throttle Body Section, for idle speed adjust procedure.) Procedure # 2 Idle Air By-Pass Valve Cleaning Only CAUTION: THIS CLEANING PROCEDURE MAY BE USED WITH SLUDGE TOLERANT THROTTLE BODIES WHICH ARE IDENTIFIED WITH A YELLOW/BLACK "ATTENTION" LABEL AND THOSE USING SERVICE KIT (F2PZ-9F939-A). NO ATTEMPT SHOULD BE MADE TO CLEAN THROTTLE BODY BORE/PLATE AREA BY DIRECT SPRAYING OR SCRUBBING. DO NOT RUN VEHICLES WITH AIR FLOW METERS DURING CLEANING PROCEDURE. 1. Plug the actuator into the connector in the Rotunda Air By-Pass Valve Adapter 113-00009, or equivalent. 2. Remove the air duct to the throttle body inlet. 3. Disconnect the idle air by-pass valve signal lead. 4. Attach the actuator harness plug to the idle air by-pass valve. 5. Start the actuator and then start the engine. NOTE: DO NOT START ENGINES THAT HAVE AIR FLOW METERS. 6. Spray the Carburetor Tune-up Cleaner for about five (5) seconds into the idle air by-pass valve inlet passage while the actuator is operating. CAUTION: AVOID DIRECT SPRAYING ON THROTTLE PLATE/BORE AREA. 7. Stop the engine and actuator. Let everything soak for fifteen (15) minutes. 8. Start the actuator and the start the engine. CAUTION: DO NOT START ENGINES THAT HAVE AIR FLOW METERS. 9. Spray Carburetor Tune-up Cleaner into the throttle bore for up to one (1) minute. CAUTION: DO NOT SPRAY FOR LONGER THAN SIX (6) CONTINUOUS SECONDS ON ENGINES THAT HAVE AIR FLOW METERS AND ARE NOT RUNNING. 10. Stop actuator and stop engine if running. 11. Reinstall the air duct. 12. Start and run the engine for about one (1) minute to dry out the solvent residue. 13. Operate the actuator to make sure the solvent is purged from the idle by-pass valve. 14. Disconnect the actuator from the idle air by-pass valve. 15. Reattach the control signal lead to the air by-pass valve. 16. Check engine for normal operation. NOTE: IT SHOULD NOT BE NECESSARY TO RESET THE IDLE SPEED SINCE ONLY THE IDLE AIR BY-PASS VALVE WAS SERVICED IN THIS PROCEDURE Warranty Coverage Throttle bodies and idle air by-pass valves on all EFI (Port Fuel Injection) engines through the 1992 model year that can be cleaned (as identified in the application charts) are covered under 5/50 Emissions Warranty Coverage. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Technical Service Bulletins > Customer Interest for Idle Speed/Throttle Actuator Electronic: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3853 For those throttle bodies identified as having sludge tolerant designs or using service kit (F2PZ-9F939-A) where cleaning is not allowed per the application charts, the warranty claims for cleaning will not be reimbursed even within the 12/12 warranty coverage period. Cleaning is not allowed. Service kit installation (single time) is covered under 5/50 emission warranty. Labor Standards Operations The labor operations shown in the following Operation/Description/Time columns are identified by procedure number and vehicle line. Specific engines for various vehicles are identified in the sludge cleaning procedure application charts. The throttle body cleaning operations with combinations and the air by-pass valve cleaning combinations will appear in future Labor Manuals under the following operation numbers. ^ 9926 B - Throttle body and idle air by-pass valve cleaning ^ 9926 B2 - Adjust idle speed ^ 9715 A - Air by-pass valve cleaning only ^ 9715 A1 - Adjust idle speed PART NUMBER PART NAME CLASS F2PZ-9F939-A Idle Air By-pass Service Kit B D9AZ-19579-AA Carburstor Tune-Up Cleaner BG OTHER APPLICABLE ARTICLES: 89-13-8 SUPERSEDES: 88-24-5, 88-24-6, 89-16-5, 91-10-9, 91-7-4 Operation Description WARRANTY STATUS: Eligible Under Warranty Coverage As Stated In The Text Of This Article OPERATION DESCRIPTION TIME 912507A Idle Air By-Pass Valve 0.5 Hr. Cleaning - 1983-85 Escort, EXP, LN7, LYNX 1.6L EFI. 912507B Idle Air By-Pass Valve 0.5 Hr. Cleaning - 1986-91 Escort 1.9L EFI, 1986/87 EXP, Lynx 1.9L EFI, 1991 Tracer 1.9L EFI. 912507C Idle Air By Pass Valve 0.5 Hr. Cleaning - 1984-87 Mustang 2.3L T/C, 1986/87 Capri, Cougar 2.3L T/C, 1984-88 T-Bird 2.3L T/C, 1987/92 Mustang 2.3L EFI. 912507D Idle By-Pass Valve Cleaning 0.6 Hr. - 1988-91 Tempo, Topaz 2.3L HSC, 1985-92 Ranger 2.3L EFI. 912507E Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1986/87 Aerostar 2.3L EFI, 1985 Bronco II 2.3L EFI. 912507F Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1986-90 Bronco II 2.9L EFI, 1986-92 Ranger 2.9L EFI. 912507G Idle Air By-Pass Valve 0.6 Hr. Cleaning - 1991/92 Probe 3.0L EFI, 1986-91 Taurus 3.0L EFI, 1987-91 Sable 3.0L EFI. 912507H Idle Air By-Pass Valve 0.7 Hr. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Technical Service Bulletins > Customer Interest for Idle Speed/Throttle Actuator Electronic: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3854 Cleaning - 1986-91 Aerostar 3.0L EFI, 1991 Ranger 3.0L EFI. 912507I Idle Air By-Pass Valve 0.6 Hr. Cleaning - 1988 Continental, Cougar, Taurus, T-Bird, Sable 3.8L EFI. 1988 Cougar, T-Bird 3.8L S/C. 912507J Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1990-92 Aerostar 4.0L EFI, 1990 Bronco II 4.0L EFI, 1991/92 Explorer 4.0L EFI, 1990-92 Ranger 4.0L EFI. 912507K Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1987-92 Bronco 4.9L EFI, 1987-92 F-Series 4.9L EFI, 1987/90 Econoline (Without Rear Heater) 4.9L EFI, 1991/92 Econoline (All) 4.9L EFI. 912507L Idle Air By-Pass Valve 0.6 Hr. Cleaning - 1986-88 Cougar, T-Bird 5.0L EFI, 1986-87 Continental, Mark VII 5.OL EFI, 1986/91 Crn - Victoria, Grn - Marquis 5.0L EFI, 1986-92 Mark VII 5.0L HO, 1982-92 Mustang 5.0L HO. 912507M Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1985-92 Bronco, E-Series, F-Series 5.0L EFI. 912507N Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1988-90 Bronco, F-Series 5.8L. 1991 Econo, F-Series, Bronco 5.8L (Do not Clean Solenoid, Calib; 1-64E-R10, 1-64H-R10, 1-64J-R10, 1-64K-R10, 1-64M-R10, 1-64P-R10, 1-64R-R10, 1-75A-R00, 1-76A-R00, 1-76B-R00, 1-76C-R00. 912507O Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1991/92 F And B Series, 7.0L EFI. 912507P Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1987-92 E-Series, F-Series 7.5L EFI. 912507Q Throttle Body And Idle Air 0.9 Hr. By-Pass Valve Cleaning - 1989/90 Probe 3.0L EFI. 912507R Throttle Body And Idle Air 0.8 Hr. By-Pass Valve Cleaning - 1987-90 Econoline (With Rear Heat) 4.9L EFI. 912507S Throttle Body And Idle Air 0.9 Hr. By-Pass Valve Cleaning - 1988-90 Econoline 5.8L EFI. 912507T Service Kit Install - All Cars 1.0 Hr. And Light Trucks (Except Aerostar And Econoline) - Refer To The Service Procedure Application Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Technical Service Bulletins > Customer Interest for Idle Speed/Throttle Actuator Electronic: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3855 Charts, For Vehicle Application. 912507U Service Kit Install - 1.2 Hr. Aerostar, Econoline - Refer To Service Procedure Application Charts - For Vehicle Application. DEALER CODING BASIC PART NO. CONDITION CODE 9E926 49 OASIS CODES: 602300, 607000, 607400, 607700, 608400, 611500, 618400 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Technical Service Bulletins > Customer Interest for Idle Speed/Throttle Actuator Electronic: > 89244 > Dec > 89 > Engine - Rough Idling Condition Idle Speed/Throttle Actuator - Electronic: Customer Interest Engine - Rough Idling Condition ^ FUEL SYSTEM-EFI ENGINES - AIR BY-PASS VALVE REPLACEMENT PART INOPERATIVE ^ IDLE - ROUGH-REPLACEMENT AIR BY-PASS VALVE INOPERATIVE Article No. 89-24-4 FORD: 1983-88 ESCORT, EXP, THUNDERBIRD 1984-88 MUSTANG 1986-88 CROWN VICTORIA, TAURUS 1988 TEMPO LINCOLN-MERCURY: 1983 LN7 1983-86 LYNX 1983-88 COUGAR 1984-86 CAPRI 1986-88 CONTINENTAL, GRAND MARQUIS, MARK VII, SABLE, TOWN CAR 1988 TOPAZ MERKUR: 1985-88 XR4TI 1988 SCORPIO LIGHT TRUCK: 1985-88 BRONCO, F-150, F-250, RANGER 1986-88 AEROSTAR, BRONCO II, ECONOLINE 1987-88 F-350 1988 F SUPER DUTY Figure 1 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Technical Service Bulletins > Customer Interest for Idle Speed/Throttle Actuator Electronic: > 89244 > Dec > 89 > Engine - Rough Idling Condition > Page 3860 ISSUE: A rough idle created when the air by-pass valve is replaced may be caused by a revision made to the valve's wiring harness. Vehicles built before the 1989 model year had a diode in the air by-pass valve wiring harness. The new replacement valves have a 3D marking on the plastic portion of the solenoid, above the connector cap, Figure 1. They have a diode in the air by-pass valve. On the air by-pass valves used on vehicles built before the 1989 model year, the positive and negative leads are not important to the operation of the valve. However, the polarity on the new replacement air by-pass valve is important because if the wiring harness is reversed the air by-pass valve will not work. ACTION: Reverse the wires in the air by-pass valve connector and retest the valve. Refer to the following EFI Engine Application Chart for engines using these air by-pass valves. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 620800 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed/Throttle Actuator - Electronic: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up Technical Service Bulletin # 91257 Date: 911213 Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up Article No. 91-25-7 12/13/91 ^ HARD COLD START - DURING INITIAL START-UP, IDLE OR DECEL - EFI ENGINES SLUDGE IN THROTTLE BODY AND/OR IDLE AIR BY-PASS VALVE ^ HESITATION/STALLS - DURING INITIAL START-UP, IDLE OR DECEL - EFI ENGINES SLUDGE IN THROTTLE BODY AND/OR IDLE AIR BY-PASS VALVE FORD: 1983-87 EXP 1983-91 ESCORT 1984-90 MUSTANG, THUNDERBIRD 1986-90 TAURUS 1986-91 CROWN VICTORIA 1988-90 TEMPO LINCOLN-MERCURY: 1983-85 LN7 1983-87 LYNX 1984-88 CAPRI 1984-90 COUGAR 1986-90 CONTINENTAL, MARK VII, SABLE 1986-91 GRAND MARQUIS, TOWN CAR 1988-90 TOPAZ 1991 TRACER LIGHT TRUCK: 1985-90 BRONCO II, BRONCO 1985-91 ECONOLINE, F-150-350 SERIES 1985-92 RANGER 1986-91 AEROSTAR 1991 EXPLORER ISSUE: Hard cold starts, hesitation and stalls on initial start-up or during idle or decel may be caused by sludge in the throttle body and/or idle by-pass valve. Sludge deposits or oil film on the throttle body bore and plate or the idle air by-pass valve may cause one or more of the following conditions. ^ Hard Cold Start ^ Stall On Initial Start-Up ^ Stall During Idle ^ Stall During Decel ^ Rough Idle ^ Rolling Idle ^ Hesitation During Acceleration ACTION: A new idle air by-pass service kit (F2PZ-9F939-A) is now available for service use to correct sludge contamination concerns of the throttle bore and plate only. It eliminates the need to clean the majority of past model throttle body applications. Cleaning is not required on sludge tolerant throttle body designs released for 1991 and newer model years. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed/Throttle Actuator - Electronic: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3866 Figure 1 Install an idle air by-pass service kit (F2PZ-9F939-A) as applicable to provide a permanent correction for symptoms caused by throttle body sludge deposits. Refer to the instruction sheet included in the kit for installation details. Refer to Figure 1 for a specific application list of EFI (port fuel Injection) engines involved in this TSB article. The idle air by-pass service kit (F2PZ-9F939-A) includes the following items. ^ One (1) Idle Adjust Spacer ^ Two (2) Gaskets Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed/Throttle Actuator - Electronic: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3867 ^ Two (2) Attaching Bolts ^ One (1) "Attention" Sticker ^ One (1) Instruction Sheet Figure 2 Refer to Figure 2 for a pictorial of the kits components. NOTE: EFFECTIVE WITH THIS TSB, THROTTLE BODY CLEANING IS NO LONGER COVERED UNDER 5/50 EMISSIONS WARRANTY, UNLESS AS SPECIFIED IN THE FOLLOWING APPLICATION CHARTS. FAILURE TO FOLLOW THE CORRECT PROCEDURE MAY RESULT IN THE CLAIM BEING DISALLOWED. The idle air adjust spacer incorporates sludge tolerant design features that eliminate throttle body sludge related conditions. Once installed, throttle body cleaning is not allowed and periodic adjustment of the throttle body is not required. Procedures, Warranty and Labor CHECKS TO MAKE PRIOR TO SERVICE KIT INSTALLATION Confirm that the following items are not causing the idle quality concern before proceeding with the service kit installation. ^ Contamination within the idle air by-pass solenoid ^ Lack of fuel system control (excessively rich or lean) ^ Ignition timing change ^ Incorrect or malfunctioning EGR system ^ Incorrect or malfunctioning cooling system ^ Vacuum leaks (air intake manifold, vacuum hoses, vacuum reservoirs, power brake booster where applicable) ^ EEC diagnostics have been performed and vehicle malfunction indicated service output codes have been resolved and cleared. If any of the areas listed above are found to be at fault, correct them before proceeding with the service kit installation. Idle Speed Adjustment Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed/Throttle Actuator - Electronic: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3868 WARNING: BEFORE PROCEEDING WITH THE IDLE SPEED ADJUSTMENT, VERIFY THAT THE FOLLOWING ITEMS ARE TAKEN CARE OF PROPERLY. ^ The transmission is in PARK or Neutral. ^ The parking brake is applied. ^ The wheels are properly blocked. ^ The engine is at operating temperature. ^ The heater, A/C, cooling fan and other accessories are OFF. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed/Throttle Actuator - Electronic: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3869 Figure 3 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed/Throttle Actuator - Electronic: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3870 Figure 4 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed/Throttle Actuator - Electronic: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3871 Figure 5 The EFI throttle body idle speed adjustment procedures for the various model year passenger cars and light trucks are outlined in step-by-step procedures featured in Figures 3, 4 and 5. Select the appropriate procedure for the vehicle involved and adjust the throttle body idle RPM accordingly, after service kit installation. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed/Throttle Actuator - Electronic: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3872 Figure 6 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed/Throttle Actuator - Electronic: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3873 Figure 7 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed/Throttle Actuator - Electronic: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3874 Figure 8 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed/Throttle Actuator - Electronic: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3875 Figure 9 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed/Throttle Actuator - Electronic: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3876 Figure 10 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed/Throttle Actuator - Electronic: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3877 Figure 11 THROTTLE BODY AND IDLE AIR BY-PASS SOLENOID SERVICE PROCEDURE Detailed application charts for throttle body and idle air by-pass solenoid service procedures by engine VIN # /engine displacement/vehicle application and model year are shown in Figures 6 through 11. Refer to these charts to see if the service kit is to be installed and which service cleaning procedure, if any, is to be used. SERVICE CLEANING PROCEDURES The following items should be noted prior to beginning the service cleaning procedure. ^ Confirm that the correct service cleaning procedure is identified in the Application Charts, Figures 6-11, for the vehicle/engine combination being Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed/Throttle Actuator - Electronic: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3878 serviced. ^ Do not clean throttle bodies identified to accept service kit (F2PZ-9F939-A), IDLE AIR ADJUST SPACER. ^ Use a 1" (25.4 mm) to 1-1/2" (38.1 mm) wire stemmed horse hair or nylon bottle cleaner type brush. ^ Use rubber gloves and eye protection. ^ Do not clean throttle bodies identified with a yellow/black "ATTENTION" label. ^ Do not clean "Black" plastic air by-pass valves. Refer to TSB 89-13-8 for service details. ^ Do not run vehicles with air flow meters when the air duct is removed. ^ Do not use carburetor cleaner as a cleaning solvent. Use Carburetor Tune-up Cleaner (D9AZ-19579-AA). Procedure # 1 THROTTLE BODY AND IDLE AIR BY-PASS VALVE CLEANING CAUTION: DO NOT RUN VEHICLES EQUIPPED WITH AIR FLOW METERS DURING THE CLEANING PROCEDURE. IF THERE IS A YELLOW/BLACK "ATTENTION" LABEL ON THE THROTTLE BODY ADVISING NOT TO CLEAN, OR IF THE VEHICLE IS IDENTIFIED AS ACCEPTING SERVICE KIT (F2PZ-9F939-A), USE PROCEDURE # 2 FOR IDLE AIR BY-PASS VALVE CLEANING ONLY. 1. Plug the actuator into the connector in the Rotunda Cleaner/Tester, Tool 113-00009. 2. Remove the air duct to the throttle body inlet. 3. Disoonnect the idle air by-pass valve signal lead. 4. Attach the actuator harness plug to the idle air by-pass valve. 5. Start the actuator and then start the engine. Do not start engines that have air flow meters. 6. Spray just enough Carburetor Tune-up Cleaner (D9AZ-19579-AA) into the throttle bore to wet the bore and throttle plate. 7. Spray the Carburetor Tune-up Cleaner for about five (5) seconds into the idle air by-pass valve inlet passage while the actuator is operating. 8. Stop the engine and actuator. Let everything soak for fifteen (15) minutes. 9. After a fifteen (15) minute soak, saturate the cleaning brush with solvent and scrub between the throttle body bore and plate while holding the throttle wide open. NOTE: IT IS NECESSARY TO APPLY SOME PRESSURE ON THE BRUSH WHILE SCRUBBING. 10. Repeat saturating the brush and scrubbing for one (1) to two (2) minutes, making sure to reach into the corners where the throttle shaft meets the bore wall. 11. Start the actuator and the start the engine. Do not start engines that have air flow meters. 12. Spray Carburetor Tune-up Cleaner into the throttle bore for up to one (1) minute to wash away residue. Do not spray for longer than six (6) continuous seconds on engines that have air flow meters and are not running. 13. Spray Carburetor Tune-up Cleaner into the idle by-pass valve passage leading to the inlet of the valve for up to one (1) minute. Do not spray for longer than six (6) continuous seconds on engines that have air flow meters and are not running. 14. Stop actuator and stop engine, if running. NOTE: MAKE SURE THE THROTTLE PLATES OPERATE FREELY AND CLOSE PROPERLY. 15. Reinstall the air duct. 16. Start and run the engine for about one (1) minute to dry out the solvent residue. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed/Throttle Actuator - Electronic: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3879 17. Operate the actuator to make sure the solvent is purged from the idle by-pass valve. 18. Disconnect the actuator from the idle air by-pass valve. 19. Reattach the control signal lead to the air by-pass valve. 20. Check engine for normal operation. It may be necessary to reset the idle speed due to a previous adjustment for an idle concern. (Refer to the respective Powertrain/Emissions Diagnosis Service Manual, Throttle Body Section, for idle speed adjust procedure.) Procedure # 2 Idle Air By-Pass Valve Cleaning Only CAUTION: THIS CLEANING PROCEDURE MAY BE USED WITH SLUDGE TOLERANT THROTTLE BODIES WHICH ARE IDENTIFIED WITH A YELLOW/BLACK "ATTENTION" LABEL AND THOSE USING SERVICE KIT (F2PZ-9F939-A). NO ATTEMPT SHOULD BE MADE TO CLEAN THROTTLE BODY BORE/PLATE AREA BY DIRECT SPRAYING OR SCRUBBING. DO NOT RUN VEHICLES WITH AIR FLOW METERS DURING CLEANING PROCEDURE. 1. Plug the actuator into the connector in the Rotunda Air By-Pass Valve Adapter 113-00009, or equivalent. 2. Remove the air duct to the throttle body inlet. 3. Disconnect the idle air by-pass valve signal lead. 4. Attach the actuator harness plug to the idle air by-pass valve. 5. Start the actuator and then start the engine. NOTE: DO NOT START ENGINES THAT HAVE AIR FLOW METERS. 6. Spray the Carburetor Tune-up Cleaner for about five (5) seconds into the idle air by-pass valve inlet passage while the actuator is operating. CAUTION: AVOID DIRECT SPRAYING ON THROTTLE PLATE/BORE AREA. 7. Stop the engine and actuator. Let everything soak for fifteen (15) minutes. 8. Start the actuator and the start the engine. CAUTION: DO NOT START ENGINES THAT HAVE AIR FLOW METERS. 9. Spray Carburetor Tune-up Cleaner into the throttle bore for up to one (1) minute. CAUTION: DO NOT SPRAY FOR LONGER THAN SIX (6) CONTINUOUS SECONDS ON ENGINES THAT HAVE AIR FLOW METERS AND ARE NOT RUNNING. 10. Stop actuator and stop engine if running. 11. Reinstall the air duct. 12. Start and run the engine for about one (1) minute to dry out the solvent residue. 13. Operate the actuator to make sure the solvent is purged from the idle by-pass valve. 14. Disconnect the actuator from the idle air by-pass valve. 15. Reattach the control signal lead to the air by-pass valve. 16. Check engine for normal operation. NOTE: IT SHOULD NOT BE NECESSARY TO RESET THE IDLE SPEED SINCE ONLY THE IDLE AIR BY-PASS VALVE WAS SERVICED IN THIS PROCEDURE Warranty Coverage Throttle bodies and idle air by-pass valves on all EFI (Port Fuel Injection) engines through the 1992 model year that can be cleaned (as identified in the application charts) are covered under 5/50 Emissions Warranty Coverage. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed/Throttle Actuator - Electronic: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3880 For those throttle bodies identified as having sludge tolerant designs or using service kit (F2PZ-9F939-A) where cleaning is not allowed per the application charts, the warranty claims for cleaning will not be reimbursed even within the 12/12 warranty coverage period. Cleaning is not allowed. Service kit installation (single time) is covered under 5/50 emission warranty. Labor Standards Operations The labor operations shown in the following Operation/Description/Time columns are identified by procedure number and vehicle line. Specific engines for various vehicles are identified in the sludge cleaning procedure application charts. The throttle body cleaning operations with combinations and the air by-pass valve cleaning combinations will appear in future Labor Manuals under the following operation numbers. ^ 9926 B - Throttle body and idle air by-pass valve cleaning ^ 9926 B2 - Adjust idle speed ^ 9715 A - Air by-pass valve cleaning only ^ 9715 A1 - Adjust idle speed PART NUMBER PART NAME CLASS F2PZ-9F939-A Idle Air By-pass Service Kit B D9AZ-19579-AA Carburstor Tune-Up Cleaner BG OTHER APPLICABLE ARTICLES: 89-13-8 SUPERSEDES: 88-24-5, 88-24-6, 89-16-5, 91-10-9, 91-7-4 Operation Description WARRANTY STATUS: Eligible Under Warranty Coverage As Stated In The Text Of This Article OPERATION DESCRIPTION TIME 912507A Idle Air By-Pass Valve 0.5 Hr. Cleaning - 1983-85 Escort, EXP, LN7, LYNX 1.6L EFI. 912507B Idle Air By-Pass Valve 0.5 Hr. Cleaning - 1986-91 Escort 1.9L EFI, 1986/87 EXP, Lynx 1.9L EFI, 1991 Tracer 1.9L EFI. 912507C Idle Air By Pass Valve 0.5 Hr. Cleaning - 1984-87 Mustang 2.3L T/C, 1986/87 Capri, Cougar 2.3L T/C, 1984-88 T-Bird 2.3L T/C, 1987/92 Mustang 2.3L EFI. 912507D Idle By-Pass Valve Cleaning 0.6 Hr. - 1988-91 Tempo, Topaz 2.3L HSC, 1985-92 Ranger 2.3L EFI. 912507E Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1986/87 Aerostar 2.3L EFI, 1985 Bronco II 2.3L EFI. 912507F Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1986-90 Bronco II 2.9L EFI, 1986-92 Ranger 2.9L EFI. 912507G Idle Air By-Pass Valve 0.6 Hr. Cleaning - 1991/92 Probe 3.0L EFI, 1986-91 Taurus 3.0L EFI, 1987-91 Sable 3.0L EFI. 912507H Idle Air By-Pass Valve 0.7 Hr. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed/Throttle Actuator - Electronic: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3881 Cleaning - 1986-91 Aerostar 3.0L EFI, 1991 Ranger 3.0L EFI. 912507I Idle Air By-Pass Valve 0.6 Hr. Cleaning - 1988 Continental, Cougar, Taurus, T-Bird, Sable 3.8L EFI. 1988 Cougar, T-Bird 3.8L S/C. 912507J Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1990-92 Aerostar 4.0L EFI, 1990 Bronco II 4.0L EFI, 1991/92 Explorer 4.0L EFI, 1990-92 Ranger 4.0L EFI. 912507K Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1987-92 Bronco 4.9L EFI, 1987-92 F-Series 4.9L EFI, 1987/90 Econoline (Without Rear Heater) 4.9L EFI, 1991/92 Econoline (All) 4.9L EFI. 912507L Idle Air By-Pass Valve 0.6 Hr. Cleaning - 1986-88 Cougar, T-Bird 5.0L EFI, 1986-87 Continental, Mark VII 5.OL EFI, 1986/91 Crn - Victoria, Grn - Marquis 5.0L EFI, 1986-92 Mark VII 5.0L HO, 1982-92 Mustang 5.0L HO. 912507M Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1985-92 Bronco, E-Series, F-Series 5.0L EFI. 912507N Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1988-90 Bronco, F-Series 5.8L. 1991 Econo, F-Series, Bronco 5.8L (Do not Clean Solenoid, Calib; 1-64E-R10, 1-64H-R10, 1-64J-R10, 1-64K-R10, 1-64M-R10, 1-64P-R10, 1-64R-R10, 1-75A-R00, 1-76A-R00, 1-76B-R00, 1-76C-R00. 912507O Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1991/92 F And B Series, 7.0L EFI. 912507P Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1987-92 E-Series, F-Series 7.5L EFI. 912507Q Throttle Body And Idle Air 0.9 Hr. By-Pass Valve Cleaning - 1989/90 Probe 3.0L EFI. 912507R Throttle Body And Idle Air 0.8 Hr. By-Pass Valve Cleaning - 1987-90 Econoline (With Rear Heat) 4.9L EFI. 912507S Throttle Body And Idle Air 0.9 Hr. By-Pass Valve Cleaning - 1988-90 Econoline 5.8L EFI. 912507T Service Kit Install - All Cars 1.0 Hr. And Light Trucks (Except Aerostar And Econoline) - Refer To The Service Procedure Application Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed/Throttle Actuator - Electronic: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3882 Charts, For Vehicle Application. 912507U Service Kit Install - 1.2 Hr. Aerostar, Econoline - Refer To Service Procedure Application Charts - For Vehicle Application. DEALER CODING BASIC PART NO. CONDITION CODE 9E926 49 OASIS CODES: 602300, 607000, 607400, 607700, 608400, 611500, 618400 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed/Throttle Actuator - Electronic: > 89244 > Dec > 89 > Engine - Rough Idling Condition Idle Speed/Throttle Actuator - Electronic: All Technical Service Bulletins Engine - Rough Idling Condition ^ FUEL SYSTEM-EFI ENGINES - AIR BY-PASS VALVE REPLACEMENT PART INOPERATIVE ^ IDLE - ROUGH-REPLACEMENT AIR BY-PASS VALVE INOPERATIVE Article No. 89-24-4 FORD: 1983-88 ESCORT, EXP, THUNDERBIRD 1984-88 MUSTANG 1986-88 CROWN VICTORIA, TAURUS 1988 TEMPO LINCOLN-MERCURY: 1983 LN7 1983-86 LYNX 1983-88 COUGAR 1984-86 CAPRI 1986-88 CONTINENTAL, GRAND MARQUIS, MARK VII, SABLE, TOWN CAR 1988 TOPAZ MERKUR: 1985-88 XR4TI 1988 SCORPIO LIGHT TRUCK: 1985-88 BRONCO, F-150, F-250, RANGER 1986-88 AEROSTAR, BRONCO II, ECONOLINE 1987-88 F-350 1988 F SUPER DUTY Figure 1 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed/Throttle Actuator - Electronic: > 89244 > Dec > 89 > Engine - Rough Idling Condition > Page 3887 ISSUE: A rough idle created when the air by-pass valve is replaced may be caused by a revision made to the valve's wiring harness. Vehicles built before the 1989 model year had a diode in the air by-pass valve wiring harness. The new replacement valves have a 3D marking on the plastic portion of the solenoid, above the connector cap, Figure 1. They have a diode in the air by-pass valve. On the air by-pass valves used on vehicles built before the 1989 model year, the positive and negative leads are not important to the operation of the valve. However, the polarity on the new replacement air by-pass valve is important because if the wiring harness is reversed the air by-pass valve will not work. ACTION: Reverse the wires in the air by-pass valve connector and retest the valve. Refer to the following EFI Engine Application Chart for engines using these air by-pass valves. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 620800 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Technical Service Bulletins > Page 3888 IDLE SPEED CONTROL - FI ENGINES W/ISC. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Mechanical > Idle Speed Vacuum Solenoid Valve > Component Information > Locations Idle Speed Vacuum Solenoid Valve: Locations RH Side Of V8-351/5. Rear Of LH Rocker Cover Applicable to: 8L Engine With EEC-IV Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle/Altitude Compensator (Non Comp. Controlled) > Component Information > Description and Operation > Altitude Compensator Idle/Altitude Compensator (Non Comp. Controlled): Description and Operation Altitude Compensator Fig. 7 Electrical type altitude compensator ELECTRICAL The electrical type altitude compensator, Fig. 7, used on some vehicles, is mounted on the ignition module. The compensator improves emissions and aids engine performance at altitudes above 4000 ft. by advancing the timing and leaning the air/fuel mixture. Fig. 8 Mechanical type altitude compensator MECHANICAL The mechanical type altitude compensator, Fig. 8, is mounted on the bulkhead. The compensator leans the air/fuel mixture at altitudes above 3000 ft. by supplying additional filtered air to the carburetor. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle/Altitude Compensator (Non Comp. Controlled) > Component Information > Description and Operation > Altitude Compensator > Page 3897 Idle/Altitude Compensator (Non Comp. Controlled): Description and Operation Hot Idle Compensator The hot idle compensator is used to cool the engine during extreme hot engine idle operation. When open, the compensator bleeds air into the manifold, which leans out the fuel-air ratio at idle. The increased air intake causes an increase in engine idle speed, which results in cooling of the engine. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle/Altitude Compensator (Non Comp. Controlled) > Component Information > Testing and Inspection > Altitude Compensator Idle/Altitude Compensator (Non Comp. Controlled): Testing and Inspection Altitude Compensator ELECTRICAL 1. Check and record engine timing. 2. Disconnect compensator from ignition module and connect suitable jumper wire across module connectors. Recheck engine timing. 3. At altitudes of 4000 ft. or lower, timing should be advanced 4° on V8-302 engine, or 6° on V8-351 engine. 4. At altitudes of 4000 ft. or higher on 6-300 engine, or 4600 ft. or more on V8-302 and V8-351 engines, there should be no change in timing. Fig. 8 Mechanical type altitude compensator MECHANICAL 1. Connect a suitable vacuum gauge to air inlet nipple, Fig. 8, and check for vacuum with engine running. 2. On 4-140 engine, there should be no vacuum at altitudes of 2500 ft. or lower and vacuum should be present at altitudes of 3000 ft. or higher. 3. On V6-232 engines, there should be no vacuum at altitudes of 3500 ft. or lower and vacuum should be present at altitudes of 4000 ft. or higher. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle/Altitude Compensator (Non Comp. Controlled) > Component Information > Testing and Inspection > Altitude Compensator > Page 3900 Idle/Altitude Compensator (Non Comp. Controlled): Testing and Inspection Hot Idle Compensator The compensator may be internal or external to the carburetor. Temperature on the bimetal lifts the normally closed valve and opens the air passage. Valves open at a higher temperature and close at a lower temperature. This opening and closing range is from -12 to -7°C (10-20°F). Nominal closing temperatures vary from 26-60°C (79-140°F). A compensator with a valve that is not fully closing can cause high idle speed and a high emission CO. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump Inertia Switch <--> [Inertia Fuel Shutoff Switch] > Component Information > Locations Fuel Pump Inertia Switch: Locations The inertia switch is located below the heater duct on the right hand side. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump Inertia Switch <--> [Inertia Fuel Shutoff Switch] > Component Information > Diagrams > Diagram Information and Instructions Fuel Pump Inertia Switch: Diagram Information and Instructions Symbol Identification Wire Color Code Identification Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump Inertia Switch <--> [Inertia Fuel Shutoff Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 3906 NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump Inertia Switch <--> [Inertia Fuel Shutoff Switch] > Component Information > Diagrams > Page 3907 Fuel Pump Inertia Switch: Description and Operation The inertia Switch, is used in conjunction with an electric fuel pump. The purpose of the inertia switch is to shut off the fuel pump in the event of an accident. It consists of a steel ball held in place by a magnet. When a sharp impact occurs, the ball breaks loose from the magnet, rolls up a conical ramp and strikes a target plate which opens the electrical contacts of the switch and thereby shuts off the electric fuel pump. Once the switch is open, it must be manually reset before re-starting the vehicle. The location of the switch is discussed in the owners guide. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump Inertia Switch <--> [Inertia Fuel Shutoff Switch] > Component Information > Diagrams > Page 3908 Fuel Pump Inertia Switch: Testing and Inspection Push down on the reset button to make sure the switch is closed. Use DVOM with LOS button On and measure voltage across both terminals of the inertia switch. If DVOM reading is greater than 0.3V, replace the inertia switch. NOTE: In the closed position, the button can be depressed an additional 1/16-inch against a spring. This is a normal condition and does not adversely effect the switch operation. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump Inertia Switch <--> [Inertia Fuel Shutoff Switch] > Component Information > Diagrams > Page 3909 Fuel Pump Inertia Switch: Service and Repair 1. Turn ignition to Off. 2. Check for leaking fuel in the engine compartment, fuel lines and tank(s). 3. If no fuel leak is apparent, reset the switch by pushing the reset button on the top of the switch. 4. Turn ignition switch to Start for a few seconds, then to Off. 5. Again, check for leaking fuel. WARNING: It you see or smell gasoline at any time other than during fueling, do not reset the switch. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Intake Air Heater > Component Information > Description and Operation Intake Air Heater: Description and Operation The Fuel Evaporation Heater (EFE) switch, is mounted upside down at the rear of the engine on the bottom of the intake manifold. The purpose of the switch is to control a relay and heater element in the early fuel evaporation system (EFE) based on engine temperature The normally closed switch will activate the relay and heater at low engine temperature and will open at the specified calibration temperature of the switch. This will open the control relay shutting off the EFE heater after engine warm-up. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Component Locations Main Relay (Computer/Fuel System): Component Locations Fuel Pump Relay Engine Compartment Components. LH Side Of Engine Compartment, On Relay Bracket. Fuel pump relay is next to the EEC Relay. Applicable to: 4.9L/6-300 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Component Locations > Page 3917 Engine Compartment Components. LH Side Of Engine Compartment, On Relay Bracket. Fuel pump relay is next to the EEC Relay. Applicable to: 5.0L/V8-302 & 5.8L/V8-350 Engine Compartment Components. LH Side Of Engine Compartment, On Relay Bracket. Fuel pump relay is next to the EEC Relay. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Component Locations > Page 3918 Applicable to: 7.5L/V8-460 EEC Power Relay Under Dash Panel Next To, Or On ECA Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Component Locations > Page 3919 Right Hand Instrument Panel Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 3920 Main Relay (Computer/Fuel System): Description and Operation There are two types of relays: the power relay and the time delay power relay. The time delay relay has a delay of 5 to 10 seconds and is used with an actuator assembly throttle control. Both relay types consist of a movable contact in the normally open position. All power relays (except time delay) have the same design with a different bracket attachment. Function EEC power relays are in parallel with the ignition switch and provide power to the EEC module. Power relays also provide reverse battery protection and increased load handling to improve ignition switch reliability. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 3921 Main Relay (Computer/Fuel System): Testing and Inspection Ford provides trouble code/symptom driven diagnostics for this component. For complete diagnosis and pinpoint testing, refer to Computers and Control Systems, Testing and Inspection. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Technical Service Bulletins > Customer Interest for Fuel Pump Relay: > 90183 > Aug > 90 > Fuel Pump - Buzzing/Humming After Engine Shut Down Fuel Pump Relay: Customer Interest Fuel Pump - Buzzing/Humming After Engine Shut Down ^ NO START - 1.9L, 2.3L, 3.0L, 3.8L, 4.9L, 5.0L, 5.8L, 7.5L - LOW STATE OF BATTERY CHARGE ^ BATTERY - DISCHARGED - 1.9L, 2.3L, 3.0L, 3.8L, 4.9L, 5.0L, 5.8L, 7.5L ^ FUEL PUMP - NOISY - 1.9L, 2.3L, 3.0L, 3.8L, 4.9L, 5.0L, 5.8L, 7.5L ^ NOISE - "BUZZING" OR "HUMMING" FROM FUEL PUMP AFTER ENGINE IS TURNED OFF Article No. 90-18-3 FORD: 1983-90 CROWN VICTORIA, ESCORT, EXP, MUSTANG, TEMPO, THUNDERBIRD 1986 LTD 1986-90 TAURUS LINCOLN-MERCURY: 1983-87 LYNX 1983-90 CONTINENTAL, COUGAR, GRAND MARQUIS, MARK VII, TOPAZ, TOWN CAR 1985-86 CAPRI, MARQUIS 1986-90 SABLE LIGHT TRUCK: 1983-90 BRONCO II, BRONCO, ECONOLINE, F-150, F-250, F-350, RANGER 1988-90 F SUPER DUTY ISSUE: A "buzzing" or "humming" noise from the fuel pump may occur after the engine has been shut off. There may also be a no start condition or a discharged battery. These conditions are caused by a sticking fuel pump relay. ACTION: Install a new fuel pump relay. Refer to the following procedure for service details. 1. Check the fuel pump relay circuit for proper operation. Refer to the appropriate EVTM for troubleshooting details. 2. Install a new fuel pump relay, if the old one is defective. 3. Check the vehicle for proper operation. PART NUMBER PART NAME F19Z-9345-A Fuel Pump Relay Assy. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION DESCRIPTION TIME 901803A 1985-86 LTD/Marquis 0.6 Hr. (includes pinpoint test) 901803A 1990 Town Car (includes 0.4 Hr. pinpoint test) 901803A All Other Cars (includes 0.5 Hr. pinpoint test) 901803A All Trucks (includes pinpoint 0.5 Hr. test) DEALER CODING BASIC PART NO. CONDITION CODE 9345 09 OASIS CODES: 404000, 603300, 203000, 203100, 702000 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Pump Relay: > 90183 > Aug > 90 > Fuel Pump - Buzzing/Humming After Engine Shut Down Fuel Pump Relay: All Technical Service Bulletins Fuel Pump - Buzzing/Humming After Engine Shut Down ^ NO START - 1.9L, 2.3L, 3.0L, 3.8L, 4.9L, 5.0L, 5.8L, 7.5L - LOW STATE OF BATTERY CHARGE ^ BATTERY - DISCHARGED - 1.9L, 2.3L, 3.0L, 3.8L, 4.9L, 5.0L, 5.8L, 7.5L ^ FUEL PUMP - NOISY - 1.9L, 2.3L, 3.0L, 3.8L, 4.9L, 5.0L, 5.8L, 7.5L ^ NOISE - "BUZZING" OR "HUMMING" FROM FUEL PUMP AFTER ENGINE IS TURNED OFF Article No. 90-18-3 FORD: 1983-90 CROWN VICTORIA, ESCORT, EXP, MUSTANG, TEMPO, THUNDERBIRD 1986 LTD 1986-90 TAURUS LINCOLN-MERCURY: 1983-87 LYNX 1983-90 CONTINENTAL, COUGAR, GRAND MARQUIS, MARK VII, TOPAZ, TOWN CAR 1985-86 CAPRI, MARQUIS 1986-90 SABLE LIGHT TRUCK: 1983-90 BRONCO II, BRONCO, ECONOLINE, F-150, F-250, F-350, RANGER 1988-90 F SUPER DUTY ISSUE: A "buzzing" or "humming" noise from the fuel pump may occur after the engine has been shut off. There may also be a no start condition or a discharged battery. These conditions are caused by a sticking fuel pump relay. ACTION: Install a new fuel pump relay. Refer to the following procedure for service details. 1. Check the fuel pump relay circuit for proper operation. Refer to the appropriate EVTM for troubleshooting details. 2. Install a new fuel pump relay, if the old one is defective. 3. Check the vehicle for proper operation. PART NUMBER PART NAME F19Z-9345-A Fuel Pump Relay Assy. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION DESCRIPTION TIME 901803A 1985-86 LTD/Marquis 0.6 Hr. (includes pinpoint test) 901803A 1990 Town Car (includes 0.4 Hr. pinpoint test) 901803A All Other Cars (includes 0.5 Hr. pinpoint test) 901803A All Trucks (includes pinpoint 0.5 Hr. test) DEALER CODING BASIC PART NO. CONDITION CODE 9345 09 OASIS CODES: 404000, 603300, 203000, 203100, 702000 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Technical Service Bulletins > Page 3936 Fuel Pump Relay: Locations The EEC Power Relay is mounted to the Electronic Control Assembly in the rear center of the instrument panel. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions Fuel Pump Relay: Diagram Information and Instructions Symbol Identification Wire Color Code Identification Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3939 NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Shut-off Solenoid Relay > Component Information > Locations Fuel Shut-off Solenoid Relay: Locations LH Side Of Dash Panel In Engine Compartment, On LH Side Of Dash Panel Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Component Locations Main Relay (Computer/Fuel System): Component Locations Fuel Pump Relay Engine Compartment Components. LH Side Of Engine Compartment, On Relay Bracket. Fuel pump relay is next to the EEC Relay. Applicable to: 4.9L/6-300 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Component Locations > Page 3947 Engine Compartment Components. LH Side Of Engine Compartment, On Relay Bracket. Fuel pump relay is next to the EEC Relay. Applicable to: 5.0L/V8-302 & 5.8L/V8-350 Engine Compartment Components. LH Side Of Engine Compartment, On Relay Bracket. Fuel pump relay is next to the EEC Relay. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Component Locations > Page 3948 Applicable to: 7.5L/V8-460 EEC Power Relay Under Dash Panel Next To, Or On ECA Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Component Locations > Page 3949 Right Hand Instrument Panel Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 3950 Main Relay (Computer/Fuel System): Description and Operation There are two types of relays: the power relay and the time delay power relay. The time delay relay has a delay of 5 to 10 seconds and is used with an actuator assembly throttle control. Both relay types consist of a movable contact in the normally open position. All power relays (except time delay) have the same design with a different bracket attachment. Function EEC power relays are in parallel with the ignition switch and provide power to the EEC module. Power relays also provide reverse battery protection and increased load handling to improve ignition switch reliability. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 3951 Main Relay (Computer/Fuel System): Testing and Inspection Ford provides trouble code/symptom driven diagnostics for this component. For complete diagnosis and pinpoint testing, refer to Computers and Control Systems, Testing and Inspection. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Tank Selector Switch > Component Information > Locations > Fuel Tank Selector Switch Fuel Tank Selector Switch: Locations Fuel Tank Selector Switch On Instrument Panel Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Tank Selector Switch > Component Information > Locations > Fuel Tank Selector Switch > Page 3957 Fuel Tank Selector Switch: Locations Fuel Tank Selector Relay LH Corner Of Dash Panel Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Tank Selector Switch > Component Information > Diagrams > Diagram Information and Instructions Fuel Tank Selector Switch: Diagram Information and Instructions Symbol Identification Wire Color Code Identification Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Tank Selector Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3960 NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Tank Selector Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3961 Fuel Tank Selector Switch: Electrical Diagrams Fig. 26 Fuel Tank Selector & Gauges Wiring Circuit. Models W/6-300 (4.9L) & V8-351 (5.8L) Engines With 8,500 GVW Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Tank Selector Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3962 Fig. 27 Fuel Tank Selector & Gauges Wiring Circuit. F150-350 W/V8-351 (5.8L) & V8-460 (7.5L) Engines & Dual Tanks (Less Electric Fuel Pumps) Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pump Inertia Switch <--> [Inertia Fuel Shutoff Switch] > Component Information > Locations Fuel Pump Inertia Switch: Locations The inertia switch is located below the heater duct on the right hand side. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pump Inertia Switch <--> [Inertia Fuel Shutoff Switch] > Component Information > Diagrams > Diagram Information and Instructions Fuel Pump Inertia Switch: Diagram Information and Instructions Symbol Identification Wire Color Code Identification Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pump Inertia Switch <--> [Inertia Fuel Shutoff Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 3968 NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pump Inertia Switch <--> [Inertia Fuel Shutoff Switch] > Component Information > Diagrams > Page 3969 Fuel Pump Inertia Switch: Description and Operation The inertia Switch, is used in conjunction with an electric fuel pump. The purpose of the inertia switch is to shut off the fuel pump in the event of an accident. It consists of a steel ball held in place by a magnet. When a sharp impact occurs, the ball breaks loose from the magnet, rolls up a conical ramp and strikes a target plate which opens the electrical contacts of the switch and thereby shuts off the electric fuel pump. Once the switch is open, it must be manually reset before re-starting the vehicle. The location of the switch is discussed in the owners guide. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pump Inertia Switch <--> [Inertia Fuel Shutoff Switch] > Component Information > Diagrams > Page 3970 Fuel Pump Inertia Switch: Testing and Inspection Push down on the reset button to make sure the switch is closed. Use DVOM with LOS button On and measure voltage across both terminals of the inertia switch. If DVOM reading is greater than 0.3V, replace the inertia switch. NOTE: In the closed position, the button can be depressed an additional 1/16-inch against a spring. This is a normal condition and does not adversely effect the switch operation. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pump Inertia Switch <--> [Inertia Fuel Shutoff Switch] > Component Information > Diagrams > Page 3971 Fuel Pump Inertia Switch: Service and Repair 1. Turn ignition to Off. 2. Check for leaking fuel in the engine compartment, fuel lines and tank(s). 3. If no fuel leak is apparent, reset the switch by pushing the reset button on the top of the switch. 4. Turn ignition switch to Start for a few seconds, then to Off. 5. Again, check for leaking fuel. WARNING: It you see or smell gasoline at any time other than during fueling, do not reset the switch. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Full Open Switch HVAC > Component Information > Description and Operation Throttle Full Open Switch HVAC: Description and Operation A switch assembly, Figure 1 is mounted on the carburetor on some gasoline engines and on the fuel injector pump on the 2.0L Diesel engine to sense a wide open throttle condition. When maximum engine power is required, this switch assembly cuts off the air conditioning compressor to reduce engine loading. Switch closed at throttle opening less than wide open throttle. Switch open at wide open throttle condition. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Throttle Position Sensor - Request For Return Throttle Position Sensor: Technical Service Bulletins Throttle Position Sensor - Request For Return Number: 92686 To: All Ford and Lincoln-Mercury Dealers Subject: Request for Return of Throttle Position Sensor E5ZZ-9B989-B (CX-1022) and E6ZZ-9B989-B (CX-1130) Because the subject parts may not meet Ford's high quality requirements, they should be withdrawn from all inventories. All used E5ZZ-9B989-B (CX-1022) and E6ZZ-9B989-B (CX-1130) should be returned to your facing PDC within 30 days from the date of this letter. Use the least expensive mode of transportation for your return. The subject parts are obsolete and replaced by E7SZ-9B989-B (CX-1200), which is available for ordering immediately. You are requested to complete a separate FPS-340 form in accordance with the instructions on the front of the form. Annotate "Return Per FPSD Instructions Purge No. PN 1026" in the Customer's Detail Explanation Section and use Reason Code J (Unsatisfactory Service Stock). You will receive full credit in your parts statement for the price of each unused part returned, plus the prepaid transportation cost. In order to receive credit, all parts must be received at the Parts Distribution Center within 30 days from the date of this letter. Material other than subject parts received on this return will be sent back to you freight collect. Any questions should be referred to your Zone Manager or facing PDC Manager. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Throttle Position Sensor - Request For Return > Page 3979 Throttle Position Sensor: Technical Service Bulletins Throttle Position Sensor - Diagnostic Tips Article No. 85-20-11 SELF-TEST CODE 53 - EEC IV - THROTTLE POSITION SENSOR DIAGNOSTIC TIP FORD 1985-86 ESCORT, EXP, TEMPO, MUSTANG, LTD, THUNDERBIRD LINCOLN-MERCURY 1985-86 LYNX, TOPAZ, CAPRI, MARQUIS, COUGAR LIGHT TRUCK 1985-86 RANGER, BRONCO II, ECONOLINE, F-SERIES CALIBRATION: All with EEC IV WARNING: This modification is authorized only for the listed engines. Performing this modification on other engine calibrations is unauthorized and could create liability under applicable federal or local laws. A new design Throttle Position Sensor (TPS) has been released for all 1986 EEC IV applications. The new TPS is designed to eliminate a false Self-Test Code 53. A Code 53 indicates the TPS system has failed at the wide open throttle position (approximately 5.0 volts), The new TPS eliminates false Code 53 by limiting the wide open throttle voltage to 4.75 volts. With the new TPS, Code 53 will only result from a circuit or TPS malfunction. The new Throttle Position Sensors can be used to replace faulty sensors on 1985 vehicles. If the old design service part is used, a false Code 53 may result. PART NUMBER PART NAME CLASS E6DZ-9B989-A Throttle Position Sensor C E6TZ-9B989-C Throttle Position Sensor WC E6DZ-9B989-C Throttle Position Sensor WC E6FZ-9B989-A Throttle Position Sensor B E6ZZ-9B989-A Throttle Position Sensor B E6ZZ-9B989-B Throttle Position Sensor WC E6TZ-9B989-A Throttle Position Sensor C OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Throttle Position Sensor - Request For Return > Page 3980 Throttle Position Sensor: Technical Service Bulletins Throttle Position Sensor - Application Chart EEC-IV THROTTLE POSITION SENSOR-APPLICATION CHART-SERVICE TIP Article No. 89-16-4 FORD: 1984-88 CROWN VICTORIA, ESCORT, EXP, MUSTANG, TAURUS, TEMPO, THUNDERBIRD LINCOLN-MERCURY: 1984-88 COUGAR, GRAND MARQUIS, LYNX, MARK VI, MARK VII, SABLE, TOPAZ, TOWN CAR LIGHT TRUCK: 1984-88 ALL LIGHT TRUCK LINES ISSUE: A quick reference throttle position sensor (TPS) application chart has been put together to assist technicians in correct part useage. If the wrong TPS is installed, it could fail prematurely. ACTION: Refer to one of the following TPS service replacement charts to make sure that the correct service part is installed. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Throttle Position Sensor - Request For Return > Page 3981 OASIS CODES: 680000 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Throttle Position Sensor - Request For Return > Page 3982 Throttle Position Sensor: Technical Service Bulletins TPS Mounting Screws - Hard to Remove THROTTLE POSITION SENSOR-MOUNTING SCREWS HARD TO REMOVE-SERVICE TIP Article No. 89-14-7 FORD: 1983-89 CROWN VICTORIA, MUSTANG, TEMPO, THUNDERBIRD 1984-89 ESCORT 1986-89 TAURUS LINCOLN-MERCURY: 1983-89 CONTINENTAL, COUGAR, GRAND MARQUIS, MARK VII, TOPAZ, TOWN CAR 1984-87 LYNX MERKUR: 1985-89 ALL MERKUR LINES LIGHT TRUCK: 1983-89 ALL LIGHT TRUCK LINES ISSUE: All Throttle Position Sensor (TPS) mounting screws have a "Pozidrive" head. The "Pozidrive" head looks a lot like a Phillips screw head. Use of a Phillips head screwdriver to remove a "Pozidrive" screw will normally result in a rounded or damaged screw head. Many technicians think it is an overtorqued or "frozen" screw. An adhesive was also used as a thread sealant starting with the 1988 model year. This adhesive requires still more effort to loosen and remove the screw. ACTION: To prevent rounded or damages screw heads when servicing the TPS mounting screws, technicians should always use a # 2 "Pozidrive" screwdriver. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 4800, 680000 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 3983 THROTTLE POSITION SENSOR SPECIFICATIONS Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 3984 Engine View Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 3985 Throttle Position Sensor: Description and Operation The Throttle Position (TP) Sensor (Rotary), Figure 1 supplies the ECA with a signal proportional to opening angle of carburetor throttle plates. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 3986 Throttle Position Sensor: Testing and Inspection Ford provides trouble code/symptom driven diagnostics for this component. For complete diagnosis and pinpoint testing, refer to Computers and Control Systems, Testing and Inspection. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 3987 Throttle Position Sensor: Adjustments ADJUSTMENT This procedure can be used to check and/or adjust level C sensors only: 1. Install an EEC-IV Breakout Box, Rotunda T83L-50 EEC-IV, or equivalent. 2. Attach a DVOM, Rotunda 014-00407 or equivalent, on 20V scale. Connect the positive lead (+) to test Pin 47 and the negative lead (-) to test Pin 46. 3. Turn ignition key to Run position (do not start engine). 4. Adjust TP Sensor (rotate) until the DVOM reads 1.0V (0.9-1.1). 5. Tighten TP Sensor screws to 1.2-1.8 N-m (11-16 lb-in). 6. While watching the DVOM, move the throttle to wide open and back to idle position. For proper operation, the DVOM should move from 1.0 to at least 4.0 and back to 1.0V. 7, Perform EEC-IV Quick Test. Refer to Powertrain Management/Computers and Control Systems/System Diagnosis Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > Customer Interest for Throttle Body: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up Technical Service Bulletin # 91257 Date: 911213 Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up Article No. 91-25-7 12/13/91 ^ HARD COLD START - DURING INITIAL START-UP, IDLE OR DECEL - EFI ENGINES SLUDGE IN THROTTLE BODY AND/OR IDLE AIR BY-PASS VALVE ^ HESITATION/STALLS - DURING INITIAL START-UP, IDLE OR DECEL - EFI ENGINES SLUDGE IN THROTTLE BODY AND/OR IDLE AIR BY-PASS VALVE FORD: 1983-87 EXP 1983-91 ESCORT 1984-90 MUSTANG, THUNDERBIRD 1986-90 TAURUS 1986-91 CROWN VICTORIA 1988-90 TEMPO LINCOLN-MERCURY: 1983-85 LN7 1983-87 LYNX 1984-88 CAPRI 1984-90 COUGAR 1986-90 CONTINENTAL, MARK VII, SABLE 1986-91 GRAND MARQUIS, TOWN CAR 1988-90 TOPAZ 1991 TRACER LIGHT TRUCK: 1985-90 BRONCO II, BRONCO 1985-91 ECONOLINE, F-150-350 SERIES 1985-92 RANGER 1986-91 AEROSTAR 1991 EXPLORER ISSUE: Hard cold starts, hesitation and stalls on initial start-up or during idle or decel may be caused by sludge in the throttle body and/or idle by-pass valve. Sludge deposits or oil film on the throttle body bore and plate or the idle air by-pass valve may cause one or more of the following conditions. ^ Hard Cold Start ^ Stall On Initial Start-Up ^ Stall During Idle ^ Stall During Decel ^ Rough Idle ^ Rolling Idle ^ Hesitation During Acceleration ACTION: A new idle air by-pass service kit (F2PZ-9F939-A) is now available for service use to correct sludge contamination concerns of the throttle bore and plate only. It eliminates the need to clean the majority of past model throttle body applications. Cleaning is not required on sludge tolerant throttle body designs released for 1991 and newer model years. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > Customer Interest for Throttle Body: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3996 Figure 1 Install an idle air by-pass service kit (F2PZ-9F939-A) as applicable to provide a permanent correction for symptoms caused by throttle body sludge deposits. Refer to the instruction sheet included in the kit for installation details. Refer to Figure 1 for a specific application list of EFI (port fuel Injection) engines involved in this TSB article. The idle air by-pass service kit (F2PZ-9F939-A) includes the following items. ^ One (1) Idle Adjust Spacer ^ Two (2) Gaskets Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > Customer Interest for Throttle Body: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3997 ^ Two (2) Attaching Bolts ^ One (1) "Attention" Sticker ^ One (1) Instruction Sheet Figure 2 Refer to Figure 2 for a pictorial of the kits components. NOTE: EFFECTIVE WITH THIS TSB, THROTTLE BODY CLEANING IS NO LONGER COVERED UNDER 5/50 EMISSIONS WARRANTY, UNLESS AS SPECIFIED IN THE FOLLOWING APPLICATION CHARTS. FAILURE TO FOLLOW THE CORRECT PROCEDURE MAY RESULT IN THE CLAIM BEING DISALLOWED. The idle air adjust spacer incorporates sludge tolerant design features that eliminate throttle body sludge related conditions. Once installed, throttle body cleaning is not allowed and periodic adjustment of the throttle body is not required. Procedures, Warranty and Labor CHECKS TO MAKE PRIOR TO SERVICE KIT INSTALLATION Confirm that the following items are not causing the idle quality concern before proceeding with the service kit installation. ^ Contamination within the idle air by-pass solenoid ^ Lack of fuel system control (excessively rich or lean) ^ Ignition timing change ^ Incorrect or malfunctioning EGR system ^ Incorrect or malfunctioning cooling system ^ Vacuum leaks (air intake manifold, vacuum hoses, vacuum reservoirs, power brake booster where applicable) ^ EEC diagnostics have been performed and vehicle malfunction indicated service output codes have been resolved and cleared. If any of the areas listed above are found to be at fault, correct them before proceeding with the service kit installation. Idle Speed Adjustment Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > Customer Interest for Throttle Body: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3998 WARNING: BEFORE PROCEEDING WITH THE IDLE SPEED ADJUSTMENT, VERIFY THAT THE FOLLOWING ITEMS ARE TAKEN CARE OF PROPERLY. ^ The transmission is in PARK or Neutral. ^ The parking brake is applied. ^ The wheels are properly blocked. ^ The engine is at operating temperature. ^ The heater, A/C, cooling fan and other accessories are OFF. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > Customer Interest for Throttle Body: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3999 Figure 3 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > Customer Interest for Throttle Body: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 4000 Figure 4 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > Customer Interest for Throttle Body: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 4001 Figure 5 The EFI throttle body idle speed adjustment procedures for the various model year passenger cars and light trucks are outlined in step-by-step procedures featured in Figures 3, 4 and 5. Select the appropriate procedure for the vehicle involved and adjust the throttle body idle RPM accordingly, after service kit installation. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > Customer Interest for Throttle Body: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 4002 Figure 6 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > Customer Interest for Throttle Body: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 4003 Figure 7 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > Customer Interest for Throttle Body: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 4004 Figure 8 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > Customer Interest for Throttle Body: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 4005 Figure 9 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > Customer Interest for Throttle Body: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 4006 Figure 10 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > Customer Interest for Throttle Body: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 4007 Figure 11 THROTTLE BODY AND IDLE AIR BY-PASS SOLENOID SERVICE PROCEDURE Detailed application charts for throttle body and idle air by-pass solenoid service procedures by engine VIN # /engine displacement/vehicle application and model year are shown in Figures 6 through 11. Refer to these charts to see if the service kit is to be installed and which service cleaning procedure, if any, is to be used. SERVICE CLEANING PROCEDURES The following items should be noted prior to beginning the service cleaning procedure. ^ Confirm that the correct service cleaning procedure is identified in the Application Charts, Figures 6-11, for the vehicle/engine combination being Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > Customer Interest for Throttle Body: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 4008 serviced. ^ Do not clean throttle bodies identified to accept service kit (F2PZ-9F939-A), IDLE AIR ADJUST SPACER. ^ Use a 1" (25.4 mm) to 1-1/2" (38.1 mm) wire stemmed horse hair or nylon bottle cleaner type brush. ^ Use rubber gloves and eye protection. ^ Do not clean throttle bodies identified with a yellow/black "ATTENTION" label. ^ Do not clean "Black" plastic air by-pass valves. Refer to TSB 89-13-8 for service details. ^ Do not run vehicles with air flow meters when the air duct is removed. ^ Do not use carburetor cleaner as a cleaning solvent. Use Carburetor Tune-up Cleaner (D9AZ-19579-AA). Procedure # 1 THROTTLE BODY AND IDLE AIR BY-PASS VALVE CLEANING CAUTION: DO NOT RUN VEHICLES EQUIPPED WITH AIR FLOW METERS DURING THE CLEANING PROCEDURE. IF THERE IS A YELLOW/BLACK "ATTENTION" LABEL ON THE THROTTLE BODY ADVISING NOT TO CLEAN, OR IF THE VEHICLE IS IDENTIFIED AS ACCEPTING SERVICE KIT (F2PZ-9F939-A), USE PROCEDURE # 2 FOR IDLE AIR BY-PASS VALVE CLEANING ONLY. 1. Plug the actuator into the connector in the Rotunda Cleaner/Tester, Tool 113-00009. 2. Remove the air duct to the throttle body inlet. 3. Disoonnect the idle air by-pass valve signal lead. 4. Attach the actuator harness plug to the idle air by-pass valve. 5. Start the actuator and then start the engine. Do not start engines that have air flow meters. 6. Spray just enough Carburetor Tune-up Cleaner (D9AZ-19579-AA) into the throttle bore to wet the bore and throttle plate. 7. Spray the Carburetor Tune-up Cleaner for about five (5) seconds into the idle air by-pass valve inlet passage while the actuator is operating. 8. Stop the engine and actuator. Let everything soak for fifteen (15) minutes. 9. After a fifteen (15) minute soak, saturate the cleaning brush with solvent and scrub between the throttle body bore and plate while holding the throttle wide open. NOTE: IT IS NECESSARY TO APPLY SOME PRESSURE ON THE BRUSH WHILE SCRUBBING. 10. Repeat saturating the brush and scrubbing for one (1) to two (2) minutes, making sure to reach into the corners where the throttle shaft meets the bore wall. 11. Start the actuator and the start the engine. Do not start engines that have air flow meters. 12. Spray Carburetor Tune-up Cleaner into the throttle bore for up to one (1) minute to wash away residue. Do not spray for longer than six (6) continuous seconds on engines that have air flow meters and are not running. 13. Spray Carburetor Tune-up Cleaner into the idle by-pass valve passage leading to the inlet of the valve for up to one (1) minute. Do not spray for longer than six (6) continuous seconds on engines that have air flow meters and are not running. 14. Stop actuator and stop engine, if running. NOTE: MAKE SURE THE THROTTLE PLATES OPERATE FREELY AND CLOSE PROPERLY. 15. Reinstall the air duct. 16. Start and run the engine for about one (1) minute to dry out the solvent residue. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > Customer Interest for Throttle Body: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 4009 17. Operate the actuator to make sure the solvent is purged from the idle by-pass valve. 18. Disconnect the actuator from the idle air by-pass valve. 19. Reattach the control signal lead to the air by-pass valve. 20. Check engine for normal operation. It may be necessary to reset the idle speed due to a previous adjustment for an idle concern. (Refer to the respective Powertrain/Emissions Diagnosis Service Manual, Throttle Body Section, for idle speed adjust procedure.) Procedure # 2 Idle Air By-Pass Valve Cleaning Only CAUTION: THIS CLEANING PROCEDURE MAY BE USED WITH SLUDGE TOLERANT THROTTLE BODIES WHICH ARE IDENTIFIED WITH A YELLOW/BLACK "ATTENTION" LABEL AND THOSE USING SERVICE KIT (F2PZ-9F939-A). NO ATTEMPT SHOULD BE MADE TO CLEAN THROTTLE BODY BORE/PLATE AREA BY DIRECT SPRAYING OR SCRUBBING. DO NOT RUN VEHICLES WITH AIR FLOW METERS DURING CLEANING PROCEDURE. 1. Plug the actuator into the connector in the Rotunda Air By-Pass Valve Adapter 113-00009, or equivalent. 2. Remove the air duct to the throttle body inlet. 3. Disconnect the idle air by-pass valve signal lead. 4. Attach the actuator harness plug to the idle air by-pass valve. 5. Start the actuator and then start the engine. NOTE: DO NOT START ENGINES THAT HAVE AIR FLOW METERS. 6. Spray the Carburetor Tune-up Cleaner for about five (5) seconds into the idle air by-pass valve inlet passage while the actuator is operating. CAUTION: AVOID DIRECT SPRAYING ON THROTTLE PLATE/BORE AREA. 7. Stop the engine and actuator. Let everything soak for fifteen (15) minutes. 8. Start the actuator and the start the engine. CAUTION: DO NOT START ENGINES THAT HAVE AIR FLOW METERS. 9. Spray Carburetor Tune-up Cleaner into the throttle bore for up to one (1) minute. CAUTION: DO NOT SPRAY FOR LONGER THAN SIX (6) CONTINUOUS SECONDS ON ENGINES THAT HAVE AIR FLOW METERS AND ARE NOT RUNNING. 10. Stop actuator and stop engine if running. 11. Reinstall the air duct. 12. Start and run the engine for about one (1) minute to dry out the solvent residue. 13. Operate the actuator to make sure the solvent is purged from the idle by-pass valve. 14. Disconnect the actuator from the idle air by-pass valve. 15. Reattach the control signal lead to the air by-pass valve. 16. Check engine for normal operation. NOTE: IT SHOULD NOT BE NECESSARY TO RESET THE IDLE SPEED SINCE ONLY THE IDLE AIR BY-PASS VALVE WAS SERVICED IN THIS PROCEDURE Warranty Coverage Throttle bodies and idle air by-pass valves on all EFI (Port Fuel Injection) engines through the 1992 model year that can be cleaned (as identified in the application charts) are covered under 5/50 Emissions Warranty Coverage. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > Customer Interest for Throttle Body: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 4010 For those throttle bodies identified as having sludge tolerant designs or using service kit (F2PZ-9F939-A) where cleaning is not allowed per the application charts, the warranty claims for cleaning will not be reimbursed even within the 12/12 warranty coverage period. Cleaning is not allowed. Service kit installation (single time) is covered under 5/50 emission warranty. Labor Standards Operations The labor operations shown in the following Operation/Description/Time columns are identified by procedure number and vehicle line. Specific engines for various vehicles are identified in the sludge cleaning procedure application charts. The throttle body cleaning operations with combinations and the air by-pass valve cleaning combinations will appear in future Labor Manuals under the following operation numbers. ^ 9926 B - Throttle body and idle air by-pass valve cleaning ^ 9926 B2 - Adjust idle speed ^ 9715 A - Air by-pass valve cleaning only ^ 9715 A1 - Adjust idle speed PART NUMBER PART NAME CLASS F2PZ-9F939-A Idle Air By-pass Service Kit B D9AZ-19579-AA Carburstor Tune-Up Cleaner BG OTHER APPLICABLE ARTICLES: 89-13-8 SUPERSEDES: 88-24-5, 88-24-6, 89-16-5, 91-10-9, 91-7-4 Operation Description WARRANTY STATUS: Eligible Under Warranty Coverage As Stated In The Text Of This Article OPERATION DESCRIPTION TIME 912507A Idle Air By-Pass Valve 0.5 Hr. Cleaning - 1983-85 Escort, EXP, LN7, LYNX 1.6L EFI. 912507B Idle Air By-Pass Valve 0.5 Hr. Cleaning - 1986-91 Escort 1.9L EFI, 1986/87 EXP, Lynx 1.9L EFI, 1991 Tracer 1.9L EFI. 912507C Idle Air By Pass Valve 0.5 Hr. Cleaning - 1984-87 Mustang 2.3L T/C, 1986/87 Capri, Cougar 2.3L T/C, 1984-88 T-Bird 2.3L T/C, 1987/92 Mustang 2.3L EFI. 912507D Idle By-Pass Valve Cleaning 0.6 Hr. - 1988-91 Tempo, Topaz 2.3L HSC, 1985-92 Ranger 2.3L EFI. 912507E Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1986/87 Aerostar 2.3L EFI, 1985 Bronco II 2.3L EFI. 912507F Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1986-90 Bronco II 2.9L EFI, 1986-92 Ranger 2.9L EFI. 912507G Idle Air By-Pass Valve 0.6 Hr. Cleaning - 1991/92 Probe 3.0L EFI, 1986-91 Taurus 3.0L EFI, 1987-91 Sable 3.0L EFI. 912507H Idle Air By-Pass Valve 0.7 Hr. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > Customer Interest for Throttle Body: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 4011 Cleaning - 1986-91 Aerostar 3.0L EFI, 1991 Ranger 3.0L EFI. 912507I Idle Air By-Pass Valve 0.6 Hr. Cleaning - 1988 Continental, Cougar, Taurus, T-Bird, Sable 3.8L EFI. 1988 Cougar, T-Bird 3.8L S/C. 912507J Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1990-92 Aerostar 4.0L EFI, 1990 Bronco II 4.0L EFI, 1991/92 Explorer 4.0L EFI, 1990-92 Ranger 4.0L EFI. 912507K Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1987-92 Bronco 4.9L EFI, 1987-92 F-Series 4.9L EFI, 1987/90 Econoline (Without Rear Heater) 4.9L EFI, 1991/92 Econoline (All) 4.9L EFI. 912507L Idle Air By-Pass Valve 0.6 Hr. Cleaning - 1986-88 Cougar, T-Bird 5.0L EFI, 1986-87 Continental, Mark VII 5.OL EFI, 1986/91 Crn - Victoria, Grn - Marquis 5.0L EFI, 1986-92 Mark VII 5.0L HO, 1982-92 Mustang 5.0L HO. 912507M Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1985-92 Bronco, E-Series, F-Series 5.0L EFI. 912507N Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1988-90 Bronco, F-Series 5.8L. 1991 Econo, F-Series, Bronco 5.8L (Do not Clean Solenoid, Calib; 1-64E-R10, 1-64H-R10, 1-64J-R10, 1-64K-R10, 1-64M-R10, 1-64P-R10, 1-64R-R10, 1-75A-R00, 1-76A-R00, 1-76B-R00, 1-76C-R00. 912507O Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1991/92 F And B Series, 7.0L EFI. 912507P Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1987-92 E-Series, F-Series 7.5L EFI. 912507Q Throttle Body And Idle Air 0.9 Hr. By-Pass Valve Cleaning - 1989/90 Probe 3.0L EFI. 912507R Throttle Body And Idle Air 0.8 Hr. By-Pass Valve Cleaning - 1987-90 Econoline (With Rear Heat) 4.9L EFI. 912507S Throttle Body And Idle Air 0.9 Hr. By-Pass Valve Cleaning - 1988-90 Econoline 5.8L EFI. 912507T Service Kit Install - All Cars 1.0 Hr. And Light Trucks (Except Aerostar And Econoline) - Refer To The Service Procedure Application Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > Customer Interest for Throttle Body: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 4012 Charts, For Vehicle Application. 912507U Service Kit Install - 1.2 Hr. Aerostar, Econoline - Refer To Service Procedure Application Charts - For Vehicle Application. DEALER CODING BASIC PART NO. CONDITION CODE 9E926 49 OASIS CODES: 602300, 607000, 607400, 607700, 608400, 611500, 618400 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Throttle Body: > 91257 > Dec > 91 > Engine Hard Cold Starts/Hesitation/Stalls On Start-Up Technical Service Bulletin # 91257 Date: 911213 Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up Article No. 91-25-7 12/13/91 ^ HARD COLD START - DURING INITIAL START-UP, IDLE OR DECEL - EFI ENGINES SLUDGE IN THROTTLE BODY AND/OR IDLE AIR BY-PASS VALVE ^ HESITATION/STALLS - DURING INITIAL START-UP, IDLE OR DECEL - EFI ENGINES SLUDGE IN THROTTLE BODY AND/OR IDLE AIR BY-PASS VALVE FORD: 1983-87 EXP 1983-91 ESCORT 1984-90 MUSTANG, THUNDERBIRD 1986-90 TAURUS 1986-91 CROWN VICTORIA 1988-90 TEMPO LINCOLN-MERCURY: 1983-85 LN7 1983-87 LYNX 1984-88 CAPRI 1984-90 COUGAR 1986-90 CONTINENTAL, MARK VII, SABLE 1986-91 GRAND MARQUIS, TOWN CAR 1988-90 TOPAZ 1991 TRACER LIGHT TRUCK: 1985-90 BRONCO II, BRONCO 1985-91 ECONOLINE, F-150-350 SERIES 1985-92 RANGER 1986-91 AEROSTAR 1991 EXPLORER ISSUE: Hard cold starts, hesitation and stalls on initial start-up or during idle or decel may be caused by sludge in the throttle body and/or idle by-pass valve. Sludge deposits or oil film on the throttle body bore and plate or the idle air by-pass valve may cause one or more of the following conditions. ^ Hard Cold Start ^ Stall On Initial Start-Up ^ Stall During Idle ^ Stall During Decel ^ Rough Idle ^ Rolling Idle ^ Hesitation During Acceleration ACTION: A new idle air by-pass service kit (F2PZ-9F939-A) is now available for service use to correct sludge contamination concerns of the throttle bore and plate only. It eliminates the need to clean the majority of past model throttle body applications. Cleaning is not required on sludge tolerant throttle body designs released for 1991 and newer model years. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Throttle Body: > 91257 > Dec > 91 > Engine Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 4018 Figure 1 Install an idle air by-pass service kit (F2PZ-9F939-A) as applicable to provide a permanent correction for symptoms caused by throttle body sludge deposits. Refer to the instruction sheet included in the kit for installation details. Refer to Figure 1 for a specific application list of EFI (port fuel Injection) engines involved in this TSB article. The idle air by-pass service kit (F2PZ-9F939-A) includes the following items. ^ One (1) Idle Adjust Spacer ^ Two (2) Gaskets Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Throttle Body: > 91257 > Dec > 91 > Engine Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 4019 ^ Two (2) Attaching Bolts ^ One (1) "Attention" Sticker ^ One (1) Instruction Sheet Figure 2 Refer to Figure 2 for a pictorial of the kits components. NOTE: EFFECTIVE WITH THIS TSB, THROTTLE BODY CLEANING IS NO LONGER COVERED UNDER 5/50 EMISSIONS WARRANTY, UNLESS AS SPECIFIED IN THE FOLLOWING APPLICATION CHARTS. FAILURE TO FOLLOW THE CORRECT PROCEDURE MAY RESULT IN THE CLAIM BEING DISALLOWED. The idle air adjust spacer incorporates sludge tolerant design features that eliminate throttle body sludge related conditions. Once installed, throttle body cleaning is not allowed and periodic adjustment of the throttle body is not required. Procedures, Warranty and Labor CHECKS TO MAKE PRIOR TO SERVICE KIT INSTALLATION Confirm that the following items are not causing the idle quality concern before proceeding with the service kit installation. ^ Contamination within the idle air by-pass solenoid ^ Lack of fuel system control (excessively rich or lean) ^ Ignition timing change ^ Incorrect or malfunctioning EGR system ^ Incorrect or malfunctioning cooling system ^ Vacuum leaks (air intake manifold, vacuum hoses, vacuum reservoirs, power brake booster where applicable) ^ EEC diagnostics have been performed and vehicle malfunction indicated service output codes have been resolved and cleared. If any of the areas listed above are found to be at fault, correct them before proceeding with the service kit installation. Idle Speed Adjustment Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Throttle Body: > 91257 > Dec > 91 > Engine Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 4020 WARNING: BEFORE PROCEEDING WITH THE IDLE SPEED ADJUSTMENT, VERIFY THAT THE FOLLOWING ITEMS ARE TAKEN CARE OF PROPERLY. ^ The transmission is in PARK or Neutral. ^ The parking brake is applied. ^ The wheels are properly blocked. ^ The engine is at operating temperature. ^ The heater, A/C, cooling fan and other accessories are OFF. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Throttle Body: > 91257 > Dec > 91 > Engine Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 4021 Figure 3 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Throttle Body: > 91257 > Dec > 91 > Engine Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 4022 Figure 4 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Throttle Body: > 91257 > Dec > 91 > Engine Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 4023 Figure 5 The EFI throttle body idle speed adjustment procedures for the various model year passenger cars and light trucks are outlined in step-by-step procedures featured in Figures 3, 4 and 5. Select the appropriate procedure for the vehicle involved and adjust the throttle body idle RPM accordingly, after service kit installation. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Throttle Body: > 91257 > Dec > 91 > Engine Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 4024 Figure 6 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Throttle Body: > 91257 > Dec > 91 > Engine Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 4025 Figure 7 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Throttle Body: > 91257 > Dec > 91 > Engine Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 4026 Figure 8 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Throttle Body: > 91257 > Dec > 91 > Engine Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 4027 Figure 9 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Throttle Body: > 91257 > Dec > 91 > Engine Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 4028 Figure 10 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Throttle Body: > 91257 > Dec > 91 > Engine Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 4029 Figure 11 THROTTLE BODY AND IDLE AIR BY-PASS SOLENOID SERVICE PROCEDURE Detailed application charts for throttle body and idle air by-pass solenoid service procedures by engine VIN # /engine displacement/vehicle application and model year are shown in Figures 6 through 11. Refer to these charts to see if the service kit is to be installed and which service cleaning procedure, if any, is to be used. SERVICE CLEANING PROCEDURES The following items should be noted prior to beginning the service cleaning procedure. ^ Confirm that the correct service cleaning procedure is identified in the Application Charts, Figures 6-11, for the vehicle/engine combination being Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Throttle Body: > 91257 > Dec > 91 > Engine Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 4030 serviced. ^ Do not clean throttle bodies identified to accept service kit (F2PZ-9F939-A), IDLE AIR ADJUST SPACER. ^ Use a 1" (25.4 mm) to 1-1/2" (38.1 mm) wire stemmed horse hair or nylon bottle cleaner type brush. ^ Use rubber gloves and eye protection. ^ Do not clean throttle bodies identified with a yellow/black "ATTENTION" label. ^ Do not clean "Black" plastic air by-pass valves. Refer to TSB 89-13-8 for service details. ^ Do not run vehicles with air flow meters when the air duct is removed. ^ Do not use carburetor cleaner as a cleaning solvent. Use Carburetor Tune-up Cleaner (D9AZ-19579-AA). Procedure # 1 THROTTLE BODY AND IDLE AIR BY-PASS VALVE CLEANING CAUTION: DO NOT RUN VEHICLES EQUIPPED WITH AIR FLOW METERS DURING THE CLEANING PROCEDURE. IF THERE IS A YELLOW/BLACK "ATTENTION" LABEL ON THE THROTTLE BODY ADVISING NOT TO CLEAN, OR IF THE VEHICLE IS IDENTIFIED AS ACCEPTING SERVICE KIT (F2PZ-9F939-A), USE PROCEDURE # 2 FOR IDLE AIR BY-PASS VALVE CLEANING ONLY. 1. Plug the actuator into the connector in the Rotunda Cleaner/Tester, Tool 113-00009. 2. Remove the air duct to the throttle body inlet. 3. Disoonnect the idle air by-pass valve signal lead. 4. Attach the actuator harness plug to the idle air by-pass valve. 5. Start the actuator and then start the engine. Do not start engines that have air flow meters. 6. Spray just enough Carburetor Tune-up Cleaner (D9AZ-19579-AA) into the throttle bore to wet the bore and throttle plate. 7. Spray the Carburetor Tune-up Cleaner for about five (5) seconds into the idle air by-pass valve inlet passage while the actuator is operating. 8. Stop the engine and actuator. Let everything soak for fifteen (15) minutes. 9. After a fifteen (15) minute soak, saturate the cleaning brush with solvent and scrub between the throttle body bore and plate while holding the throttle wide open. NOTE: IT IS NECESSARY TO APPLY SOME PRESSURE ON THE BRUSH WHILE SCRUBBING. 10. Repeat saturating the brush and scrubbing for one (1) to two (2) minutes, making sure to reach into the corners where the throttle shaft meets the bore wall. 11. Start the actuator and the start the engine. Do not start engines that have air flow meters. 12. Spray Carburetor Tune-up Cleaner into the throttle bore for up to one (1) minute to wash away residue. Do not spray for longer than six (6) continuous seconds on engines that have air flow meters and are not running. 13. Spray Carburetor Tune-up Cleaner into the idle by-pass valve passage leading to the inlet of the valve for up to one (1) minute. Do not spray for longer than six (6) continuous seconds on engines that have air flow meters and are not running. 14. Stop actuator and stop engine, if running. NOTE: MAKE SURE THE THROTTLE PLATES OPERATE FREELY AND CLOSE PROPERLY. 15. Reinstall the air duct. 16. Start and run the engine for about one (1) minute to dry out the solvent residue. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Throttle Body: > 91257 > Dec > 91 > Engine Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 4031 17. Operate the actuator to make sure the solvent is purged from the idle by-pass valve. 18. Disconnect the actuator from the idle air by-pass valve. 19. Reattach the control signal lead to the air by-pass valve. 20. Check engine for normal operation. It may be necessary to reset the idle speed due to a previous adjustment for an idle concern. (Refer to the respective Powertrain/Emissions Diagnosis Service Manual, Throttle Body Section, for idle speed adjust procedure.) Procedure # 2 Idle Air By-Pass Valve Cleaning Only CAUTION: THIS CLEANING PROCEDURE MAY BE USED WITH SLUDGE TOLERANT THROTTLE BODIES WHICH ARE IDENTIFIED WITH A YELLOW/BLACK "ATTENTION" LABEL AND THOSE USING SERVICE KIT (F2PZ-9F939-A). NO ATTEMPT SHOULD BE MADE TO CLEAN THROTTLE BODY BORE/PLATE AREA BY DIRECT SPRAYING OR SCRUBBING. DO NOT RUN VEHICLES WITH AIR FLOW METERS DURING CLEANING PROCEDURE. 1. Plug the actuator into the connector in the Rotunda Air By-Pass Valve Adapter 113-00009, or equivalent. 2. Remove the air duct to the throttle body inlet. 3. Disconnect the idle air by-pass valve signal lead. 4. Attach the actuator harness plug to the idle air by-pass valve. 5. Start the actuator and then start the engine. NOTE: DO NOT START ENGINES THAT HAVE AIR FLOW METERS. 6. Spray the Carburetor Tune-up Cleaner for about five (5) seconds into the idle air by-pass valve inlet passage while the actuator is operating. CAUTION: AVOID DIRECT SPRAYING ON THROTTLE PLATE/BORE AREA. 7. Stop the engine and actuator. Let everything soak for fifteen (15) minutes. 8. Start the actuator and the start the engine. CAUTION: DO NOT START ENGINES THAT HAVE AIR FLOW METERS. 9. Spray Carburetor Tune-up Cleaner into the throttle bore for up to one (1) minute. CAUTION: DO NOT SPRAY FOR LONGER THAN SIX (6) CONTINUOUS SECONDS ON ENGINES THAT HAVE AIR FLOW METERS AND ARE NOT RUNNING. 10. Stop actuator and stop engine if running. 11. Reinstall the air duct. 12. Start and run the engine for about one (1) minute to dry out the solvent residue. 13. Operate the actuator to make sure the solvent is purged from the idle by-pass valve. 14. Disconnect the actuator from the idle air by-pass valve. 15. Reattach the control signal lead to the air by-pass valve. 16. Check engine for normal operation. NOTE: IT SHOULD NOT BE NECESSARY TO RESET THE IDLE SPEED SINCE ONLY THE IDLE AIR BY-PASS VALVE WAS SERVICED IN THIS PROCEDURE Warranty Coverage Throttle bodies and idle air by-pass valves on all EFI (Port Fuel Injection) engines through the 1992 model year that can be cleaned (as identified in the application charts) are covered under 5/50 Emissions Warranty Coverage. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Throttle Body: > 91257 > Dec > 91 > Engine Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 4032 For those throttle bodies identified as having sludge tolerant designs or using service kit (F2PZ-9F939-A) where cleaning is not allowed per the application charts, the warranty claims for cleaning will not be reimbursed even within the 12/12 warranty coverage period. Cleaning is not allowed. Service kit installation (single time) is covered under 5/50 emission warranty. Labor Standards Operations The labor operations shown in the following Operation/Description/Time columns are identified by procedure number and vehicle line. Specific engines for various vehicles are identified in the sludge cleaning procedure application charts. The throttle body cleaning operations with combinations and the air by-pass valve cleaning combinations will appear in future Labor Manuals under the following operation numbers. ^ 9926 B - Throttle body and idle air by-pass valve cleaning ^ 9926 B2 - Adjust idle speed ^ 9715 A - Air by-pass valve cleaning only ^ 9715 A1 - Adjust idle speed PART NUMBER PART NAME CLASS F2PZ-9F939-A Idle Air By-pass Service Kit B D9AZ-19579-AA Carburstor Tune-Up Cleaner BG OTHER APPLICABLE ARTICLES: 89-13-8 SUPERSEDES: 88-24-5, 88-24-6, 89-16-5, 91-10-9, 91-7-4 Operation Description WARRANTY STATUS: Eligible Under Warranty Coverage As Stated In The Text Of This Article OPERATION DESCRIPTION TIME 912507A Idle Air By-Pass Valve 0.5 Hr. Cleaning - 1983-85 Escort, EXP, LN7, LYNX 1.6L EFI. 912507B Idle Air By-Pass Valve 0.5 Hr. Cleaning - 1986-91 Escort 1.9L EFI, 1986/87 EXP, Lynx 1.9L EFI, 1991 Tracer 1.9L EFI. 912507C Idle Air By Pass Valve 0.5 Hr. Cleaning - 1984-87 Mustang 2.3L T/C, 1986/87 Capri, Cougar 2.3L T/C, 1984-88 T-Bird 2.3L T/C, 1987/92 Mustang 2.3L EFI. 912507D Idle By-Pass Valve Cleaning 0.6 Hr. - 1988-91 Tempo, Topaz 2.3L HSC, 1985-92 Ranger 2.3L EFI. 912507E Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1986/87 Aerostar 2.3L EFI, 1985 Bronco II 2.3L EFI. 912507F Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1986-90 Bronco II 2.9L EFI, 1986-92 Ranger 2.9L EFI. 912507G Idle Air By-Pass Valve 0.6 Hr. Cleaning - 1991/92 Probe 3.0L EFI, 1986-91 Taurus 3.0L EFI, 1987-91 Sable 3.0L EFI. 912507H Idle Air By-Pass Valve 0.7 Hr. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Throttle Body: > 91257 > Dec > 91 > Engine Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 4033 Cleaning - 1986-91 Aerostar 3.0L EFI, 1991 Ranger 3.0L EFI. 912507I Idle Air By-Pass Valve 0.6 Hr. Cleaning - 1988 Continental, Cougar, Taurus, T-Bird, Sable 3.8L EFI. 1988 Cougar, T-Bird 3.8L S/C. 912507J Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1990-92 Aerostar 4.0L EFI, 1990 Bronco II 4.0L EFI, 1991/92 Explorer 4.0L EFI, 1990-92 Ranger 4.0L EFI. 912507K Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1987-92 Bronco 4.9L EFI, 1987-92 F-Series 4.9L EFI, 1987/90 Econoline (Without Rear Heater) 4.9L EFI, 1991/92 Econoline (All) 4.9L EFI. 912507L Idle Air By-Pass Valve 0.6 Hr. Cleaning - 1986-88 Cougar, T-Bird 5.0L EFI, 1986-87 Continental, Mark VII 5.OL EFI, 1986/91 Crn - Victoria, Grn - Marquis 5.0L EFI, 1986-92 Mark VII 5.0L HO, 1982-92 Mustang 5.0L HO. 912507M Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1985-92 Bronco, E-Series, F-Series 5.0L EFI. 912507N Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1988-90 Bronco, F-Series 5.8L. 1991 Econo, F-Series, Bronco 5.8L (Do not Clean Solenoid, Calib; 1-64E-R10, 1-64H-R10, 1-64J-R10, 1-64K-R10, 1-64M-R10, 1-64P-R10, 1-64R-R10, 1-75A-R00, 1-76A-R00, 1-76B-R00, 1-76C-R00. 912507O Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1991/92 F And B Series, 7.0L EFI. 912507P Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1987-92 E-Series, F-Series 7.5L EFI. 912507Q Throttle Body And Idle Air 0.9 Hr. By-Pass Valve Cleaning - 1989/90 Probe 3.0L EFI. 912507R Throttle Body And Idle Air 0.8 Hr. By-Pass Valve Cleaning - 1987-90 Econoline (With Rear Heat) 4.9L EFI. 912507S Throttle Body And Idle Air 0.9 Hr. By-Pass Valve Cleaning - 1988-90 Econoline 5.8L EFI. 912507T Service Kit Install - All Cars 1.0 Hr. And Light Trucks (Except Aerostar And Econoline) - Refer To The Service Procedure Application Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Throttle Body: > 91257 > Dec > 91 > Engine Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 4034 Charts, For Vehicle Application. 912507U Service Kit Install - 1.2 Hr. Aerostar, Econoline - Refer To Service Procedure Application Charts - For Vehicle Application. DEALER CODING BASIC PART NO. CONDITION CODE 9E926 49 OASIS CODES: 602300, 607000, 607400, 607700, 608400, 611500, 618400 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Full Open Switch HVAC > Component Information > Description and Operation Throttle Full Open Switch HVAC: Description and Operation A switch assembly, Figure 1 is mounted on the carburetor on some gasoline engines and on the fuel injector pump on the 2.0L Diesel engine to sense a wide open throttle condition. When maximum engine power is required, this switch assembly cuts off the air conditioning compressor to reduce engine loading. Switch closed at throttle opening less than wide open throttle. Switch open at wide open throttle condition. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Throttle Position Sensor - Request For Return Throttle Position Sensor: Technical Service Bulletins Throttle Position Sensor - Request For Return Number: 92686 To: All Ford and Lincoln-Mercury Dealers Subject: Request for Return of Throttle Position Sensor E5ZZ-9B989-B (CX-1022) and E6ZZ-9B989-B (CX-1130) Because the subject parts may not meet Ford's high quality requirements, they should be withdrawn from all inventories. All used E5ZZ-9B989-B (CX-1022) and E6ZZ-9B989-B (CX-1130) should be returned to your facing PDC within 30 days from the date of this letter. Use the least expensive mode of transportation for your return. The subject parts are obsolete and replaced by E7SZ-9B989-B (CX-1200), which is available for ordering immediately. You are requested to complete a separate FPS-340 form in accordance with the instructions on the front of the form. Annotate "Return Per FPSD Instructions Purge No. PN 1026" in the Customer's Detail Explanation Section and use Reason Code J (Unsatisfactory Service Stock). You will receive full credit in your parts statement for the price of each unused part returned, plus the prepaid transportation cost. In order to receive credit, all parts must be received at the Parts Distribution Center within 30 days from the date of this letter. Material other than subject parts received on this return will be sent back to you freight collect. Any questions should be referred to your Zone Manager or facing PDC Manager. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Throttle Position Sensor - Request For Return > Page 4042 Throttle Position Sensor: Technical Service Bulletins Throttle Position Sensor - Diagnostic Tips Article No. 85-20-11 SELF-TEST CODE 53 - EEC IV - THROTTLE POSITION SENSOR DIAGNOSTIC TIP FORD 1985-86 ESCORT, EXP, TEMPO, MUSTANG, LTD, THUNDERBIRD LINCOLN-MERCURY 1985-86 LYNX, TOPAZ, CAPRI, MARQUIS, COUGAR LIGHT TRUCK 1985-86 RANGER, BRONCO II, ECONOLINE, F-SERIES CALIBRATION: All with EEC IV WARNING: This modification is authorized only for the listed engines. Performing this modification on other engine calibrations is unauthorized and could create liability under applicable federal or local laws. A new design Throttle Position Sensor (TPS) has been released for all 1986 EEC IV applications. The new TPS is designed to eliminate a false Self-Test Code 53. A Code 53 indicates the TPS system has failed at the wide open throttle position (approximately 5.0 volts), The new TPS eliminates false Code 53 by limiting the wide open throttle voltage to 4.75 volts. With the new TPS, Code 53 will only result from a circuit or TPS malfunction. The new Throttle Position Sensors can be used to replace faulty sensors on 1985 vehicles. If the old design service part is used, a false Code 53 may result. PART NUMBER PART NAME CLASS E6DZ-9B989-A Throttle Position Sensor C E6TZ-9B989-C Throttle Position Sensor WC E6DZ-9B989-C Throttle Position Sensor WC E6FZ-9B989-A Throttle Position Sensor B E6ZZ-9B989-A Throttle Position Sensor B E6ZZ-9B989-B Throttle Position Sensor WC E6TZ-9B989-A Throttle Position Sensor C OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Throttle Position Sensor - Request For Return > Page 4043 Throttle Position Sensor: Technical Service Bulletins Throttle Position Sensor - Application Chart EEC-IV THROTTLE POSITION SENSOR-APPLICATION CHART-SERVICE TIP Article No. 89-16-4 FORD: 1984-88 CROWN VICTORIA, ESCORT, EXP, MUSTANG, TAURUS, TEMPO, THUNDERBIRD LINCOLN-MERCURY: 1984-88 COUGAR, GRAND MARQUIS, LYNX, MARK VI, MARK VII, SABLE, TOPAZ, TOWN CAR LIGHT TRUCK: 1984-88 ALL LIGHT TRUCK LINES ISSUE: A quick reference throttle position sensor (TPS) application chart has been put together to assist technicians in correct part useage. If the wrong TPS is installed, it could fail prematurely. ACTION: Refer to one of the following TPS service replacement charts to make sure that the correct service part is installed. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Throttle Position Sensor - Request For Return > Page 4044 OASIS CODES: 680000 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Throttle Position Sensor - Request For Return > Page 4045 Throttle Position Sensor: Technical Service Bulletins TPS Mounting Screws - Hard to Remove THROTTLE POSITION SENSOR-MOUNTING SCREWS HARD TO REMOVE-SERVICE TIP Article No. 89-14-7 FORD: 1983-89 CROWN VICTORIA, MUSTANG, TEMPO, THUNDERBIRD 1984-89 ESCORT 1986-89 TAURUS LINCOLN-MERCURY: 1983-89 CONTINENTAL, COUGAR, GRAND MARQUIS, MARK VII, TOPAZ, TOWN CAR 1984-87 LYNX MERKUR: 1985-89 ALL MERKUR LINES LIGHT TRUCK: 1983-89 ALL LIGHT TRUCK LINES ISSUE: All Throttle Position Sensor (TPS) mounting screws have a "Pozidrive" head. The "Pozidrive" head looks a lot like a Phillips screw head. Use of a Phillips head screwdriver to remove a "Pozidrive" screw will normally result in a rounded or damaged screw head. Many technicians think it is an overtorqued or "frozen" screw. An adhesive was also used as a thread sealant starting with the 1988 model year. This adhesive requires still more effort to loosen and remove the screw. ACTION: To prevent rounded or damages screw heads when servicing the TPS mounting screws, technicians should always use a # 2 "Pozidrive" screwdriver. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 4800, 680000 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 4046 THROTTLE POSITION SENSOR SPECIFICATIONS Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 4047 Engine View Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 4048 Throttle Position Sensor: Description and Operation The Throttle Position (TP) Sensor (Rotary), Figure 1 supplies the ECA with a signal proportional to opening angle of carburetor throttle plates. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 4049 Throttle Position Sensor: Testing and Inspection Ford provides trouble code/symptom driven diagnostics for this component. For complete diagnosis and pinpoint testing, refer to Computers and Control Systems, Testing and Inspection. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 4050 Throttle Position Sensor: Adjustments ADJUSTMENT This procedure can be used to check and/or adjust level C sensors only: 1. Install an EEC-IV Breakout Box, Rotunda T83L-50 EEC-IV, or equivalent. 2. Attach a DVOM, Rotunda 014-00407 or equivalent, on 20V scale. Connect the positive lead (+) to test Pin 47 and the negative lead (-) to test Pin 46. 3. Turn ignition key to Run position (do not start engine). 4. Adjust TP Sensor (rotate) until the DVOM reads 1.0V (0.9-1.1). 5. Tighten TP Sensor screws to 1.2-1.8 N-m (11-16 lb-in). 6. While watching the DVOM, move the throttle to wide open and back to idle position. For proper operation, the DVOM should move from 1.0 to at least 4.0 and back to 1.0V. 7, Perform EEC-IV Quick Test. Refer to Powertrain Management/Computers and Control Systems/System Diagnosis Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Firing Order > Component Information > Specifications Firing Order: Specifications Location On Distributor FIRING ORDER: 1-3-7-2-6-5-4-8 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Timing > Ignition Timing Connector > Component Information > Description and Operation Ignition Timing Connector: Description and Operation Fig. 20 Ignition Timing Vacuum Switch Below vacuum setting, this switch, Fig. 20, used on some vehicles, is open and signals the ignition module to retard spark timing. The switch is closed above the vacuum setting and the ignition module is in the non-retard spark timing mode. Calibration resistors inside the switch control the amount of retard. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Timing > Ignition Timing Connector > Component Information > Description and Operation > Page 4059 Ignition Timing Connector: Testing and Inspection Ignition Timing Vacuum Switch Ignition Timing Vacuum Switch Test Chart 1. Disconnect switch from ignition module. 2. Connect suitable ohmmeter across switch terminals and compare resistance measured to ``less than'' values in the Ignition Timing vacuum Switch Test chart. 3. Apply vacuum to switch, using an outside vacuum source. Compare resistance now measured across switch terminals to ``greater than'' values in the Ignition Timing vacuum Switch Test chart. 4. Replace switch if resistance is not within specifications. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Timing > Number One Cylinder > Component Information > Locations Number One Cylinder: Locations Cylinder Numbering And Distributor Location Location On Distributor Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Timing > Timing Marks and Indicators > System Information > Diagrams Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Resistor <--> [Ignition Ballast Resistor] > Component Information > Specifications Ignition Resistor: Specifications BALLAST RESISTOR: Wire Type - Resistance: 1.1 Ohms + or - .05 Ohms Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Resistor <--> [Ignition Ballast Resistor] > Component Information > Specifications > Page 4069 Ignition Resistor: Locations The Ballast Resistor is a wire type and is in-line with the ignition wiring harness located near the steering column. NOTE: Verify vehicle has a ballast resistor by referencing wiring diagram. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Resistor <--> [Ignition Ballast Resistor] > Component Information > Specifications > Page 4070 Ignition Resistor: Description and Operation The ballast resistor, (wire type), maintains a specific resistance between the positive (Batt.) terminal of the ignition coil connector and the wiring harness connector. It is not in operation during engine cranking enabling the coil to receive a hotter signal for starting. Once the engine is running, the resistor is used to protect the coil from voltage overload. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Resistor <--> [Ignition Ballast Resistor] > Component Information > Specifications > Page 4071 Ignition Resistor: Testing and Inspection 1. Disconnect module connector with red and white wires then, ignition coil connector. 2. Using a suitable ohmmeter, measure resistance between Batt. terminal of ignition coil connector and wiring harness connector wire that joins red wire in module connector. 3. If resistance is 0.8---1.6 ohms, ballast resistor is satisfactory. If resistance is less than 0.8 ohms or greater than 1.6 ohms, replace ballast resistor. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Camshaft Position Sensor: Diagram Information and Instructions Symbol Identification Wire Color Code Identification Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4076 NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Crankshaft Position Sensor: Diagram Information and Instructions Symbol Identification Wire Color Code Identification Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4081 NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Distributor, Ignition > Distributor Advance Unit > Component Information > Specifications DISTRIBUTOR TIMING ADVANCE Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Distributor, Ignition > Distributor Advance Unit > Component Information > Description and Operation > Vacuum Spark Advance Mechanism Distributor Advance Unit: Description and Operation Vacuum Spark Advance Mechanism The vacuum spark control mechanism can provide spark advance if a single diaphragm assembly is used or spark advance and retard if a dual diaphragm assembly is used. The diaphragm assembly used depends on the engine calibration. Single Diaphragm Assembly SINGLE DIAPHRAGM ASSEMBLY The single diaphragm assembly, Fig. 11, also changes the armature to stator relationship to give spark advance. The stator assembly position is changed by means of vacuum being applied to the diaphragm assembly. Vacuum applied to the diaphragm assembly causes the diaphragm and attached diaphragm rod to move, compressing the advance spring, which controls the rate of advance. The movement of the diaphragm rod, which is attached to the stator assembly, makes the the stator assembly move with respect to the armature. This changes the initial armature to stator relationship set during initial timing, causing spark advance. The stator assembly is mounted on the lower plate assembly which with the diaphragm assembly, is attached to the distributor base. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Distributor, Ignition > Distributor Advance Unit > Component Information > Description and Operation > Vacuum Spark Advance Mechanism > Page 4088 Dual Diaphragm Assembly DUAL DIAPHRAGM ASSEMBLY The dual diaphragm assembly, Fig. 12, obtains spark advance in the same manner as the single diaphragm assembly. In this case vacuum applied to the vacuum advance port causes the advance diaphragm and attached rod to move, otherwise the action is the same. Spark retard is done by applying vacuum to the vacuum retard port. This causes the retard diaphragm to move, compressing the retard spring, which controls the rate of spark retard. Compressing the retard spring allows the diaphragm rod stop to move due to the force applied by the advance spring pushing against it by means of the diaphragm rod. The result is the diaphragm rod moves causing the attached stator assembly to change position with respect to the armature. In this instance the direction of the stator assembly movement is opposite that occurring during vacuum advance, resulting in spark retard. NOTE: Any vacuum applied to the advance port overrides any spark retard caused by vacuum being applied to the retard port. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Distributor, Ignition > Distributor Advance Unit > Component Information > Description and Operation > Vacuum Spark Advance Mechanism > Page 4089 Distributor Advance Unit: Description and Operation Centrifugal Spark Advance Mechanism Distributor - Exploded view The centrifugal advance mechanism varies the relationship of the armature to the stator assembly. The armature is mounted to the sleeve and plate assembly which rotates in relation to the distributor shaft. The rotation is a result of the centrifugal weights moving in response to engine RPM. The movement of the weights change the initial relationship of the armature to the stator assembly by rotating the sleeve and plate assembly ahead of its static position on the distributor shaft Fig. 1. This produces spark advance. The rate of movement of the weights is controlled by calibrated springs. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Distributor, Ignition > Distributor Advance Unit > Component Information > Description and Operation > Page 4090 Distributor Advance Unit: Service and Repair 1. Remove distributor cap and rotor. 2. Disconnect vacuum lines, then remove snap ring that secures vacuum advance link to pickup assembly. 3. Remove vacuum advance attaching screws, then tilt unit downward to disconnect link. 4. Carefully remove unit from distributor. 5. Reverse procedure to install. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Distributor, Ignition > Distributor Cap > Component Information > Technical Service Bulletins > Engine - Lack of Power/No Start Diagnosis Distributor Cap: Technical Service Bulletins Engine - Lack of Power/No Start Diagnosis Article No. 91-12-11 06/12/91 LACK OF POWER 7.5L, 5.8L, 5.0L, 4.9L - CATALYTIC CONVERTER DIAGNOSTIC TIPS LIGHT TRUCK: 1986-91 BRONCO, ECONOLINE, F-150-350 SERIES 1988-91 F SUPER DUTY, F47 ISSUE: Lack of power or a no start condition may be diagnosed as an exhaust restriction caused by a plugged catalytic converter. A plugged catalytic converter (internal deterioration) is usually caused by abnormal engine operation. ACTION: Diagnose the catalytic converter to confirm internal failure. Refer to the Catalyst and Exhaust System Diagnostic Section, in the Engine/Emissions Diagnostic Shop Manual and the following procedures for service details. 1. Lack of proper HEGO operation may cause, or be the result of a rich or lean fuel condition, which could cause additional heat in the catalyst. Perform self test KOEO and KOER, service any codes. NOTE: IF TWO DIGIT CODES 41, 42, 85 OR THREE DIGIT CODES 171, 172, 173, 179, 181, 182, 183 AND 565 ARE RECEIVED, CHECK FOR PROPER HEGO GROUND. If the HEGO ground is good, the following areas may be at fault: ^ Ignition Coil ^ Distributor Cap ^ Distributor Rotor ^ Fouled Spark Plug ^ Spark Plug Wires ^ Air Filter ^ Stuck Open Injector ^ Fuel Contamination Engine OIL ^ Manifold Leaks Intake/ Exhaust ^ Fuel Pressure ^ Poor Power Ground ^ Engine Not At Normal Operating Temperature ^ HEGO Sensor 2. Spark timing that is retarded from specification may increase exhaust gas temperature and shorten catalyst life. Refer to the following procedure for service details. a. Check spark timing. Check base timing with spout disconnected. Set base timing to the specification on the vehicle emission decal. b. Check computed timing with spout connected. NOTE: COMPUTED TIMING IS EQUAL TO BASE TIMING PLUS 20~ BTDC +/- 3~. 3. Misfiring spark plugs may cause an unburned fuel air mixture to pass through the catalyst, which could cause higher than normal catalyst temperatures. Refer to the following procedure for service details. a. Check secondary ignition, hook the vehicle up to an engine analyzer and check for a secondary ignition misfire. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Distributor, Ignition > Distributor Cap > Component Information > Technical Service Bulletins > Engine - Lack of Power/No Start Diagnosis > Page 4095 NOTE: SERVICE ANY ITEM THAT IS NOT PERFORMING AT PROPER SPECIFICATIONS BEFORE CONTINUING. 4. Fuel pressure that is too high may cause rich air fuel mixtures to pass through the catalyst which could cause higher than normal catalyst temperatures. Refer to the following procedure for service details. a. Check fuel pressure, install fuel pressure gauge, start and run the engine at idle. Fuel pressures between 28 and 34 PSI are typical (4.9L typically is 15 PSI higher). b. Disconnect the vacuum line going to the fuel pressure regulator. Fuel pressure typically jumps to 40 PSI +/- 3 PSI (4.9L typically is 15 PSI higher). Visually inspect vacuum line for raw fuel. NOTE: FUEL PRESSURES ABOVE THESE VALUES SHOULD BE CORRECTED. HOWEVER, THIS MAY NOT BE THE CAUSE OF THE CONCERN. SERVICE AS NECESSARY. 5. Throttle plates in the throttle body not returning to the proper closed position may cause excessive catalyst temperatures during downhill grades. Refer to the following procedure for service details. a. Visually inspect the throttle body and linkage for: ^ Binding or sticking throttle linkage. ^ Tight speed control linkage or cable. ^ Vacuum line interference. ^ Electrical harness interference. NOTE: AFTERMARKET GOVERNORS, THROTTLE LINKAGE AND CABLES ASSOCIATED WITH POWER TAKE-OFF UNITS, MAY ALSO INTERFERE WITH PROPER THROTTLE RETURN. SERVICE AS NECESSARY. 6. It is extremely important that all systems related to the engine and emission systems operate properly. a. Visually inspect the engine compartment to make sure all vacuum hoses and spark plug wires are properly routed and securely connected. b. Inspect all wiring harnesses and connectors for insulation damage, burned, overheated, loose or broken conditions. c. Verify proper operation of the thermactor system. Thermactor systems that fail to dump thermactor air to the atmosphere properly or at the correct time can cause high catalyst temperatures. d. Visually inspect thermactor system for damaged or kinked hoses and perform a function test on following components: air control valve, check valve, silencer, filter and the air bypass solenoid. e. Verify proper operation of the engine cooling system thermostat. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under Basic Warranty Coverage, Emissions Warranty Coverage OPERATION DESCRIPTION TIME 911211A Diagnostics - Perform 0.5 Hrs. KOEO And KOER Self Tests 911211B Timing - Check Or Adjust 0.5 Hrs. Spark Timing, Check Computed Timing And Check Secondary Ignition System With Engine Analyzer. 911211C Check - Fuel Pressure And 0.2 Hrs. Inspect Vacuum Line For Raw Fuel. 911211D Inspect - Throttle Body And 0.1 Hrs. Linkage. 911211E Inspect - Vacuum Hoses, 0.1 Hrs. Electrical Harnesses, Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Distributor, Ignition > Distributor Cap > Component Information > Technical Service Bulletins > Engine - Lack of Power/No Start Diagnosis > Page 4096 Connectors And Spark Plug Wires For Routing Damage. 911211F Thermactor System - 0.3 Hrs. Inspect For Proper Operation And Damaged Component. Includes Function Check Of Air Control Valve, Thermactor Air Bypass Solenoid, Check Valves, Silencer And Filter. 911211G Thermostat - Check For 0.2 Hrs. Proper Operation. DEALER CODING BASIC PART NO. CONDITION CODE 5E212 25 OASIS CODES: 403000, 603300, 614000 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Distributor, Ignition > Ignition Rotor > Component Information > Technical Service Bulletins > Customer Interest: > 85218 > Oct > 85 > Distributor Rotor - Engine Bucking/Surging Ignition Rotor: Customer Interest Distributor Rotor - Engine Bucking/Surging Article No. 85-21-8 ENGINE MISS - DISTRIBUTOR WITH BLADE ROTOR - SILICONE GREASE ENGINE SURGE - DISTRIBUTOR WITH BLADE ROTOR - SILICONE GREASE RADIO NOISE - DISTRIBUTOR WITH BLADE ROTOR - SILICONE GREASE FORD 1986 ESCORT, EXP, TEMPO, MUSTANG, THUNDERBIRD, TAURUS, LTD, CROWN VICTORIA LINCOLN-MERCURY 1986 LYNX, TOPAZ, CAPRI, COUGAR, SABLE, MARQUIS, CONTINENTAL, MARK VII, LINCOLN LIGHT TRUCK 1986 E/F SERIES, BRONCO, RANGER, BRONCO II, AEROSTAR CALIBRATION: All with EEC IV 1986 vehicles are equipped with a new "blade" design distributor rotor. This design replaces the multi-point rotor used in recent model years. This new rotor requires the use of silicone grease on the blade. Electrical interference can result from a blade rotor that does not have silicone grease. The electrical interference affects the distributor stator assembly and can cause engine "missing", "bucking", or "surging". These drive concerns are usually intermittent and tend to occur during crank and heavy or wide-open throttle. It is important to remember not to remove the silicone grease for radio noise concerns, on 1986 vehicles with EEC IV; removing the grease can cause driveability concerns. A future TSB article will address the radio noise issue. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Distributor, Ignition > Ignition Rotor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Rotor: > 911211 > Jun > 91 > Engine Lack of Power/No Start Diagnosis Ignition Rotor: All Technical Service Bulletins Engine - Lack of Power/No Start Diagnosis Article No. 91-12-11 06/12/91 LACK OF POWER 7.5L, 5.8L, 5.0L, 4.9L - CATALYTIC CONVERTER DIAGNOSTIC TIPS LIGHT TRUCK: 1986-91 BRONCO, ECONOLINE, F-150-350 SERIES 1988-91 F SUPER DUTY, F47 ISSUE: Lack of power or a no start condition may be diagnosed as an exhaust restriction caused by a plugged catalytic converter. A plugged catalytic converter (internal deterioration) is usually caused by abnormal engine operation. ACTION: Diagnose the catalytic converter to confirm internal failure. Refer to the Catalyst and Exhaust System Diagnostic Section, in the Engine/Emissions Diagnostic Shop Manual and the following procedures for service details. 1. Lack of proper HEGO operation may cause, or be the result of a rich or lean fuel condition, which could cause additional heat in the catalyst. Perform self test KOEO and KOER, service any codes. NOTE: IF TWO DIGIT CODES 41, 42, 85 OR THREE DIGIT CODES 171, 172, 173, 179, 181, 182, 183 AND 565 ARE RECEIVED, CHECK FOR PROPER HEGO GROUND. If the HEGO ground is good, the following areas may be at fault: ^ Ignition Coil ^ Distributor Cap ^ Distributor Rotor ^ Fouled Spark Plug ^ Spark Plug Wires ^ Air Filter ^ Stuck Open Injector ^ Fuel Contamination Engine OIL ^ Manifold Leaks Intake/ Exhaust ^ Fuel Pressure ^ Poor Power Ground ^ Engine Not At Normal Operating Temperature ^ HEGO Sensor 2. Spark timing that is retarded from specification may increase exhaust gas temperature and shorten catalyst life. Refer to the following procedure for service details. a. Check spark timing. Check base timing with spout disconnected. Set base timing to the specification on the vehicle emission decal. b. Check computed timing with spout connected. NOTE: COMPUTED TIMING IS EQUAL TO BASE TIMING PLUS 20~ BTDC +/- 3~. 3. Misfiring spark plugs may cause an unburned fuel air mixture to pass through the catalyst, which could cause higher than normal catalyst temperatures. Refer to the following procedure for service details. a. Check secondary ignition, hook the vehicle up to an engine analyzer and check for a secondary ignition misfire. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Distributor, Ignition > Ignition Rotor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Rotor: > 911211 > Jun > 91 > Engine Lack of Power/No Start Diagnosis > Page 4110 NOTE: SERVICE ANY ITEM THAT IS NOT PERFORMING AT PROPER SPECIFICATIONS BEFORE CONTINUING. 4. Fuel pressure that is too high may cause rich air fuel mixtures to pass through the catalyst which could cause higher than normal catalyst temperatures. Refer to the following procedure for service details. a. Check fuel pressure, install fuel pressure gauge, start and run the engine at idle. Fuel pressures between 28 and 34 PSI are typical (4.9L typically is 15 PSI higher). b. Disconnect the vacuum line going to the fuel pressure regulator. Fuel pressure typically jumps to 40 PSI +/- 3 PSI (4.9L typically is 15 PSI higher). Visually inspect vacuum line for raw fuel. NOTE: FUEL PRESSURES ABOVE THESE VALUES SHOULD BE CORRECTED. HOWEVER, THIS MAY NOT BE THE CAUSE OF THE CONCERN. SERVICE AS NECESSARY. 5. Throttle plates in the throttle body not returning to the proper closed position may cause excessive catalyst temperatures during downhill grades. Refer to the following procedure for service details. a. Visually inspect the throttle body and linkage for: ^ Binding or sticking throttle linkage. ^ Tight speed control linkage or cable. ^ Vacuum line interference. ^ Electrical harness interference. NOTE: AFTERMARKET GOVERNORS, THROTTLE LINKAGE AND CABLES ASSOCIATED WITH POWER TAKE-OFF UNITS, MAY ALSO INTERFERE WITH PROPER THROTTLE RETURN. SERVICE AS NECESSARY. 6. It is extremely important that all systems related to the engine and emission systems operate properly. a. Visually inspect the engine compartment to make sure all vacuum hoses and spark plug wires are properly routed and securely connected. b. Inspect all wiring harnesses and connectors for insulation damage, burned, overheated, loose or broken conditions. c. Verify proper operation of the thermactor system. Thermactor systems that fail to dump thermactor air to the atmosphere properly or at the correct time can cause high catalyst temperatures. d. Visually inspect thermactor system for damaged or kinked hoses and perform a function test on following components: air control valve, check valve, silencer, filter and the air bypass solenoid. e. Verify proper operation of the engine cooling system thermostat. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under Basic Warranty Coverage, Emissions Warranty Coverage OPERATION DESCRIPTION TIME 911211A Diagnostics - Perform 0.5 Hrs. KOEO And KOER Self Tests 911211B Timing - Check Or Adjust 0.5 Hrs. Spark Timing, Check Computed Timing And Check Secondary Ignition System With Engine Analyzer. 911211C Check - Fuel Pressure And 0.2 Hrs. Inspect Vacuum Line For Raw Fuel. 911211D Inspect - Throttle Body And 0.1 Hrs. Linkage. 911211E Inspect - Vacuum Hoses, 0.1 Hrs. Electrical Harnesses, Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Distributor, Ignition > Ignition Rotor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Rotor: > 911211 > Jun > 91 > Engine Lack of Power/No Start Diagnosis > Page 4111 Connectors And Spark Plug Wires For Routing Damage. 911211F Thermactor System - 0.3 Hrs. Inspect For Proper Operation And Damaged Component. Includes Function Check Of Air Control Valve, Thermactor Air Bypass Solenoid, Check Valves, Silencer And Filter. 911211G Thermostat - Check For 0.2 Hrs. Proper Operation. DEALER CODING BASIC PART NO. CONDITION CODE 5E212 25 OASIS CODES: 403000, 603300, 614000 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Distributor, Ignition > Ignition Rotor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Rotor: > 85218 > Oct > 85 > Distributor Rotor - Engine Bucking/Surging Ignition Rotor: All Technical Service Bulletins Distributor Rotor - Engine Bucking/Surging Article No. 85-21-8 ENGINE MISS - DISTRIBUTOR WITH BLADE ROTOR - SILICONE GREASE ENGINE SURGE - DISTRIBUTOR WITH BLADE ROTOR - SILICONE GREASE RADIO NOISE - DISTRIBUTOR WITH BLADE ROTOR - SILICONE GREASE FORD 1986 ESCORT, EXP, TEMPO, MUSTANG, THUNDERBIRD, TAURUS, LTD, CROWN VICTORIA LINCOLN-MERCURY 1986 LYNX, TOPAZ, CAPRI, COUGAR, SABLE, MARQUIS, CONTINENTAL, MARK VII, LINCOLN LIGHT TRUCK 1986 E/F SERIES, BRONCO, RANGER, BRONCO II, AEROSTAR CALIBRATION: All with EEC IV 1986 vehicles are equipped with a new "blade" design distributor rotor. This design replaces the multi-point rotor used in recent model years. This new rotor requires the use of silicone grease on the blade. Electrical interference can result from a blade rotor that does not have silicone grease. The electrical interference affects the distributor stator assembly and can cause engine "missing", "bucking", or "surging". These drive concerns are usually intermittent and tend to occur during crank and heavy or wide-open throttle. It is important to remember not to remove the silicone grease for radio noise concerns, on 1986 vehicles with EEC IV; removing the grease can cause driveability concerns. A future TSB article will address the radio noise issue. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Distributor, Ignition > Ignition Rotor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Rotor: > 911211 > Jun > 91 > Engine Lack of Power/No Start Diagnosis Ignition Rotor: All Technical Service Bulletins Engine - Lack of Power/No Start Diagnosis Article No. 91-12-11 06/12/91 LACK OF POWER 7.5L, 5.8L, 5.0L, 4.9L - CATALYTIC CONVERTER DIAGNOSTIC TIPS LIGHT TRUCK: 1986-91 BRONCO, ECONOLINE, F-150-350 SERIES 1988-91 F SUPER DUTY, F47 ISSUE: Lack of power or a no start condition may be diagnosed as an exhaust restriction caused by a plugged catalytic converter. A plugged catalytic converter (internal deterioration) is usually caused by abnormal engine operation. ACTION: Diagnose the catalytic converter to confirm internal failure. Refer to the Catalyst and Exhaust System Diagnostic Section, in the Engine/Emissions Diagnostic Shop Manual and the following procedures for service details. 1. Lack of proper HEGO operation may cause, or be the result of a rich or lean fuel condition, which could cause additional heat in the catalyst. Perform self test KOEO and KOER, service any codes. NOTE: IF TWO DIGIT CODES 41, 42, 85 OR THREE DIGIT CODES 171, 172, 173, 179, 181, 182, 183 AND 565 ARE RECEIVED, CHECK FOR PROPER HEGO GROUND. If the HEGO ground is good, the following areas may be at fault: ^ Ignition Coil ^ Distributor Cap ^ Distributor Rotor ^ Fouled Spark Plug ^ Spark Plug Wires ^ Air Filter ^ Stuck Open Injector ^ Fuel Contamination Engine OIL ^ Manifold Leaks Intake/ Exhaust ^ Fuel Pressure ^ Poor Power Ground ^ Engine Not At Normal Operating Temperature ^ HEGO Sensor 2. Spark timing that is retarded from specification may increase exhaust gas temperature and shorten catalyst life. Refer to the following procedure for service details. a. Check spark timing. Check base timing with spout disconnected. Set base timing to the specification on the vehicle emission decal. b. Check computed timing with spout connected. NOTE: COMPUTED TIMING IS EQUAL TO BASE TIMING PLUS 20~ BTDC +/- 3~. 3. Misfiring spark plugs may cause an unburned fuel air mixture to pass through the catalyst, which could cause higher than normal catalyst temperatures. Refer to the following procedure for service details. a. Check secondary ignition, hook the vehicle up to an engine analyzer and check for a secondary ignition misfire. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Distributor, Ignition > Ignition Rotor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Rotor: > 911211 > Jun > 91 > Engine Lack of Power/No Start Diagnosis > Page 4121 NOTE: SERVICE ANY ITEM THAT IS NOT PERFORMING AT PROPER SPECIFICATIONS BEFORE CONTINUING. 4. Fuel pressure that is too high may cause rich air fuel mixtures to pass through the catalyst which could cause higher than normal catalyst temperatures. Refer to the following procedure for service details. a. Check fuel pressure, install fuel pressure gauge, start and run the engine at idle. Fuel pressures between 28 and 34 PSI are typical (4.9L typically is 15 PSI higher). b. Disconnect the vacuum line going to the fuel pressure regulator. Fuel pressure typically jumps to 40 PSI +/- 3 PSI (4.9L typically is 15 PSI higher). Visually inspect vacuum line for raw fuel. NOTE: FUEL PRESSURES ABOVE THESE VALUES SHOULD BE CORRECTED. HOWEVER, THIS MAY NOT BE THE CAUSE OF THE CONCERN. SERVICE AS NECESSARY. 5. Throttle plates in the throttle body not returning to the proper closed position may cause excessive catalyst temperatures during downhill grades. Refer to the following procedure for service details. a. Visually inspect the throttle body and linkage for: ^ Binding or sticking throttle linkage. ^ Tight speed control linkage or cable. ^ Vacuum line interference. ^ Electrical harness interference. NOTE: AFTERMARKET GOVERNORS, THROTTLE LINKAGE AND CABLES ASSOCIATED WITH POWER TAKE-OFF UNITS, MAY ALSO INTERFERE WITH PROPER THROTTLE RETURN. SERVICE AS NECESSARY. 6. It is extremely important that all systems related to the engine and emission systems operate properly. a. Visually inspect the engine compartment to make sure all vacuum hoses and spark plug wires are properly routed and securely connected. b. Inspect all wiring harnesses and connectors for insulation damage, burned, overheated, loose or broken conditions. c. Verify proper operation of the thermactor system. Thermactor systems that fail to dump thermactor air to the atmosphere properly or at the correct time can cause high catalyst temperatures. d. Visually inspect thermactor system for damaged or kinked hoses and perform a function test on following components: air control valve, check valve, silencer, filter and the air bypass solenoid. e. Verify proper operation of the engine cooling system thermostat. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under Basic Warranty Coverage, Emissions Warranty Coverage OPERATION DESCRIPTION TIME 911211A Diagnostics - Perform 0.5 Hrs. KOEO And KOER Self Tests 911211B Timing - Check Or Adjust 0.5 Hrs. Spark Timing, Check Computed Timing And Check Secondary Ignition System With Engine Analyzer. 911211C Check - Fuel Pressure And 0.2 Hrs. Inspect Vacuum Line For Raw Fuel. 911211D Inspect - Throttle Body And 0.1 Hrs. Linkage. 911211E Inspect - Vacuum Hoses, 0.1 Hrs. Electrical Harnesses, Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Distributor, Ignition > Ignition Rotor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Rotor: > 911211 > Jun > 91 > Engine Lack of Power/No Start Diagnosis > Page 4122 Connectors And Spark Plug Wires For Routing Damage. 911211F Thermactor System - 0.3 Hrs. Inspect For Proper Operation And Damaged Component. Includes Function Check Of Air Control Valve, Thermactor Air Bypass Solenoid, Check Valves, Silencer And Filter. 911211G Thermostat - Check For 0.2 Hrs. Proper Operation. DEALER CODING BASIC PART NO. CONDITION CODE 5E212 25 OASIS CODES: 403000, 603300, 614000 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Distributor, Ignition > Distributor Plate W/ Pick-up Sensor > Component Information > Service and Repair Distributor Plate W/ Pick-up Sensor: Service and Repair 1. Remove distributor cap and rotor. 2. Remove vacuum advance unit and magnetic pickup assembly. 3. Remove attaching screws and lift base plate from distributor. 4. Reverse procedure to install. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Hall Effect Sensor, Ignition > Component Information > Description and Operation Hall Effect Sensor: Description and Operation Profile Ignition Pickup The PIP signal is created in the Hall Effect and Stator assembly and indicates crankshaft position and engine RPM Fig. 21. The PIP signal is fed to both the TFI module and the ECA. PIP Sensor COMPONENTS The Hall Effect device is made up of a voltage regulator, a Hall voltage generator, Darlington amplifier, Schmitt trigger, and an open collector output stage integrated in a single monolithic silicon chip Fig. 22. A signal is produced when a ferrous material is passed through the opening and the flux lines decrease. The Hall generator (Hall device) sends a sine wave signal to the Darlington amplifier. The Darlington amplifier inverts the signal. When the signal is low the output is high. When the signal is high the output is low. This output then goes to the Schmitt trigger. The Schmitt trigger shapes the signal into a square wave (digital high) signal. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Hall Effect Sensor, Ignition > Component Information > Description and Operation > Page 4129 PIP Signal Operation OPERATION The output signal to the Darlington amplifier is high when the window (on the armature) allows the magnetic field to reach the Hall device (switch off) Fig. 23. When the TAB shunts the magnetic field (closes) away from the Hall device the signal is low to the Darlington amplifier (switch on). Hall Effect Sensor In other words when one of the windows or openings is in the gap between the Hall device and the permanent magnet, the field stays strong and the voltage is high since the magnetic path is complete from the magnet, through the Hall device, and back to the magnet. In this case the switch is off and the Hall Effect does not send a signal. When the TAB enters the gap, the armature cuts off the magnetic path to the Hall device and its voltage drops. In this case the switch is on and the Hall Effect device sends a signal. The signal is switched On and Off as long as the armature is rotating (distributor is turning) and opening and closing the magnetic path. This is the signal used by the ECA to interpret crankshaft position and engine RPM. The signal can also be used by the TFI module if the SPOUT signal from the ECA is lost. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Hall Effect Sensor, Ignition > Component Information > Description and Operation > Page 4130 Signature PIP SIGNATURE PIP Some Electronic Engine Control (EEC) vehicles are equipped with a signature profile ignition pickup signal. The regular type armature used for the PIP signal has the same size tabs and windows. In a signature PIP signal armature, one of the tabs is narrower than the others Fig. 25. The narrower tab provides a different signal to the ECA when it passes through the Hall Effect switch. When the ECA sees the narrow tab it knows when to properly pulse the fuel injectors. This system is used on cars and trucks where the ECA needs to know when to pulse certain injectors. For example, on sequential electronic fuel injection (SEFI) systems, each injector is pulsed to coincide with its intake valve opening. With the signature PIP, the ECA knows when the No. 1 cylinder needs to be supplied with fuel. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Hall Effect Sensor, Ignition > Component Information > Description and Operation > Page 4131 Hall Effect Sensor: Service and Repair Removal Do not attempt to replace stator without an arbor press. 1. Remove distributor. Remove rotor, then the TFI module. 2. If distributor uses push on type rotor, remove two retaining screws holding armature, then the armature. Hold gear to loosen armature screws, do not hold armature. 3. Mark stator, armature, gear and collar with felt tip pen to aid in reassembly. 4. Remove and discard pins in gear and collar if equipped. 5. Invert distributor and place in Axle Bearing Seal Plate and press off gear using Bearing Removal Tool. 6. Deburr and polish shaft with emery paper and wipe clean so that shaft slides out freely from distributor base. 7. Remove shaft assembly, then the thrust washer from shaft. Next remove octane rod. 8. Remove stator assembly screws, then the stator assembly from top of bowl. 9. Inspect base bushing for wear of signs of excess heat concentration, replace distributor assembly if damaged. 10. Inspect base O-ring for cuts or damage and replace as necessary. 11. Inspect base for cracks and wear, replace distributor assembly if damage is found. Installation 1. Place stator assembly over bushing and press down to seat. 2. Place stator connector in position, tab should fit in notch on base with fastening eyelets aligned with screw holes. 3. Install stator screws and Torque to 15-35 inch lbs. Next install octane rod. 4. Install thrust washer on top of bushing, then apply lubricant to distributor shaft below armature. Do not over lubricate. 5. Insert shaft through base bushing, then place collar, if equipped, over shaft and line up mark on armature and collar to aid alignment with original drill hole. Use a suitable drift punch to assure proper alignment. 6. Drill holes through shaft and collar should align on both sides of shaft. If holes do not align, collar may be 180 degrees out of alignment on shaft. Rotate collar on shaft one half rotation, then check. 7. Insert new roll pin through collar and shaft, pin should be flush with both sides of collar when seated. 8. If distributor uses push on type rotor, place a 1/2 inch deep well socket over shaft, invert and place on arbor plate. 9. If distributor uses screw down type rotor, invert and place on arbor plate. 10. Place distributor gear on shaft and line up marks on armature and gear. Hole in shaft and gear must line up as accurately as possible to assure ease of roll pin insertion. 11. Place a 5/8 inch deep well socket over shaft and gear, then press gear to align with original drill hole. 12. If gear holes do not align, gear must be removed and repressed on. Drift punch will not align holes, as in collar, holes should align. 13. Insert new roll pin through gear and shaft, pin should extrude evenly on both sides. 14. Install armature, if removed, and Torque screws to 25-35 inch lbs. 15. Install TFI module, rotor, then distributor. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Technical Service Bulletins > Engine - Lack of Power/No Start Diagnosis Ignition Cable: Technical Service Bulletins Engine - Lack of Power/No Start Diagnosis Article No. 91-12-11 06/12/91 LACK OF POWER 7.5L, 5.8L, 5.0L, 4.9L - CATALYTIC CONVERTER DIAGNOSTIC TIPS LIGHT TRUCK: 1986-91 BRONCO, ECONOLINE, F-150-350 SERIES 1988-91 F SUPER DUTY, F47 ISSUE: Lack of power or a no start condition may be diagnosed as an exhaust restriction caused by a plugged catalytic converter. A plugged catalytic converter (internal deterioration) is usually caused by abnormal engine operation. ACTION: Diagnose the catalytic converter to confirm internal failure. Refer to the Catalyst and Exhaust System Diagnostic Section, in the Engine/Emissions Diagnostic Shop Manual and the following procedures for service details. 1. Lack of proper HEGO operation may cause, or be the result of a rich or lean fuel condition, which could cause additional heat in the catalyst. Perform self test KOEO and KOER, service any codes. NOTE: IF TWO DIGIT CODES 41, 42, 85 OR THREE DIGIT CODES 171, 172, 173, 179, 181, 182, 183 AND 565 ARE RECEIVED, CHECK FOR PROPER HEGO GROUND. If the HEGO ground is good, the following areas may be at fault: ^ Ignition Coil ^ Distributor Cap ^ Distributor Rotor ^ Fouled Spark Plug ^ Spark Plug Wires ^ Air Filter ^ Stuck Open Injector ^ Fuel Contamination Engine OIL ^ Manifold Leaks Intake/ Exhaust ^ Fuel Pressure ^ Poor Power Ground ^ Engine Not At Normal Operating Temperature ^ HEGO Sensor 2. Spark timing that is retarded from specification may increase exhaust gas temperature and shorten catalyst life. Refer to the following procedure for service details. a. Check spark timing. Check base timing with spout disconnected. Set base timing to the specification on the vehicle emission decal. b. Check computed timing with spout connected. NOTE: COMPUTED TIMING IS EQUAL TO BASE TIMING PLUS 20~ BTDC +/- 3~. 3. Misfiring spark plugs may cause an unburned fuel air mixture to pass through the catalyst, which could cause higher than normal catalyst temperatures. Refer to the following procedure for service details. a. Check secondary ignition, hook the vehicle up to an engine analyzer and check for a secondary ignition misfire. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Technical Service Bulletins > Engine - Lack of Power/No Start Diagnosis > Page 4136 NOTE: SERVICE ANY ITEM THAT IS NOT PERFORMING AT PROPER SPECIFICATIONS BEFORE CONTINUING. 4. Fuel pressure that is too high may cause rich air fuel mixtures to pass through the catalyst which could cause higher than normal catalyst temperatures. Refer to the following procedure for service details. a. Check fuel pressure, install fuel pressure gauge, start and run the engine at idle. Fuel pressures between 28 and 34 PSI are typical (4.9L typically is 15 PSI higher). b. Disconnect the vacuum line going to the fuel pressure regulator. Fuel pressure typically jumps to 40 PSI +/- 3 PSI (4.9L typically is 15 PSI higher). Visually inspect vacuum line for raw fuel. NOTE: FUEL PRESSURES ABOVE THESE VALUES SHOULD BE CORRECTED. HOWEVER, THIS MAY NOT BE THE CAUSE OF THE CONCERN. SERVICE AS NECESSARY. 5. Throttle plates in the throttle body not returning to the proper closed position may cause excessive catalyst temperatures during downhill grades. Refer to the following procedure for service details. a. Visually inspect the throttle body and linkage for: ^ Binding or sticking throttle linkage. ^ Tight speed control linkage or cable. ^ Vacuum line interference. ^ Electrical harness interference. NOTE: AFTERMARKET GOVERNORS, THROTTLE LINKAGE AND CABLES ASSOCIATED WITH POWER TAKE-OFF UNITS, MAY ALSO INTERFERE WITH PROPER THROTTLE RETURN. SERVICE AS NECESSARY. 6. It is extremely important that all systems related to the engine and emission systems operate properly. a. Visually inspect the engine compartment to make sure all vacuum hoses and spark plug wires are properly routed and securely connected. b. Inspect all wiring harnesses and connectors for insulation damage, burned, overheated, loose or broken conditions. c. Verify proper operation of the thermactor system. Thermactor systems that fail to dump thermactor air to the atmosphere properly or at the correct time can cause high catalyst temperatures. d. Visually inspect thermactor system for damaged or kinked hoses and perform a function test on following components: air control valve, check valve, silencer, filter and the air bypass solenoid. e. Verify proper operation of the engine cooling system thermostat. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under Basic Warranty Coverage, Emissions Warranty Coverage OPERATION DESCRIPTION TIME 911211A Diagnostics - Perform 0.5 Hrs. KOEO And KOER Self Tests 911211B Timing - Check Or Adjust 0.5 Hrs. Spark Timing, Check Computed Timing And Check Secondary Ignition System With Engine Analyzer. 911211C Check - Fuel Pressure And 0.2 Hrs. Inspect Vacuum Line For Raw Fuel. 911211D Inspect - Throttle Body And 0.1 Hrs. Linkage. 911211E Inspect - Vacuum Hoses, 0.1 Hrs. Electrical Harnesses, Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Technical Service Bulletins > Engine - Lack of Power/No Start Diagnosis > Page 4137 Connectors And Spark Plug Wires For Routing Damage. 911211F Thermactor System - 0.3 Hrs. Inspect For Proper Operation And Damaged Component. Includes Function Check Of Air Control Valve, Thermactor Air Bypass Solenoid, Check Valves, Silencer And Filter. 911211G Thermostat - Check For 0.2 Hrs. Proper Operation. DEALER CODING BASIC PART NO. CONDITION CODE 5E212 25 OASIS CODES: 403000, 603300, 614000 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Technical Service Bulletins > Engine - Lack of Power/No Start Diagnosis > Page 4138 Ignition Cable: Technical Service Bulletins Ignition System - Diagnostics Manual Correction Article No. 89-5A-4 EEC IV - TFI IV - IGNITION SYSTEM - REVISED TIMING PROCEDURES AND DIAGNOSTICS SHOP MANUAL CORRECTION FORD: 1984-86 LTD 1984-88 EXP 1984-88 ESCORT THUNDERBIRD, MUSTANG, TEMPO, AND CROWN VICTORIA LINCOLN-MERCURY: 1984-86 CAPRI, MARQUIS 1984-87 LYNX 1984-88 COUGAR, TOPAZ, GRAND MARQUIS, CONTINENTAL, MARK VII, AND LINCOLN TOWN CAR LIGHT TRUCK: 1984-88 RANGER, BRONCO II, ECONOLINE, BRONCO, AND F-SERIES 1986-88 AEROSTAR ISSUE: The Ignition Coil and Secondary Wire Test Steps on pages 13-51 and 13-65 of the 1989 Engine Emissions Diagnosis Shop Manual, Volume H, have been revised. The new service information directs technicians to use a substitute coil instead of a resistance test. ACTION: Refer to this TSB for revised ignition coil and secondary wire test information. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" OASIS CODES: 680000 1989 Ignition Systems, Timing Procedures and Diagnostics 13-51 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Technical Service Bulletins > Engine - Lack of Power/No Start Diagnosis > Page 4139 Ignition Coil and Secondary Wire TFI-IV And TFI With CCD Part 2 Test 7 1989 13-52 Ignition Systems, Timing Procedures and Diagnostics Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Technical Service Bulletins > Engine - Lack of Power/No Start Diagnosis > Page 4140 EEC-IV - TFI-IV TFI-IV And TFI-IV With CCD Part 2 Test 8 1989 Ignition Systems, Timing Procedures and Diagnostics 13-65 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Technical Service Bulletins > Engine - Lack of Power/No Start Diagnosis > Page 4141 Ignition Coil And Secondary Wire TFI-IV Closed Bowl Distributor Part 2 Test 8 1989 13-66 Ignition Systems, Timing Procedures and Diagnostics Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Technical Service Bulletins > Engine - Lack of Power/No Start Diagnosis > Page 4142 EEC-IV - Wiring TFI-IV Closed Bowl Distributor Part 2 Test 9 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Technical Service Bulletins > Page 4143 Ignition Cable: Testing and Inspection Spark Plug Wire Resistance *** UPDATED BY TSB #85-9-33 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical Service Bulletins > Customer Interest: > 872018 > Oct > 87 > Engine/Ignition - No Start Condition Ignition Coil: Customer Interest Engine/Ignition - No Start Condition NO START - EEC IV - "E" COIL Article No. 87-20-18 FORD: 1983-86 LTD 1983-87 ESCORT, EXP, MUSTANG, THUNDERBIRD, CROWN VICTORIA 1984-87 TEMPO 1986-87 TAURUS LINCOLN-MERCURY: 1983 LN7 1983-86 MARQUIS 1983-87 LYNX, COUGAR, GRAND MARQUIS, MARK VII, CONTINENTAL, LINCOLN TOWN CAR 1984-87 TOPAZ 1986-87 SABLE LIGHT TRUCK: 1983-87 RANGER, E-SERIES, F-SERIES, BRONCO 1984-87 BRONCO II 1986-87 AEROSTAR This article is being republished in its entirety to expand the model year coverage. ISSUE: The primary winding of the E-core ignition coil may be damaged if the wire harness containing the tachometer circuit has a short to ground. ACTION: Before replacing the E-core ignition coil, perform the following diagnostic procedure. 1. Turn ignition to "ON" position. 2. Measure and record battery voltage. Figure 50 3. Measure and record voltage between negative terminal and coil and battery ground post as shown, Figure 50. 4. If the differencce in readings is greater than 1.0 volt, check tachometer circuit for a potential short to ground. 5. If a short is present, make necessary wire harness repair. 6. Replace ignition coil as required. OTHER APPLICABLE ARTICLES: Supersedes 84-14-18, 84-14-18-S, 85-16-13, 86-2-21 WARRANTY STATUS: "INFORMATION ONLY" Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical Service Bulletins > Customer Interest: > 8628 > Jan > 86 > Ignition Coil - Stumbles/Stalls/Noise In Radio Ignition Coil: Customer Interest Ignition Coil - Stumbles/Stalls/Noise In Radio Article No. 86-2-8 STUMBLES, STALLS - EEC - E-CORE IGNITION COIL NOISE IN RADIO - EEC - E-CORE IGNITION COIL CLOCK ERRATIC PERFORMANCE - EEC - E-CORE IGNITION COIL FORD 1983-86 ALL LINCOLN-MERCURY 1983-86 ALL LIGHT TRUCK 1983-86 ALL CALIBRATIONS: All with E-Core Ignition Coils This article is being reprinted to include 1986 vehicle applications. Stumbles, stals, poor performance, ignition noise in the radio, erratic electronic clock performance or erratic service codes during vehicle Quick Test can be caused by high voltage arc in the E-core ignition coil. Figure 8 The arc is a result of an open or high resistance in the coil secondary winding. The arc generates high fre quency noise in the vehicle electrical system. This noise can disrupt the EEC syste and invalid service codes such as 22,10,20,30, or 40 BCT. This condition can be checked as follows: 1. Place the ignition switch in the OFF position. 2. Disconnect the E-core ignition coil primary and secondary leads. 3. Using Rotunda digital volt-ohmmeter 007-00001, measure the resistance between the primary (+) terminal and the high voltage secondary terminal. (Figure 8). 4. If the resistance is greater than 14,000 ohms, replace the coil. 5. Reconnect the high voltage secondary lead and confirm that the protective boot is fully seated. 6. Reconnect the coil primary lead. 7. Verify that the reported condition has been cor rected. PART NUMBER PART NAME CLASS E3FZ-12029-A Ignition Coil A OTHER APPLICABLE ARTICLES: 84-23-1, 85-13-2 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical Service Bulletins > Customer Interest: > 8628 > Jan > 86 > Ignition Coil - Stumbles/Stalls/Noise In Radio > Page 4156 WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION: SP12029B84 TIME: 0.5 Hr. - F150-350, Bronco 0.6 Hr. - Econoline 0.3 Hr. - All Other DLR. CODING: Basic Part No. 12029 - Code: 28 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical Service Bulletins > Customer Interest: > 86220 > Jan > 86 > Ignition System - Weak/No Spark Ignition Coil: Customer Interest Ignition System - Weak/No Spark Article No. 86-2-20 IGNITION SYSTEM - TFI - WEAK OR NO SPARK - DIAGNOSTIC TIP FORD 1982-86 ESCORT, EXP; 1983-86 THUNDERBIRD, LTD, CROWN VICTORIA, MUSTANG; 1984-86 TEMPO; 1986 TAURUS LINCOLN-MERCURY 1982-83 LN7; 1982-86 LYNX; 1983-86 COUGAR, MERCURY, GRAND MARQUIS, CONTINENTAL, MARK VII, LINCOLN; 1984-86 TOPAZ; 1986 SABLE LIGHT TRUCK 1983-86 EAND F-SERIES, RANGER, BRONCO; 1984-86 BRONCO II; 1986 AEROSTAR CALIBRATIONS: All with TFI Systems If the TFI module fails and causes a short to ground, the primary winding of the ignition coil can be damaged. The TFI diagnostic procedure published in the Shop Manual will not identify this condition. When servicing a weak or no spark condition, perform the following: 1. Check for spark using the procedures found in the Manual Information, Computerized Engine, Quick Test Section, Test 1. 2. If there is no spark, test the coil primary resistance using Rotunda digital volt-ohmmeter 007-00001, as shown. 3. If the coil primary resistance is O.K., continue with the diagnostic procedure in Test 1. 4. If the coil primary resistance is not O.K., replace the coil and recheck for weak or no spark. If the spark is now O.K., the problem is resolved. 5. If the spark is still NOT O.K., continue with normal diagnostic procedure in Test 1. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Wiring Harness TFI-IV Part 2 Test 5 TEST EQUIPMENT: VOM, STRAIGHT PIN TEST PROCEDURE 1. Separate wiring harness connector from ignition module. Inspect for dirt, corrosion, and damage. NOTE: PUSH connector tabs to separate. 2. Disconnect wire at S terminal of starter relay. 3. Attach negative (-) VOM, Rotunda Number 007-00001, lead to distributor base. 4. Measure battery voltage. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical Service Bulletins > Customer Interest: > 86220 > Jan > 86 > Ignition System - Weak/No Spark > Page 4161 5. Following table below, measure connector terminal voltage by attaching VOM to small straight pin inserted into connector terminal and turning ignition switch to position shown. CAUTION: Do not allow straight pin to contact electrical ground. CONNECTOR IGNITION SWITCH TERMINAL WIRE/CIRCUIT TEST POSITION #2 TO IGNITION RUN COIL (-) TERMINAL #3 RUN CIRCUIT RUN AND START #4 START CIRCUIT START 6. Turn ignition switch to Off position. 7. Remove straight pin. 8. Reconnect wire to S terminal of starter relay. TEST RESULT TEST RESOLUTION 90 percent of ^ Test result OK. battery ^ Go to Part 2, Test 6. voltage minimum Less than 90 ^ Inspect for faults in wiring percent of harness and connectors. battery ^ Refer to vehicle wiring voltage diagram for appropriate circuit. ^ Damaged or worn ignition switch, Refer to Shop Manual, Group 33. Primary Circuit Continuity TFI-IV Part 2 Test 8 TEST EQUIPMENT: VOM, STRAIGHT PIN TEST PROCEDURE 1. Separate wiring harness connector from ignition module. Inspect for dirt, corrosion, and damage. NOTE: PUSH connector tabs to separate. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical Service Bulletins > Customer Interest: > 86220 > Jan > 86 > Ignition System - Weak/No Spark > Page 4162 2. Attach negative (-) VOM, Rotunda Number 007-00001, lead to distributor base. 3. Measure battery voltage. 4. Attach VOM to small straight pin inserted into connector terminal No. 2. CAUTION: Do not allow straight pin to contact electrical ground. 5. Turn ignition switch to Run position and measure terminal No. 2 voltage. 6. Turn ignition switch to Off position. 7. Remove straight pin. TEST RESULT TEST RESOLUTION 90 percent of ^ Go to Part 2, Test 5. battery voltage minimum Less than 90 ^ Go to Part 2, Test 9. percent of battery voltage Ignition Coil Primary Resistance TFI-IV Part 2 Test 3 TEST EQUIPMENT: VOM TEST PROCEDURE 1. Turn ignition switch to Off. 2. Disconnect ignition coil connector. Inspect for dirt, corrosion, and damage. 3. Measure resistance from positive (+) to negative (-) terminal of ignition coil, using Rotunda digital volt-ohmmeter 007-00001. TEST RESULT TEST RESOLUTION 0.3 to 1.0 ^ Test result OK. ohm ^ Go to Test 4. Less than ^ Replace ignition coil. 0.3 ohm or greater than 1.0 ohm Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Coil: > 911211 > Jun > 91 > Engine - Lack of Power/No Start Diagnosis Ignition Coil: All Technical Service Bulletins Engine - Lack of Power/No Start Diagnosis Article No. 91-12-11 06/12/91 LACK OF POWER 7.5L, 5.8L, 5.0L, 4.9L - CATALYTIC CONVERTER DIAGNOSTIC TIPS LIGHT TRUCK: 1986-91 BRONCO, ECONOLINE, F-150-350 SERIES 1988-91 F SUPER DUTY, F47 ISSUE: Lack of power or a no start condition may be diagnosed as an exhaust restriction caused by a plugged catalytic converter. A plugged catalytic converter (internal deterioration) is usually caused by abnormal engine operation. ACTION: Diagnose the catalytic converter to confirm internal failure. Refer to the Catalyst and Exhaust System Diagnostic Section, in the Engine/Emissions Diagnostic Shop Manual and the following procedures for service details. 1. Lack of proper HEGO operation may cause, or be the result of a rich or lean fuel condition, which could cause additional heat in the catalyst. Perform self test KOEO and KOER, service any codes. NOTE: IF TWO DIGIT CODES 41, 42, 85 OR THREE DIGIT CODES 171, 172, 173, 179, 181, 182, 183 AND 565 ARE RECEIVED, CHECK FOR PROPER HEGO GROUND. If the HEGO ground is good, the following areas may be at fault: ^ Ignition Coil ^ Distributor Cap ^ Distributor Rotor ^ Fouled Spark Plug ^ Spark Plug Wires ^ Air Filter ^ Stuck Open Injector ^ Fuel Contamination Engine OIL ^ Manifold Leaks Intake/ Exhaust ^ Fuel Pressure ^ Poor Power Ground ^ Engine Not At Normal Operating Temperature ^ HEGO Sensor 2. Spark timing that is retarded from specification may increase exhaust gas temperature and shorten catalyst life. Refer to the following procedure for service details. a. Check spark timing. Check base timing with spout disconnected. Set base timing to the specification on the vehicle emission decal. b. Check computed timing with spout connected. NOTE: COMPUTED TIMING IS EQUAL TO BASE TIMING PLUS 20~ BTDC +/- 3~. 3. Misfiring spark plugs may cause an unburned fuel air mixture to pass through the catalyst, which could cause higher than normal catalyst temperatures. Refer to the following procedure for service details. a. Check secondary ignition, hook the vehicle up to an engine analyzer and check for a secondary ignition misfire. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Coil: > 911211 > Jun > 91 > Engine - Lack of Power/No Start Diagnosis > Page 4168 NOTE: SERVICE ANY ITEM THAT IS NOT PERFORMING AT PROPER SPECIFICATIONS BEFORE CONTINUING. 4. Fuel pressure that is too high may cause rich air fuel mixtures to pass through the catalyst which could cause higher than normal catalyst temperatures. Refer to the following procedure for service details. a. Check fuel pressure, install fuel pressure gauge, start and run the engine at idle. Fuel pressures between 28 and 34 PSI are typical (4.9L typically is 15 PSI higher). b. Disconnect the vacuum line going to the fuel pressure regulator. Fuel pressure typically jumps to 40 PSI +/- 3 PSI (4.9L typically is 15 PSI higher). Visually inspect vacuum line for raw fuel. NOTE: FUEL PRESSURES ABOVE THESE VALUES SHOULD BE CORRECTED. HOWEVER, THIS MAY NOT BE THE CAUSE OF THE CONCERN. SERVICE AS NECESSARY. 5. Throttle plates in the throttle body not returning to the proper closed position may cause excessive catalyst temperatures during downhill grades. Refer to the following procedure for service details. a. Visually inspect the throttle body and linkage for: ^ Binding or sticking throttle linkage. ^ Tight speed control linkage or cable. ^ Vacuum line interference. ^ Electrical harness interference. NOTE: AFTERMARKET GOVERNORS, THROTTLE LINKAGE AND CABLES ASSOCIATED WITH POWER TAKE-OFF UNITS, MAY ALSO INTERFERE WITH PROPER THROTTLE RETURN. SERVICE AS NECESSARY. 6. It is extremely important that all systems related to the engine and emission systems operate properly. a. Visually inspect the engine compartment to make sure all vacuum hoses and spark plug wires are properly routed and securely connected. b. Inspect all wiring harnesses and connectors for insulation damage, burned, overheated, loose or broken conditions. c. Verify proper operation of the thermactor system. Thermactor systems that fail to dump thermactor air to the atmosphere properly or at the correct time can cause high catalyst temperatures. d. Visually inspect thermactor system for damaged or kinked hoses and perform a function test on following components: air control valve, check valve, silencer, filter and the air bypass solenoid. e. Verify proper operation of the engine cooling system thermostat. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under Basic Warranty Coverage, Emissions Warranty Coverage OPERATION DESCRIPTION TIME 911211A Diagnostics - Perform 0.5 Hrs. KOEO And KOER Self Tests 911211B Timing - Check Or Adjust 0.5 Hrs. Spark Timing, Check Computed Timing And Check Secondary Ignition System With Engine Analyzer. 911211C Check - Fuel Pressure And 0.2 Hrs. Inspect Vacuum Line For Raw Fuel. 911211D Inspect - Throttle Body And 0.1 Hrs. Linkage. 911211E Inspect - Vacuum Hoses, 0.1 Hrs. Electrical Harnesses, Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Coil: > 911211 > Jun > 91 > Engine - Lack of Power/No Start Diagnosis > Page 4169 Connectors And Spark Plug Wires For Routing Damage. 911211F Thermactor System - 0.3 Hrs. Inspect For Proper Operation And Damaged Component. Includes Function Check Of Air Control Valve, Thermactor Air Bypass Solenoid, Check Valves, Silencer And Filter. 911211G Thermostat - Check For 0.2 Hrs. Proper Operation. DEALER CODING BASIC PART NO. CONDITION CODE 5E212 25 OASIS CODES: 403000, 603300, 614000 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Coil: > 895A4 > Mar > 89 > Ignition System - Diagnostics Manual Correction Ignition Coil: All Technical Service Bulletins Ignition System - Diagnostics Manual Correction Article No. 89-5A-4 EEC IV - TFI IV - IGNITION SYSTEM - REVISED TIMING PROCEDURES AND DIAGNOSTICS SHOP MANUAL CORRECTION FORD: 1984-86 LTD 1984-88 EXP 1984-88 ESCORT THUNDERBIRD, MUSTANG, TEMPO, AND CROWN VICTORIA LINCOLN-MERCURY: 1984-86 CAPRI, MARQUIS 1984-87 LYNX 1984-88 COUGAR, TOPAZ, GRAND MARQUIS, CONTINENTAL, MARK VII, AND LINCOLN TOWN CAR LIGHT TRUCK: 1984-88 RANGER, BRONCO II, ECONOLINE, BRONCO, AND F-SERIES 1986-88 AEROSTAR ISSUE: The Ignition Coil and Secondary Wire Test Steps on pages 13-51 and 13-65 of the 1989 Engine Emissions Diagnosis Shop Manual, Volume H, have been revised. The new service information directs technicians to use a substitute coil instead of a resistance test. ACTION: Refer to this TSB for revised ignition coil and secondary wire test information. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" OASIS CODES: 680000 1989 Ignition Systems, Timing Procedures and Diagnostics 13-51 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Coil: > 895A4 > Mar > 89 > Ignition System - Diagnostics Manual Correction > Page 4174 Ignition Coil and Secondary Wire TFI-IV And TFI With CCD Part 2 Test 7 1989 13-52 Ignition Systems, Timing Procedures and Diagnostics Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Coil: > 895A4 > Mar > 89 > Ignition System - Diagnostics Manual Correction > Page 4175 EEC-IV - TFI-IV TFI-IV And TFI-IV With CCD Part 2 Test 8 1989 Ignition Systems, Timing Procedures and Diagnostics 13-65 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Coil: > 895A4 > Mar > 89 > Ignition System - Diagnostics Manual Correction > Page 4176 Ignition Coil And Secondary Wire TFI-IV Closed Bowl Distributor Part 2 Test 8 1989 13-66 Ignition Systems, Timing Procedures and Diagnostics Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Coil: > 895A4 > Mar > 89 > Ignition System - Diagnostics Manual Correction > Page 4177 EEC-IV - Wiring TFI-IV Closed Bowl Distributor Part 2 Test 9 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Coil: > 872018 > Oct > 87 > Engine/Ignition - No Start Condition Ignition Coil: All Technical Service Bulletins Engine/Ignition - No Start Condition NO START - EEC IV - "E" COIL Article No. 87-20-18 FORD: 1983-86 LTD 1983-87 ESCORT, EXP, MUSTANG, THUNDERBIRD, CROWN VICTORIA 1984-87 TEMPO 1986-87 TAURUS LINCOLN-MERCURY: 1983 LN7 1983-86 MARQUIS 1983-87 LYNX, COUGAR, GRAND MARQUIS, MARK VII, CONTINENTAL, LINCOLN TOWN CAR 1984-87 TOPAZ 1986-87 SABLE LIGHT TRUCK: 1983-87 RANGER, E-SERIES, F-SERIES, BRONCO 1984-87 BRONCO II 1986-87 AEROSTAR This article is being republished in its entirety to expand the model year coverage. ISSUE: The primary winding of the E-core ignition coil may be damaged if the wire harness containing the tachometer circuit has a short to ground. ACTION: Before replacing the E-core ignition coil, perform the following diagnostic procedure. 1. Turn ignition to "ON" position. 2. Measure and record battery voltage. Figure 50 3. Measure and record voltage between negative terminal and coil and battery ground post as shown, Figure 50. 4. If the differencce in readings is greater than 1.0 volt, check tachometer circuit for a potential short to ground. 5. If a short is present, make necessary wire harness repair. 6. Replace ignition coil as required. OTHER APPLICABLE ARTICLES: Supersedes 84-14-18, 84-14-18-S, 85-16-13, 86-2-21 WARRANTY STATUS: "INFORMATION ONLY" Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Coil: > 8628 > Jan > 86 > Ignition Coil - Stumbles/Stalls/Noise In Radio Ignition Coil: All Technical Service Bulletins Ignition Coil - Stumbles/Stalls/Noise In Radio Article No. 86-2-8 STUMBLES, STALLS - EEC - E-CORE IGNITION COIL NOISE IN RADIO - EEC - E-CORE IGNITION COIL CLOCK ERRATIC PERFORMANCE - EEC - E-CORE IGNITION COIL FORD 1983-86 ALL LINCOLN-MERCURY 1983-86 ALL LIGHT TRUCK 1983-86 ALL CALIBRATIONS: All with E-Core Ignition Coils This article is being reprinted to include 1986 vehicle applications. Stumbles, stals, poor performance, ignition noise in the radio, erratic electronic clock performance or erratic service codes during vehicle Quick Test can be caused by high voltage arc in the E-core ignition coil. Figure 8 The arc is a result of an open or high resistance in the coil secondary winding. The arc generates high fre quency noise in the vehicle electrical system. This noise can disrupt the EEC syste and invalid service codes such as 22,10,20,30, or 40 BCT. This condition can be checked as follows: 1. Place the ignition switch in the OFF position. 2. Disconnect the E-core ignition coil primary and secondary leads. 3. Using Rotunda digital volt-ohmmeter 007-00001, measure the resistance between the primary (+) terminal and the high voltage secondary terminal. (Figure 8). 4. If the resistance is greater than 14,000 ohms, replace the coil. 5. Reconnect the high voltage secondary lead and confirm that the protective boot is fully seated. 6. Reconnect the coil primary lead. 7. Verify that the reported condition has been cor rected. PART NUMBER PART NAME CLASS E3FZ-12029-A Ignition Coil A OTHER APPLICABLE ARTICLES: 84-23-1, 85-13-2 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Coil: > 8628 > Jan > 86 > Ignition Coil - Stumbles/Stalls/Noise In Radio > Page 4186 WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION: SP12029B84 TIME: 0.5 Hr. - F150-350, Bronco 0.6 Hr. - Econoline 0.3 Hr. - All Other DLR. CODING: Basic Part No. 12029 - Code: 28 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Coil: > 86220 > Jan > 86 > Ignition System - Weak/No Spark Ignition Coil: All Technical Service Bulletins Ignition System - Weak/No Spark Article No. 86-2-20 IGNITION SYSTEM - TFI - WEAK OR NO SPARK - DIAGNOSTIC TIP FORD 1982-86 ESCORT, EXP; 1983-86 THUNDERBIRD, LTD, CROWN VICTORIA, MUSTANG; 1984-86 TEMPO; 1986 TAURUS LINCOLN-MERCURY 1982-83 LN7; 1982-86 LYNX; 1983-86 COUGAR, MERCURY, GRAND MARQUIS, CONTINENTAL, MARK VII, LINCOLN; 1984-86 TOPAZ; 1986 SABLE LIGHT TRUCK 1983-86 EAND F-SERIES, RANGER, BRONCO; 1984-86 BRONCO II; 1986 AEROSTAR CALIBRATIONS: All with TFI Systems If the TFI module fails and causes a short to ground, the primary winding of the ignition coil can be damaged. The TFI diagnostic procedure published in the Shop Manual will not identify this condition. When servicing a weak or no spark condition, perform the following: 1. Check for spark using the procedures found in the Manual Information, Computerized Engine, Quick Test Section, Test 1. 2. If there is no spark, test the coil primary resistance using Rotunda digital volt-ohmmeter 007-00001, as shown. 3. If the coil primary resistance is O.K., continue with the diagnostic procedure in Test 1. 4. If the coil primary resistance is not O.K., replace the coil and recheck for weak or no spark. If the spark is now O.K., the problem is resolved. 5. If the spark is still NOT O.K., continue with normal diagnostic procedure in Test 1. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Wiring Harness TFI-IV Part 2 Test 5 TEST EQUIPMENT: VOM, STRAIGHT PIN TEST PROCEDURE 1. Separate wiring harness connector from ignition module. Inspect for dirt, corrosion, and damage. NOTE: PUSH connector tabs to separate. 2. Disconnect wire at S terminal of starter relay. 3. Attach negative (-) VOM, Rotunda Number 007-00001, lead to distributor base. 4. Measure battery voltage. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Coil: > 86220 > Jan > 86 > Ignition System - Weak/No Spark > Page 4191 5. Following table below, measure connector terminal voltage by attaching VOM to small straight pin inserted into connector terminal and turning ignition switch to position shown. CAUTION: Do not allow straight pin to contact electrical ground. CONNECTOR IGNITION SWITCH TERMINAL WIRE/CIRCUIT TEST POSITION #2 TO IGNITION RUN COIL (-) TERMINAL #3 RUN CIRCUIT RUN AND START #4 START CIRCUIT START 6. Turn ignition switch to Off position. 7. Remove straight pin. 8. Reconnect wire to S terminal of starter relay. TEST RESULT TEST RESOLUTION 90 percent of ^ Test result OK. battery ^ Go to Part 2, Test 6. voltage minimum Less than 90 ^ Inspect for faults in wiring percent of harness and connectors. battery ^ Refer to vehicle wiring voltage diagram for appropriate circuit. ^ Damaged or worn ignition switch, Refer to Shop Manual, Group 33. Primary Circuit Continuity TFI-IV Part 2 Test 8 TEST EQUIPMENT: VOM, STRAIGHT PIN TEST PROCEDURE 1. Separate wiring harness connector from ignition module. Inspect for dirt, corrosion, and damage. NOTE: PUSH connector tabs to separate. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Coil: > 86220 > Jan > 86 > Ignition System - Weak/No Spark > Page 4192 2. Attach negative (-) VOM, Rotunda Number 007-00001, lead to distributor base. 3. Measure battery voltage. 4. Attach VOM to small straight pin inserted into connector terminal No. 2. CAUTION: Do not allow straight pin to contact electrical ground. 5. Turn ignition switch to Run position and measure terminal No. 2 voltage. 6. Turn ignition switch to Off position. 7. Remove straight pin. TEST RESULT TEST RESOLUTION 90 percent of ^ Go to Part 2, Test 5. battery voltage minimum Less than 90 ^ Go to Part 2, Test 9. percent of battery voltage Ignition Coil Primary Resistance TFI-IV Part 2 Test 3 TEST EQUIPMENT: VOM TEST PROCEDURE 1. Turn ignition switch to Off. 2. Disconnect ignition coil connector. Inspect for dirt, corrosion, and damage. 3. Measure resistance from positive (+) to negative (-) terminal of ignition coil, using Rotunda digital volt-ohmmeter 007-00001. TEST RESULT TEST RESOLUTION 0.3 to 1.0 ^ Test result OK. ohm ^ Go to Test 4. Less than ^ Replace ignition coil. 0.3 ohm or greater than 1.0 ohm Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Coil: > 911211 > Jun > 91 > Engine - Lack of Power/No Start Diagnosis Ignition Coil: All Technical Service Bulletins Engine - Lack of Power/No Start Diagnosis Article No. 91-12-11 06/12/91 LACK OF POWER 7.5L, 5.8L, 5.0L, 4.9L - CATALYTIC CONVERTER DIAGNOSTIC TIPS LIGHT TRUCK: 1986-91 BRONCO, ECONOLINE, F-150-350 SERIES 1988-91 F SUPER DUTY, F47 ISSUE: Lack of power or a no start condition may be diagnosed as an exhaust restriction caused by a plugged catalytic converter. A plugged catalytic converter (internal deterioration) is usually caused by abnormal engine operation. ACTION: Diagnose the catalytic converter to confirm internal failure. Refer to the Catalyst and Exhaust System Diagnostic Section, in the Engine/Emissions Diagnostic Shop Manual and the following procedures for service details. 1. Lack of proper HEGO operation may cause, or be the result of a rich or lean fuel condition, which could cause additional heat in the catalyst. Perform self test KOEO and KOER, service any codes. NOTE: IF TWO DIGIT CODES 41, 42, 85 OR THREE DIGIT CODES 171, 172, 173, 179, 181, 182, 183 AND 565 ARE RECEIVED, CHECK FOR PROPER HEGO GROUND. If the HEGO ground is good, the following areas may be at fault: ^ Ignition Coil ^ Distributor Cap ^ Distributor Rotor ^ Fouled Spark Plug ^ Spark Plug Wires ^ Air Filter ^ Stuck Open Injector ^ Fuel Contamination Engine OIL ^ Manifold Leaks Intake/ Exhaust ^ Fuel Pressure ^ Poor Power Ground ^ Engine Not At Normal Operating Temperature ^ HEGO Sensor 2. Spark timing that is retarded from specification may increase exhaust gas temperature and shorten catalyst life. Refer to the following procedure for service details. a. Check spark timing. Check base timing with spout disconnected. Set base timing to the specification on the vehicle emission decal. b. Check computed timing with spout connected. NOTE: COMPUTED TIMING IS EQUAL TO BASE TIMING PLUS 20~ BTDC +/- 3~. 3. Misfiring spark plugs may cause an unburned fuel air mixture to pass through the catalyst, which could cause higher than normal catalyst temperatures. Refer to the following procedure for service details. a. Check secondary ignition, hook the vehicle up to an engine analyzer and check for a secondary ignition misfire. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Coil: > 911211 > Jun > 91 > Engine - Lack of Power/No Start Diagnosis > Page 4198 NOTE: SERVICE ANY ITEM THAT IS NOT PERFORMING AT PROPER SPECIFICATIONS BEFORE CONTINUING. 4. Fuel pressure that is too high may cause rich air fuel mixtures to pass through the catalyst which could cause higher than normal catalyst temperatures. Refer to the following procedure for service details. a. Check fuel pressure, install fuel pressure gauge, start and run the engine at idle. Fuel pressures between 28 and 34 PSI are typical (4.9L typically is 15 PSI higher). b. Disconnect the vacuum line going to the fuel pressure regulator. Fuel pressure typically jumps to 40 PSI +/- 3 PSI (4.9L typically is 15 PSI higher). Visually inspect vacuum line for raw fuel. NOTE: FUEL PRESSURES ABOVE THESE VALUES SHOULD BE CORRECTED. HOWEVER, THIS MAY NOT BE THE CAUSE OF THE CONCERN. SERVICE AS NECESSARY. 5. Throttle plates in the throttle body not returning to the proper closed position may cause excessive catalyst temperatures during downhill grades. Refer to the following procedure for service details. a. Visually inspect the throttle body and linkage for: ^ Binding or sticking throttle linkage. ^ Tight speed control linkage or cable. ^ Vacuum line interference. ^ Electrical harness interference. NOTE: AFTERMARKET GOVERNORS, THROTTLE LINKAGE AND CABLES ASSOCIATED WITH POWER TAKE-OFF UNITS, MAY ALSO INTERFERE WITH PROPER THROTTLE RETURN. SERVICE AS NECESSARY. 6. It is extremely important that all systems related to the engine and emission systems operate properly. a. Visually inspect the engine compartment to make sure all vacuum hoses and spark plug wires are properly routed and securely connected. b. Inspect all wiring harnesses and connectors for insulation damage, burned, overheated, loose or broken conditions. c. Verify proper operation of the thermactor system. Thermactor systems that fail to dump thermactor air to the atmosphere properly or at the correct time can cause high catalyst temperatures. d. Visually inspect thermactor system for damaged or kinked hoses and perform a function test on following components: air control valve, check valve, silencer, filter and the air bypass solenoid. e. Verify proper operation of the engine cooling system thermostat. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under Basic Warranty Coverage, Emissions Warranty Coverage OPERATION DESCRIPTION TIME 911211A Diagnostics - Perform 0.5 Hrs. KOEO And KOER Self Tests 911211B Timing - Check Or Adjust 0.5 Hrs. Spark Timing, Check Computed Timing And Check Secondary Ignition System With Engine Analyzer. 911211C Check - Fuel Pressure And 0.2 Hrs. Inspect Vacuum Line For Raw Fuel. 911211D Inspect - Throttle Body And 0.1 Hrs. Linkage. 911211E Inspect - Vacuum Hoses, 0.1 Hrs. Electrical Harnesses, Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Coil: > 911211 > Jun > 91 > Engine - Lack of Power/No Start Diagnosis > Page 4199 Connectors And Spark Plug Wires For Routing Damage. 911211F Thermactor System - 0.3 Hrs. Inspect For Proper Operation And Damaged Component. Includes Function Check Of Air Control Valve, Thermactor Air Bypass Solenoid, Check Valves, Silencer And Filter. 911211G Thermostat - Check For 0.2 Hrs. Proper Operation. DEALER CODING BASIC PART NO. CONDITION CODE 5E212 25 OASIS CODES: 403000, 603300, 614000 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Coil: > 895A4 > Mar > 89 > Ignition System - Diagnostics Manual Correction Ignition Coil: All Technical Service Bulletins Ignition System - Diagnostics Manual Correction Article No. 89-5A-4 EEC IV - TFI IV - IGNITION SYSTEM - REVISED TIMING PROCEDURES AND DIAGNOSTICS SHOP MANUAL CORRECTION FORD: 1984-86 LTD 1984-88 EXP 1984-88 ESCORT THUNDERBIRD, MUSTANG, TEMPO, AND CROWN VICTORIA LINCOLN-MERCURY: 1984-86 CAPRI, MARQUIS 1984-87 LYNX 1984-88 COUGAR, TOPAZ, GRAND MARQUIS, CONTINENTAL, MARK VII, AND LINCOLN TOWN CAR LIGHT TRUCK: 1984-88 RANGER, BRONCO II, ECONOLINE, BRONCO, AND F-SERIES 1986-88 AEROSTAR ISSUE: The Ignition Coil and Secondary Wire Test Steps on pages 13-51 and 13-65 of the 1989 Engine Emissions Diagnosis Shop Manual, Volume H, have been revised. The new service information directs technicians to use a substitute coil instead of a resistance test. ACTION: Refer to this TSB for revised ignition coil and secondary wire test information. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" OASIS CODES: 680000 1989 Ignition Systems, Timing Procedures and Diagnostics 13-51 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Coil: > 895A4 > Mar > 89 > Ignition System - Diagnostics Manual Correction > Page 4204 Ignition Coil and Secondary Wire TFI-IV And TFI With CCD Part 2 Test 7 1989 13-52 Ignition Systems, Timing Procedures and Diagnostics Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Coil: > 895A4 > Mar > 89 > Ignition System - Diagnostics Manual Correction > Page 4205 EEC-IV - TFI-IV TFI-IV And TFI-IV With CCD Part 2 Test 8 1989 Ignition Systems, Timing Procedures and Diagnostics 13-65 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Coil: > 895A4 > Mar > 89 > Ignition System - Diagnostics Manual Correction > Page 4206 Ignition Coil And Secondary Wire TFI-IV Closed Bowl Distributor Part 2 Test 8 1989 13-66 Ignition Systems, Timing Procedures and Diagnostics Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Coil: > 895A4 > Mar > 89 > Ignition System - Diagnostics Manual Correction > Page 4207 EEC-IV - Wiring TFI-IV Closed Bowl Distributor Part 2 Test 9 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical Service Bulletins > Page 4208 Ignition Coil: Specifications Winding Resistance (ohms at 75 degrees F or 24 degrees C) 1982-88 w/TFI (EEC IV): Primary, 0.3-1.0; Secondary, 8000-11,500. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical Service Bulletins > Page 4209 Ignition Coil: Locations Component Locations - RH View TFI-IV Ignition Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical Service Bulletins > Page 4210 Component Locations - RH View Duraspark II Federal and High Altitude Models Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical Service Bulletins > Page 4211 Component Locations - RH View Duraspark II Canadian Models Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical Service Bulletins > Page 4212 Ignition Coil: Testing and Inspection For Diagnosis and Testing, refer to Computers and Control Systems, Testing and Inspection Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 87720 > Apr > 87 > Tape Player - Ignition Noise Through Speakers Ignition Control Module: Customer Interest Tape Player - Ignition Noise Through Speakers RADIO - IGNITION NOISE THROUGH FACTORY Article No. TAPE PLAYER - 4.9L - WITH TSB MODIFICATION87-3-20 87-7-20 LIGHT TRUCK: 1984-86 F SERIES, BRONCO ISSUE: Ignition noise through the radio speakers when operating the radio in the tape player mode may result if a new multispark ignition module was installed to correct a rough idle condition per TSB 87-3-20. ACTION: To correct this, modify the multi-spark ignition module wire harness as outlined in the following service procedure. 1. Shorten the heavy gauge BLACK wire on the module to 14 inches (357 mm). Crimp on a new solderless lug and hook up wire directly to negative terminal of battery. 2. Perform TSB 86-24-26 to eliminate the radio noise. OTHER APPLICABLE ARTICLES: 86-24-26, 87-3-20 WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual OPERATION: SP870720A TIME: 0.3 Hr. DLR. CODING: Basic Part No. 12A199 Code: 85 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 87610 > Mar > 87 > Engine - Stalling and/or A No Start Condition Ignition Control Module: Customer Interest Engine - Stalling and/or A No Start Condition ^ STALL - THICK FILM IGNITION (TFI) MODULE - Article No. EEC IV VEHICLES 87-6-10 ^ STALL/NO START - THICK FILM IGNITION (TFI) MODULE - EEC IV VEHICLES FORD 1984-87 ALL LINCOLN-MERCURY 1984-87 ALL MERKUR 1985-87 XR4Ti LIGHT TRUCK 1984-87 ALL ISSUE: Stalling and/or a no-start condition on vehicles with EEC IV and certain TFI modules may be caused by moisture or salt splash entering at the upper right hand mounting hole of the TFI module housing. This condition will result in a service code 14. ACTION: To correct this, use the following diagnostic and service procedure to seal the hole and prevent further concerns. NOTE: The distributor does not have to be removed to perform this repair. 1. Check to see if the TFI-IV module part number suffix is A2A and the date code is 6K08 or prior, (mounting hole was sealed after 6K08). If the suffix is not A2A, use normal diagnostic procedures and do not perform Steps 2 and 3. 2. Thoroughly clean and dry upper right hand mounting hole of the TFI module with a clean paper towel. 3. Fill the cleaned hole with silicone grease (D7AZ-19A331-A). 4. Clear service code 14 from memory. PART NUMBER PART NAME CLASS D7AZ-19A331-A Silicone Grease AM OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual OPERATION: SP870610A TIME: 1.0 Hr. DLR. CODING: Basic Part No. 12A297 - Code: 09 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 86220 > Jan > 86 > Ignition System - Weak/No Spark Ignition Control Module: Customer Interest Ignition System - Weak/No Spark Article No. 86-2-20 IGNITION SYSTEM - TFI - WEAK OR NO SPARK - DIAGNOSTIC TIP FORD 1982-86 ESCORT, EXP; 1983-86 THUNDERBIRD, LTD, CROWN VICTORIA, MUSTANG; 1984-86 TEMPO; 1986 TAURUS LINCOLN-MERCURY 1982-83 LN7; 1982-86 LYNX; 1983-86 COUGAR, MERCURY, GRAND MARQUIS, CONTINENTAL, MARK VII, LINCOLN; 1984-86 TOPAZ; 1986 SABLE LIGHT TRUCK 1983-86 EAND F-SERIES, RANGER, BRONCO; 1984-86 BRONCO II; 1986 AEROSTAR CALIBRATIONS: All with TFI Systems If the TFI module fails and causes a short to ground, the primary winding of the ignition coil can be damaged. The TFI diagnostic procedure published in the Shop Manual will not identify this condition. When servicing a weak or no spark condition, perform the following: 1. Check for spark using the procedures found in the Manual Information, Computerized Engine, Quick Test Section, Test 1. 2. If there is no spark, test the coil primary resistance using Rotunda digital volt-ohmmeter 007-00001, as shown. 3. If the coil primary resistance is O.K., continue with the diagnostic procedure in Test 1. 4. If the coil primary resistance is not O.K., replace the coil and recheck for weak or no spark. If the spark is now O.K., the problem is resolved. 5. If the spark is still NOT O.K., continue with normal diagnostic procedure in Test 1. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Wiring Harness TFI-IV Part 2 Test 5 TEST EQUIPMENT: VOM, STRAIGHT PIN TEST PROCEDURE 1. Separate wiring harness connector from ignition module. Inspect for dirt, corrosion, and damage. NOTE: PUSH connector tabs to separate. 2. Disconnect wire at S terminal of starter relay. 3. Attach negative (-) VOM, Rotunda Number 007-00001, lead to distributor base. 4. Measure battery voltage. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 86220 > Jan > 86 > Ignition System - Weak/No Spark > Page 4229 5. Following table below, measure connector terminal voltage by attaching VOM to small straight pin inserted into connector terminal and turning ignition switch to position shown. CAUTION: Do not allow straight pin to contact electrical ground. CONNECTOR IGNITION SWITCH TERMINAL WIRE/CIRCUIT TEST POSITION #2 TO IGNITION RUN COIL (-) TERMINAL #3 RUN CIRCUIT RUN AND START #4 START CIRCUIT START 6. Turn ignition switch to Off position. 7. Remove straight pin. 8. Reconnect wire to S terminal of starter relay. TEST RESULT TEST RESOLUTION 90 percent of ^ Test result OK. battery ^ Go to Part 2, Test 6. voltage minimum Less than 90 ^ Inspect for faults in wiring percent of harness and connectors. battery ^ Refer to vehicle wiring voltage diagram for appropriate circuit. ^ Damaged or worn ignition switch, Refer to Shop Manual, Group 33. Primary Circuit Continuity TFI-IV Part 2 Test 8 TEST EQUIPMENT: VOM, STRAIGHT PIN TEST PROCEDURE 1. Separate wiring harness connector from ignition module. Inspect for dirt, corrosion, and damage. NOTE: PUSH connector tabs to separate. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 86220 > Jan > 86 > Ignition System - Weak/No Spark > Page 4230 2. Attach negative (-) VOM, Rotunda Number 007-00001, lead to distributor base. 3. Measure battery voltage. 4. Attach VOM to small straight pin inserted into connector terminal No. 2. CAUTION: Do not allow straight pin to contact electrical ground. 5. Turn ignition switch to Run position and measure terminal No. 2 voltage. 6. Turn ignition switch to Off position. 7. Remove straight pin. TEST RESULT TEST RESOLUTION 90 percent of ^ Go to Part 2, Test 5. battery voltage minimum Less than 90 ^ Go to Part 2, Test 9. percent of battery voltage Ignition Coil Primary Resistance TFI-IV Part 2 Test 3 TEST EQUIPMENT: VOM TEST PROCEDURE 1. Turn ignition switch to Off. 2. Disconnect ignition coil connector. Inspect for dirt, corrosion, and damage. 3. Measure resistance from positive (+) to negative (-) terminal of ignition coil, using Rotunda digital volt-ohmmeter 007-00001. TEST RESULT TEST RESOLUTION 0.3 to 1.0 ^ Test result OK. ohm ^ Go to Test 4. Less than ^ Replace ignition coil. 0.3 ohm or greater than 1.0 ohm Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure Technical Service Bulletin # 872110 Date: 871021 TFI Module/PIP Sensor - New Diagnostic Procedure EEC IV - TFI MODULE AND PIP SENSOR - Article No. NEW DIAGNOSTIC PROCEDURE 87-21-10 FORD: 1983-88 ESCORT/EXP, MUSTANG, THUNDERBIRD, FORD 1984-88 TEMPO 1986-88 TAURUS LINCOLN-MERCURY: 1983 MARK VI 1983-86 CAPRI 1983-87 LYNX 1983-88 COUGAR, MERCURY, CONTINENTAL, LINCOLN TOWN CAR 1984-88 TOPAZ, MARK VII 1986-88 SABLE MERKUR: 1985-88 XR4Ti 1988 SCORPIO LIGHT TRUCK: 1983-88 ALL LIGHT TRUCK LINES ISSUE: A new diagnostic procedure for testing the TFI module and PIP sensor has been developed. This new procedure allows the technician to take a direct path when testing the TFI module and PIP sensor with the use of the new TFI IV diagnostic tester (Rotunda No. 105-00003). ACTION: If service is required, use the diagnostic procedures on pages 29 through 60 of this TSB. Insert these pages in the Engine/Emission Diagnosis Manual, Volume H, Section 15. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Preliminary Checkout, Equipment & Notes CHECKOUT ^ Visually inspect the engine compartment to ensure all vacuum hoses and spark plug wires are properly routed and securely connected. ^ Examine all wiring harnesses and connectors for insulation damage, burned, overheated, loose or broken conditions. ^ Check that the TFI module is securely fastened to the distributor base. ^ Be certain the battery is fully charged. ^ All accessories should be off during diagnosis. EQUIPMENT Obtain the following test equipment or an equivalent: ^ Spark Tester, Special Service Tool D81P-6666-A. See note. ^ Volt/Ohm Meter Rotunda 014-00407. ^ 12 Volt Test Light. ^ Small straight pin. ^ Remote Starter Switch. ^ TFI Ignition Tester, Rotunda 105-00002. NOTES ^ A spark plug with a broken side electrode is not sufficient to check for spark and may lead to incorrect results. ^ When instructed to inspect a wiring harness, both a visual inspection and a continuity test should be performed. ^ When making measurements on a wiring harness or connector, it is good practice to wiggle the wires while measuring. ^ References to pin-in-line connector apply to a shorting bar type connector used to set base timing. ^ This procedure is intended to identify faulty components or wiring while the fault is present. If the complaint is of an intermittent condition, refer to Intermittent Diagnosis. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 4236 Functional Schematic TFI-IV The TFI-IV system electrical schematic is shown below. For detailed information, refer to the vehicle wiring diagram. Ignition Coil Secondary Voltage (Crank Mode) TFI-IV Part 2 Test 1 & 2 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 4237 Ignition Coil Secondary Voltage (Run Mode) TFI-IV Part 2 Test 2 Wiring Harness Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 4238 TFI-IV Part 2 Test 3 Stator - TFI Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 4239 TFI-IV Part 2 Test 4 & 5 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 4240 Stator - TFI-IV TFI-IV Part 2 Test 5 TFI Module TFI-IV Part 2 Test 6 Ignition Coils - Secondary & Primary Resistance Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 4241 Ignition Coil Primary Resistance TFI-IV Part 2 Test 7 & 8 Ignition Coil Secondary Resistance TFI-IV Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 4242 Part 2 Test 8 EEC-IV - TFI-IV TFI-IV Part 2 Test 9 Ignition Coil Supply Voltage Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 4243 TFI-IV Part 2 Test 10 Wiring Harness Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 4244 TFI-IV Part 2 Test 11 Preliminary Checkout, Equipment & Notes CHECKOUT ^ Visually inspect the engine compartment to ensure all vacuum hoses and spark plug wires are properly routed and securely connected. ^ Examine all wiring harnesses and connectors for insulation damage, burned, overheated, loose, or broken conditions. ^ Be certain the battery is fully charged. ^ All accessories should be off during diagnosis. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 4245 EQUIPMENT Obtain the following test equipment or an equivalent: ^ Spark Tester, Special Service Tool D81P-6666-A. See note. ^ Volt/Ohm Meter Rotunda 014-00407. ^ 12 Volt Test Light. ^ Small straight pin. ^ Remote Starter Switch. ^ TFI Ignition Tester, Rotunda 105-00003. NOTES ^ A spark plug with a broken side electrode is not sufficient to check for spark and may lead to incorrect results. ^ When instructed to inspect a wiring harness, both a visual inspection and a continuity test should be performed. ^ When making measurements on a wiring harness or connector, it is good practice to wiggle the wires while measuring. ^ References to pin-in-line connector apply to shorting bar type connector used to set base timing. ^ This procedure is intended to identify faulty components or wiring while the fault is present. If the complaint is of an intermittent condition refer to Intermittent Diagnosis. Functional Schematic TFI-IV Closed Bowl Distributor The TFI-IV Closed Bowl Distributor system electrical schematic is shown below. For detailed information, refer to the vehicle wiring diagram. Ignition Coil Secondary Voltage - Crank Mode Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 4246 TFI-IV Closed Bowl Distributor Part 2 Test 1 & 2 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 4247 Ignition Coil Secondary Voltage - Run Mode TFI-IV Closed Bowl Distributor Part 2 Test 2 Wiring Harness Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 4248 TFI-IV Closed Bowl Distributor Part 2 Test 3 Stator Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 4249 TFI-IV Closed Bowl Distributor Part 2 Test 4, 5 & 6 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 4250 Stator TFI-IV Closed Bowl Distributor Part 2 Test 5 Stator TFI-IV Closed Bowl Distributor Part 2 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 4251 Test 6 TFI Module TFI-IV Closed Bowl Distributor Part 2 Test 7 Ignition Coil, Primary & Secondary Ignition Coil Primary Resistance TFI-IV Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 4252 Closed Bowl Distributor Part 2 Test 8 Ignition Coil Secondary Resistance TFI-IV Closed Bowl Distributor Part 2 Test 9 EEC IV - Wiring Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 4253 TFI-IV Closed Bowl Distributor Part 2 Test 10 Wiring Harness Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 4254 TFI IV Closed Bowl Distributor Part 2 Test 11 Ignition Coil, TFI & Stator Voltage Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 4255 Ignition Coil Supply Voltage TFI IV Closed Bowl Distributor Part 2 Test 12 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 4256 TFI Supply Voltage TFI-IV Closed Bowl Distributor Part 2 Test 13 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 4257 Stator Supply Voltage TFI IV Closed Bowl Distributor Part 2 Test 14 Wiring Harness Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 4258 TFI IV Closed Bowl Distributor Part 2 Test 15 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 87720 > Apr > 87 > Tape Player Ignition Noise Through Speakers Ignition Control Module: All Technical Service Bulletins Tape Player - Ignition Noise Through Speakers RADIO - IGNITION NOISE THROUGH FACTORY Article No. TAPE PLAYER - 4.9L - WITH TSB MODIFICATION87-3-20 87-7-20 LIGHT TRUCK: 1984-86 F SERIES, BRONCO ISSUE: Ignition noise through the radio speakers when operating the radio in the tape player mode may result if a new multispark ignition module was installed to correct a rough idle condition per TSB 87-3-20. ACTION: To correct this, modify the multi-spark ignition module wire harness as outlined in the following service procedure. 1. Shorten the heavy gauge BLACK wire on the module to 14 inches (357 mm). Crimp on a new solderless lug and hook up wire directly to negative terminal of battery. 2. Perform TSB 86-24-26 to eliminate the radio noise. OTHER APPLICABLE ARTICLES: 86-24-26, 87-3-20 WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual OPERATION: SP870720A TIME: 0.3 Hr. DLR. CODING: Basic Part No. 12A199 Code: 85 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 87610 > Mar > 87 > Engine Stalling and/or A No Start Condition Ignition Control Module: All Technical Service Bulletins Engine - Stalling and/or A No Start Condition ^ STALL - THICK FILM IGNITION (TFI) MODULE - Article No. EEC IV VEHICLES 87-6-10 ^ STALL/NO START - THICK FILM IGNITION (TFI) MODULE - EEC IV VEHICLES FORD 1984-87 ALL LINCOLN-MERCURY 1984-87 ALL MERKUR 1985-87 XR4Ti LIGHT TRUCK 1984-87 ALL ISSUE: Stalling and/or a no-start condition on vehicles with EEC IV and certain TFI modules may be caused by moisture or salt splash entering at the upper right hand mounting hole of the TFI module housing. This condition will result in a service code 14. ACTION: To correct this, use the following diagnostic and service procedure to seal the hole and prevent further concerns. NOTE: The distributor does not have to be removed to perform this repair. 1. Check to see if the TFI-IV module part number suffix is A2A and the date code is 6K08 or prior, (mounting hole was sealed after 6K08). If the suffix is not A2A, use normal diagnostic procedures and do not perform Steps 2 and 3. 2. Thoroughly clean and dry upper right hand mounting hole of the TFI module with a clean paper towel. 3. Fill the cleaned hole with silicone grease (D7AZ-19A331-A). 4. Clear service code 14 from memory. PART NUMBER PART NAME CLASS D7AZ-19A331-A Silicone Grease AM OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual OPERATION: SP870610A TIME: 1.0 Hr. DLR. CODING: Basic Part No. 12A297 - Code: 09 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 86219 > Jan > 86 > Ignition System Resistance - Manual Revision Ignition Control Module: All Technical Service Bulletins Ignition System Resistance - Manual Revision Article No. 86-2-19 IGNITION SYSTEM - RESISTANCE TESTS - SHOP MANUAL REVISION EMISSION DIAGNOSIS MANUAL FORD 1982-86 ESCORT, EXP; 1983-86 LTD, THUNDERBIRD, CROWN VICTORIA, MUSTANG; 1984-86 TEMPO; 1986 TAURUS LINCOLN-MERCURY 1982-83 LN7; 1982-86 LYNX; 1983-86 MARQUIS, COUGAR, MERCURY, CONTINENTAL, MARK VII, LINCOLN; 1984-86 TOPAZ; 1986 SABLE LIGHT TRUCK 1983-86 EAND F-SERIES, BRONCO, RANGER; 1984-86 BRONCO II; 1986 AEROSTAR If your voltmeter has a high impedance, it will not draw enough current to show a voltage drop when testing TFI power circuits for resistive connections. To assure an accurate test, attach a test light between the circuit being tested and ground as shown. The light will draw current through the connection and allow measurement of the voltage drop so a resistive connection can be identified. IMPORTANT Do not use a test light while monitoring the PIP or SPOUT signal. The test light draws more current than the signal circuit can supply. The test light should be used only on power circuits. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 86220 > Jan > 86 > Ignition System - Weak/No Spark Ignition Control Module: All Technical Service Bulletins Ignition System - Weak/No Spark Article No. 86-2-20 IGNITION SYSTEM - TFI - WEAK OR NO SPARK - DIAGNOSTIC TIP FORD 1982-86 ESCORT, EXP; 1983-86 THUNDERBIRD, LTD, CROWN VICTORIA, MUSTANG; 1984-86 TEMPO; 1986 TAURUS LINCOLN-MERCURY 1982-83 LN7; 1982-86 LYNX; 1983-86 COUGAR, MERCURY, GRAND MARQUIS, CONTINENTAL, MARK VII, LINCOLN; 1984-86 TOPAZ; 1986 SABLE LIGHT TRUCK 1983-86 EAND F-SERIES, RANGER, BRONCO; 1984-86 BRONCO II; 1986 AEROSTAR CALIBRATIONS: All with TFI Systems If the TFI module fails and causes a short to ground, the primary winding of the ignition coil can be damaged. The TFI diagnostic procedure published in the Shop Manual will not identify this condition. When servicing a weak or no spark condition, perform the following: 1. Check for spark using the procedures found in the Manual Information, Computerized Engine, Quick Test Section, Test 1. 2. If there is no spark, test the coil primary resistance using Rotunda digital volt-ohmmeter 007-00001, as shown. 3. If the coil primary resistance is O.K., continue with the diagnostic procedure in Test 1. 4. If the coil primary resistance is not O.K., replace the coil and recheck for weak or no spark. If the spark is now O.K., the problem is resolved. 5. If the spark is still NOT O.K., continue with normal diagnostic procedure in Test 1. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Wiring Harness TFI-IV Part 2 Test 5 TEST EQUIPMENT: VOM, STRAIGHT PIN TEST PROCEDURE 1. Separate wiring harness connector from ignition module. Inspect for dirt, corrosion, and damage. NOTE: PUSH connector tabs to separate. 2. Disconnect wire at S terminal of starter relay. 3. Attach negative (-) VOM, Rotunda Number 007-00001, lead to distributor base. 4. Measure battery voltage. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 86220 > Jan > 86 > Ignition System - Weak/No Spark > Page 4275 5. Following table below, measure connector terminal voltage by attaching VOM to small straight pin inserted into connector terminal and turning ignition switch to position shown. CAUTION: Do not allow straight pin to contact electrical ground. CONNECTOR IGNITION SWITCH TERMINAL WIRE/CIRCUIT TEST POSITION #2 TO IGNITION RUN COIL (-) TERMINAL #3 RUN CIRCUIT RUN AND START #4 START CIRCUIT START 6. Turn ignition switch to Off position. 7. Remove straight pin. 8. Reconnect wire to S terminal of starter relay. TEST RESULT TEST RESOLUTION 90 percent of ^ Test result OK. battery ^ Go to Part 2, Test 6. voltage minimum Less than 90 ^ Inspect for faults in wiring percent of harness and connectors. battery ^ Refer to vehicle wiring voltage diagram for appropriate circuit. ^ Damaged or worn ignition switch, Refer to Shop Manual, Group 33. Primary Circuit Continuity TFI-IV Part 2 Test 8 TEST EQUIPMENT: VOM, STRAIGHT PIN TEST PROCEDURE 1. Separate wiring harness connector from ignition module. Inspect for dirt, corrosion, and damage. NOTE: PUSH connector tabs to separate. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 86220 > Jan > 86 > Ignition System - Weak/No Spark > Page 4276 2. Attach negative (-) VOM, Rotunda Number 007-00001, lead to distributor base. 3. Measure battery voltage. 4. Attach VOM to small straight pin inserted into connector terminal No. 2. CAUTION: Do not allow straight pin to contact electrical ground. 5. Turn ignition switch to Run position and measure terminal No. 2 voltage. 6. Turn ignition switch to Off position. 7. Remove straight pin. TEST RESULT TEST RESOLUTION 90 percent of ^ Go to Part 2, Test 5. battery voltage minimum Less than 90 ^ Go to Part 2, Test 9. percent of battery voltage Ignition Coil Primary Resistance TFI-IV Part 2 Test 3 TEST EQUIPMENT: VOM TEST PROCEDURE 1. Turn ignition switch to Off. 2. Disconnect ignition coil connector. Inspect for dirt, corrosion, and damage. 3. Measure resistance from positive (+) to negative (-) terminal of ignition coil, using Rotunda digital volt-ohmmeter 007-00001. TEST RESULT TEST RESOLUTION 0.3 to 1.0 ^ Test result OK. ohm ^ Go to Test 4. Less than ^ Replace ignition coil. 0.3 ohm or greater than 1.0 ohm Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure Technical Service Bulletin # 872110 Date: 871021 TFI Module/PIP Sensor - New Diagnostic Procedure EEC IV - TFI MODULE AND PIP SENSOR - Article No. NEW DIAGNOSTIC PROCEDURE 87-21-10 FORD: 1983-88 ESCORT/EXP, MUSTANG, THUNDERBIRD, FORD 1984-88 TEMPO 1986-88 TAURUS LINCOLN-MERCURY: 1983 MARK VI 1983-86 CAPRI 1983-87 LYNX 1983-88 COUGAR, MERCURY, CONTINENTAL, LINCOLN TOWN CAR 1984-88 TOPAZ, MARK VII 1986-88 SABLE MERKUR: 1985-88 XR4Ti 1988 SCORPIO LIGHT TRUCK: 1983-88 ALL LIGHT TRUCK LINES ISSUE: A new diagnostic procedure for testing the TFI module and PIP sensor has been developed. This new procedure allows the technician to take a direct path when testing the TFI module and PIP sensor with the use of the new TFI IV diagnostic tester (Rotunda No. 105-00003). ACTION: If service is required, use the diagnostic procedures on pages 29 through 60 of this TSB. Insert these pages in the Engine/Emission Diagnosis Manual, Volume H, Section 15. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Preliminary Checkout, Equipment & Notes CHECKOUT ^ Visually inspect the engine compartment to ensure all vacuum hoses and spark plug wires are properly routed and securely connected. ^ Examine all wiring harnesses and connectors for insulation damage, burned, overheated, loose or broken conditions. ^ Check that the TFI module is securely fastened to the distributor base. ^ Be certain the battery is fully charged. ^ All accessories should be off during diagnosis. EQUIPMENT Obtain the following test equipment or an equivalent: ^ Spark Tester, Special Service Tool D81P-6666-A. See note. ^ Volt/Ohm Meter Rotunda 014-00407. ^ 12 Volt Test Light. ^ Small straight pin. ^ Remote Starter Switch. ^ TFI Ignition Tester, Rotunda 105-00002. NOTES ^ A spark plug with a broken side electrode is not sufficient to check for spark and may lead to incorrect results. ^ When instructed to inspect a wiring harness, both a visual inspection and a continuity test should be performed. ^ When making measurements on a wiring harness or connector, it is good practice to wiggle the wires while measuring. ^ References to pin-in-line connector apply to a shorting bar type connector used to set base timing. ^ This procedure is intended to identify faulty components or wiring while the fault is present. If the complaint is of an intermittent condition, refer to Intermittent Diagnosis. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 4282 Functional Schematic TFI-IV The TFI-IV system electrical schematic is shown below. For detailed information, refer to the vehicle wiring diagram. Ignition Coil Secondary Voltage (Crank Mode) TFI-IV Part 2 Test 1 & 2 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 4283 Ignition Coil Secondary Voltage (Run Mode) TFI-IV Part 2 Test 2 Wiring Harness Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 4284 TFI-IV Part 2 Test 3 Stator - TFI Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 4285 TFI-IV Part 2 Test 4 & 5 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 4286 Stator - TFI-IV TFI-IV Part 2 Test 5 TFI Module TFI-IV Part 2 Test 6 Ignition Coils - Secondary & Primary Resistance Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 4287 Ignition Coil Primary Resistance TFI-IV Part 2 Test 7 & 8 Ignition Coil Secondary Resistance TFI-IV Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 4288 Part 2 Test 8 EEC-IV - TFI-IV TFI-IV Part 2 Test 9 Ignition Coil Supply Voltage Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 4289 TFI-IV Part 2 Test 10 Wiring Harness Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 4290 TFI-IV Part 2 Test 11 Preliminary Checkout, Equipment & Notes CHECKOUT ^ Visually inspect the engine compartment to ensure all vacuum hoses and spark plug wires are properly routed and securely connected. ^ Examine all wiring harnesses and connectors for insulation damage, burned, overheated, loose, or broken conditions. ^ Be certain the battery is fully charged. ^ All accessories should be off during diagnosis. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 4291 EQUIPMENT Obtain the following test equipment or an equivalent: ^ Spark Tester, Special Service Tool D81P-6666-A. See note. ^ Volt/Ohm Meter Rotunda 014-00407. ^ 12 Volt Test Light. ^ Small straight pin. ^ Remote Starter Switch. ^ TFI Ignition Tester, Rotunda 105-00003. NOTES ^ A spark plug with a broken side electrode is not sufficient to check for spark and may lead to incorrect results. ^ When instructed to inspect a wiring harness, both a visual inspection and a continuity test should be performed. ^ When making measurements on a wiring harness or connector, it is good practice to wiggle the wires while measuring. ^ References to pin-in-line connector apply to shorting bar type connector used to set base timing. ^ This procedure is intended to identify faulty components or wiring while the fault is present. If the complaint is of an intermittent condition refer to Intermittent Diagnosis. Functional Schematic TFI-IV Closed Bowl Distributor The TFI-IV Closed Bowl Distributor system electrical schematic is shown below. For detailed information, refer to the vehicle wiring diagram. Ignition Coil Secondary Voltage - Crank Mode Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 4292 TFI-IV Closed Bowl Distributor Part 2 Test 1 & 2 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 4293 Ignition Coil Secondary Voltage - Run Mode TFI-IV Closed Bowl Distributor Part 2 Test 2 Wiring Harness Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 4294 TFI-IV Closed Bowl Distributor Part 2 Test 3 Stator Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 4295 TFI-IV Closed Bowl Distributor Part 2 Test 4, 5 & 6 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 4296 Stator TFI-IV Closed Bowl Distributor Part 2 Test 5 Stator TFI-IV Closed Bowl Distributor Part 2 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 4297 Test 6 TFI Module TFI-IV Closed Bowl Distributor Part 2 Test 7 Ignition Coil, Primary & Secondary Ignition Coil Primary Resistance TFI-IV Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 4298 Closed Bowl Distributor Part 2 Test 8 Ignition Coil Secondary Resistance TFI-IV Closed Bowl Distributor Part 2 Test 9 EEC IV - Wiring Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 4299 TFI-IV Closed Bowl Distributor Part 2 Test 10 Wiring Harness Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 4300 TFI IV Closed Bowl Distributor Part 2 Test 11 Ignition Coil, TFI & Stator Voltage Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 4301 Ignition Coil Supply Voltage TFI IV Closed Bowl Distributor Part 2 Test 12 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 4302 TFI Supply Voltage TFI-IV Closed Bowl Distributor Part 2 Test 13 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 4303 Stator Supply Voltage TFI IV Closed Bowl Distributor Part 2 Test 14 Wiring Harness Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 4304 TFI IV Closed Bowl Distributor Part 2 Test 15 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 86219 > Jan > 86 > Ignition System Resistance - Manual Revision Ignition Control Module: All Technical Service Bulletins Ignition System Resistance - Manual Revision Article No. 86-2-19 IGNITION SYSTEM - RESISTANCE TESTS - SHOP MANUAL REVISION EMISSION DIAGNOSIS MANUAL FORD 1982-86 ESCORT, EXP; 1983-86 LTD, THUNDERBIRD, CROWN VICTORIA, MUSTANG; 1984-86 TEMPO; 1986 TAURUS LINCOLN-MERCURY 1982-83 LN7; 1982-86 LYNX; 1983-86 MARQUIS, COUGAR, MERCURY, CONTINENTAL, MARK VII, LINCOLN; 1984-86 TOPAZ; 1986 SABLE LIGHT TRUCK 1983-86 EAND F-SERIES, BRONCO, RANGER; 1984-86 BRONCO II; 1986 AEROSTAR If your voltmeter has a high impedance, it will not draw enough current to show a voltage drop when testing TFI power circuits for resistive connections. To assure an accurate test, attach a test light between the circuit being tested and ground as shown. The light will draw current through the connection and allow measurement of the voltage drop so a resistive connection can be identified. IMPORTANT Do not use a test light while monitoring the PIP or SPOUT signal. The test light draws more current than the signal circuit can supply. The test light should be used only on power circuits. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > Page 4309 Ignition Control Module: Locations LH Inner Fender Well Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > Page 4310 Ignition Control Module: Description and Operation Typical Ignition System The Ignition Module shuts off the primary circuit each time it receives a pulse from the magnetic pick-up Fig. 9. A timing circuit in the ignition module turns the primary current back on after a short period of time. High voltage is created each time the magnetic field is built up and collapsed. The red ignition module wire provides operating voltage for the module's electronic components in the Run mode. The white module wire and start bypass provide increased voltage for the module and coil during Start mode. Ignition Modules Dura Spark II systems with UIM (Universal Ignition Module) Fig. 10 can respond to another control signal from either an Ignition Barometric Pressure Switch, Ignition Timing Vacuum Switch, or the Microprocessor Control Unit (MCU), depending on the engine calibration. Responding to this second signal, the UIM provides additional spark timing control for certain operating conditions by shutting off the ignition coil current flow at a different time than with just the distributor pick-up signal. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > Page 4311 Module Identification Chart For proper ignition module identification refer to Fig. 1. The modules are not interchangeable, Dura Spark II has 6 wire connector while Dura Spark III has a 5 wire connector. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > Page 4312 Ignition Control Module: Service and Repair Open Bowl Distributor 1. Remove distributor cap and adapter. Position cap and wires aside. 2. Disconnect TFI wiring. 3. Remove distributor from engine using tool T82L-12270-A or equivalent to remove security-type hold-down bolt, if equipped. 4. Place distributor on workbench and remove 2 TFI module screws, Fig. 2. 5. Pull right side of module down distributor mounting flange and then back up to disengage module terminals from connector in distributor base. Module may then be pulled toward flange and away from distributor. Do not attempt to lift module from mounting surface before moving entire TFI module toward distributor flange, as pins at distributor/module connector will break otherwise. 6. Coat metal base plate of TFI ignition module with 1/32 inch thick layer of silicone grease D7AZ-19A331-A, or equivalent. 7. Place TFI module on distributor base mounting flange. Carefully position TFI module assembly toward distributor bowl and securely engage 3 distributor connector pins. 8. Install 2 TFI module mounting screws and torque to 9---35 inch lbs. 9. Install distributor on engine. 10. Install distributor cap and adapter. 11. Connect TFI wiring. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > Page 4313 12. Check and, if necessary adjust engine timing according to decal. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Timing Connector > Component Information > Description and Operation Ignition Timing Connector: Description and Operation Fig. 20 Ignition Timing Vacuum Switch Below vacuum setting, this switch, Fig. 20, used on some vehicles, is open and signals the ignition module to retard spark timing. The switch is closed above the vacuum setting and the ignition module is in the non-retard spark timing mode. Calibration resistors inside the switch control the amount of retard. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Timing Connector > Component Information > Description and Operation > Page 4317 Ignition Timing Connector: Testing and Inspection Ignition Timing Vacuum Switch Ignition Timing Vacuum Switch Test Chart 1. Disconnect switch from ignition module. 2. Connect suitable ohmmeter across switch terminals and compare resistance measured to ``less than'' values in the Ignition Timing vacuum Switch Test chart. 3. Apply vacuum to switch, using an outside vacuum source. Compare resistance now measured across switch terminals to ``greater than'' values in the Ignition Timing vacuum Switch Test chart. 4. Replace switch if resistance is not within specifications. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Description and Operation Knock Sensor: Description and Operation The Knock Sensor, is a piezoelectric accelerometer with the sensor designed to resonate at approximately the same frequency as the engine knock frequency. The sensor uses the resonant frequency to mechanically amplify the vibrations. This method allows relatively large signals to be achieved without electrical amplification and with small package size. The sensor has a thin circular piezoelectric ceramic disk which is bonded to a metal diaphragm. Electrical connections are made through a two pin integral connector. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Description and Operation > Page 4321 Knock Sensor: Testing and Inspection Ford provides trouble code/symptom driven diagnostics for this component. For complete diagnosis and pinpoint testing, refer to Computers and Control Systems, Testing and Inspection. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Pick-Up Coil, Ignition > Component Information > Specifications > Electrical Specifications DISTRIBUTOR PICKUP Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Pick-Up Coil, Ignition > Component Information > Specifications > Electrical Specifications > Page 4326 DISTRIBUTOR PICKUP Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Pick-Up Coil, Ignition > Component Information > Specifications > Page 4327 Pick-Up Coil: Testing and Inspection Procedure 1. Disconnect distributor electrical connector. Inspect connections for dirt or corrosion. 2. Using a suitable ohmmeter, measure resistance across orange and purple wires in distributor connector. 3. If readings obtained are within 400---1000 ohms, circuit is satisfactory. If readings are less than 400 or more than 1000 ohms, replace stator assembly. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 87720 > Apr > 87 > Tape Player - Ignition Noise Through Speakers Ignition Control Module: Customer Interest Tape Player - Ignition Noise Through Speakers RADIO - IGNITION NOISE THROUGH FACTORY Article No. TAPE PLAYER - 4.9L - WITH TSB MODIFICATION87-3-20 87-7-20 LIGHT TRUCK: 1984-86 F SERIES, BRONCO ISSUE: Ignition noise through the radio speakers when operating the radio in the tape player mode may result if a new multispark ignition module was installed to correct a rough idle condition per TSB 87-3-20. ACTION: To correct this, modify the multi-spark ignition module wire harness as outlined in the following service procedure. 1. Shorten the heavy gauge BLACK wire on the module to 14 inches (357 mm). Crimp on a new solderless lug and hook up wire directly to negative terminal of battery. 2. Perform TSB 86-24-26 to eliminate the radio noise. OTHER APPLICABLE ARTICLES: 86-24-26, 87-3-20 WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual OPERATION: SP870720A TIME: 0.3 Hr. DLR. CODING: Basic Part No. 12A199 Code: 85 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 87610 > Mar > 87 > Engine Stalling and/or A No Start Condition Ignition Control Module: Customer Interest Engine - Stalling and/or A No Start Condition ^ STALL - THICK FILM IGNITION (TFI) MODULE - Article No. EEC IV VEHICLES 87-6-10 ^ STALL/NO START - THICK FILM IGNITION (TFI) MODULE - EEC IV VEHICLES FORD 1984-87 ALL LINCOLN-MERCURY 1984-87 ALL MERKUR 1985-87 XR4Ti LIGHT TRUCK 1984-87 ALL ISSUE: Stalling and/or a no-start condition on vehicles with EEC IV and certain TFI modules may be caused by moisture or salt splash entering at the upper right hand mounting hole of the TFI module housing. This condition will result in a service code 14. ACTION: To correct this, use the following diagnostic and service procedure to seal the hole and prevent further concerns. NOTE: The distributor does not have to be removed to perform this repair. 1. Check to see if the TFI-IV module part number suffix is A2A and the date code is 6K08 or prior, (mounting hole was sealed after 6K08). If the suffix is not A2A, use normal diagnostic procedures and do not perform Steps 2 and 3. 2. Thoroughly clean and dry upper right hand mounting hole of the TFI module with a clean paper towel. 3. Fill the cleaned hole with silicone grease (D7AZ-19A331-A). 4. Clear service code 14 from memory. PART NUMBER PART NAME CLASS D7AZ-19A331-A Silicone Grease AM OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual OPERATION: SP870610A TIME: 1.0 Hr. DLR. CODING: Basic Part No. 12A297 - Code: 09 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 86220 > Jan > 86 > Ignition System - Weak/No Spark Ignition Control Module: Customer Interest Ignition System - Weak/No Spark Article No. 86-2-20 IGNITION SYSTEM - TFI - WEAK OR NO SPARK - DIAGNOSTIC TIP FORD 1982-86 ESCORT, EXP; 1983-86 THUNDERBIRD, LTD, CROWN VICTORIA, MUSTANG; 1984-86 TEMPO; 1986 TAURUS LINCOLN-MERCURY 1982-83 LN7; 1982-86 LYNX; 1983-86 COUGAR, MERCURY, GRAND MARQUIS, CONTINENTAL, MARK VII, LINCOLN; 1984-86 TOPAZ; 1986 SABLE LIGHT TRUCK 1983-86 EAND F-SERIES, RANGER, BRONCO; 1984-86 BRONCO II; 1986 AEROSTAR CALIBRATIONS: All with TFI Systems If the TFI module fails and causes a short to ground, the primary winding of the ignition coil can be damaged. The TFI diagnostic procedure published in the Shop Manual will not identify this condition. When servicing a weak or no spark condition, perform the following: 1. Check for spark using the procedures found in the Manual Information, Computerized Engine, Quick Test Section, Test 1. 2. If there is no spark, test the coil primary resistance using Rotunda digital volt-ohmmeter 007-00001, as shown. 3. If the coil primary resistance is O.K., continue with the diagnostic procedure in Test 1. 4. If the coil primary resistance is not O.K., replace the coil and recheck for weak or no spark. If the spark is now O.K., the problem is resolved. 5. If the spark is still NOT O.K., continue with normal diagnostic procedure in Test 1. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Wiring Harness TFI-IV Part 2 Test 5 TEST EQUIPMENT: VOM, STRAIGHT PIN TEST PROCEDURE 1. Separate wiring harness connector from ignition module. Inspect for dirt, corrosion, and damage. NOTE: PUSH connector tabs to separate. 2. Disconnect wire at S terminal of starter relay. 3. Attach negative (-) VOM, Rotunda Number 007-00001, lead to distributor base. 4. Measure battery voltage. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 86220 > Jan > 86 > Ignition System - Weak/No Spark > Page 4345 5. Following table below, measure connector terminal voltage by attaching VOM to small straight pin inserted into connector terminal and turning ignition switch to position shown. CAUTION: Do not allow straight pin to contact electrical ground. CONNECTOR IGNITION SWITCH TERMINAL WIRE/CIRCUIT TEST POSITION #2 TO IGNITION RUN COIL (-) TERMINAL #3 RUN CIRCUIT RUN AND START #4 START CIRCUIT START 6. Turn ignition switch to Off position. 7. Remove straight pin. 8. Reconnect wire to S terminal of starter relay. TEST RESULT TEST RESOLUTION 90 percent of ^ Test result OK. battery ^ Go to Part 2, Test 6. voltage minimum Less than 90 ^ Inspect for faults in wiring percent of harness and connectors. battery ^ Refer to vehicle wiring voltage diagram for appropriate circuit. ^ Damaged or worn ignition switch, Refer to Shop Manual, Group 33. Primary Circuit Continuity TFI-IV Part 2 Test 8 TEST EQUIPMENT: VOM, STRAIGHT PIN TEST PROCEDURE 1. Separate wiring harness connector from ignition module. Inspect for dirt, corrosion, and damage. NOTE: PUSH connector tabs to separate. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 86220 > Jan > 86 > Ignition System - Weak/No Spark > Page 4346 2. Attach negative (-) VOM, Rotunda Number 007-00001, lead to distributor base. 3. Measure battery voltage. 4. Attach VOM to small straight pin inserted into connector terminal No. 2. CAUTION: Do not allow straight pin to contact electrical ground. 5. Turn ignition switch to Run position and measure terminal No. 2 voltage. 6. Turn ignition switch to Off position. 7. Remove straight pin. TEST RESULT TEST RESOLUTION 90 percent of ^ Go to Part 2, Test 5. battery voltage minimum Less than 90 ^ Go to Part 2, Test 9. percent of battery voltage Ignition Coil Primary Resistance TFI-IV Part 2 Test 3 TEST EQUIPMENT: VOM TEST PROCEDURE 1. Turn ignition switch to Off. 2. Disconnect ignition coil connector. Inspect for dirt, corrosion, and damage. 3. Measure resistance from positive (+) to negative (-) terminal of ignition coil, using Rotunda digital volt-ohmmeter 007-00001. TEST RESULT TEST RESOLUTION 0.3 to 1.0 ^ Test result OK. ohm ^ Go to Test 4. Less than ^ Replace ignition coil. 0.3 ohm or greater than 1.0 ohm Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure Technical Service Bulletin # 872110 Date: 871021 TFI Module/PIP Sensor - New Diagnostic Procedure EEC IV - TFI MODULE AND PIP SENSOR - Article No. NEW DIAGNOSTIC PROCEDURE 87-21-10 FORD: 1983-88 ESCORT/EXP, MUSTANG, THUNDERBIRD, FORD 1984-88 TEMPO 1986-88 TAURUS LINCOLN-MERCURY: 1983 MARK VI 1983-86 CAPRI 1983-87 LYNX 1983-88 COUGAR, MERCURY, CONTINENTAL, LINCOLN TOWN CAR 1984-88 TOPAZ, MARK VII 1986-88 SABLE MERKUR: 1985-88 XR4Ti 1988 SCORPIO LIGHT TRUCK: 1983-88 ALL LIGHT TRUCK LINES ISSUE: A new diagnostic procedure for testing the TFI module and PIP sensor has been developed. This new procedure allows the technician to take a direct path when testing the TFI module and PIP sensor with the use of the new TFI IV diagnostic tester (Rotunda No. 105-00003). ACTION: If service is required, use the diagnostic procedures on pages 29 through 60 of this TSB. Insert these pages in the Engine/Emission Diagnosis Manual, Volume H, Section 15. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Preliminary Checkout, Equipment & Notes CHECKOUT ^ Visually inspect the engine compartment to ensure all vacuum hoses and spark plug wires are properly routed and securely connected. ^ Examine all wiring harnesses and connectors for insulation damage, burned, overheated, loose or broken conditions. ^ Check that the TFI module is securely fastened to the distributor base. ^ Be certain the battery is fully charged. ^ All accessories should be off during diagnosis. EQUIPMENT Obtain the following test equipment or an equivalent: ^ Spark Tester, Special Service Tool D81P-6666-A. See note. ^ Volt/Ohm Meter Rotunda 014-00407. ^ 12 Volt Test Light. ^ Small straight pin. ^ Remote Starter Switch. ^ TFI Ignition Tester, Rotunda 105-00002. NOTES ^ A spark plug with a broken side electrode is not sufficient to check for spark and may lead to incorrect results. ^ When instructed to inspect a wiring harness, both a visual inspection and a continuity test should be performed. ^ When making measurements on a wiring harness or connector, it is good practice to wiggle the wires while measuring. ^ References to pin-in-line connector apply to a shorting bar type connector used to set base timing. ^ This procedure is intended to identify faulty components or wiring while the fault is present. If the complaint is of an intermittent condition, refer to Intermittent Diagnosis. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 4352 Functional Schematic TFI-IV The TFI-IV system electrical schematic is shown below. For detailed information, refer to the vehicle wiring diagram. Ignition Coil Secondary Voltage (Crank Mode) TFI-IV Part 2 Test 1 & 2 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 4353 Ignition Coil Secondary Voltage (Run Mode) TFI-IV Part 2 Test 2 Wiring Harness Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 4354 TFI-IV Part 2 Test 3 Stator - TFI Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 4355 TFI-IV Part 2 Test 4 & 5 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 4356 Stator - TFI-IV TFI-IV Part 2 Test 5 TFI Module TFI-IV Part 2 Test 6 Ignition Coils - Secondary & Primary Resistance Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 4357 Ignition Coil Primary Resistance TFI-IV Part 2 Test 7 & 8 Ignition Coil Secondary Resistance TFI-IV Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 4358 Part 2 Test 8 EEC-IV - TFI-IV TFI-IV Part 2 Test 9 Ignition Coil Supply Voltage Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 4359 TFI-IV Part 2 Test 10 Wiring Harness Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 4360 TFI-IV Part 2 Test 11 Preliminary Checkout, Equipment & Notes CHECKOUT ^ Visually inspect the engine compartment to ensure all vacuum hoses and spark plug wires are properly routed and securely connected. ^ Examine all wiring harnesses and connectors for insulation damage, burned, overheated, loose, or broken conditions. ^ Be certain the battery is fully charged. ^ All accessories should be off during diagnosis. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 4361 EQUIPMENT Obtain the following test equipment or an equivalent: ^ Spark Tester, Special Service Tool D81P-6666-A. See note. ^ Volt/Ohm Meter Rotunda 014-00407. ^ 12 Volt Test Light. ^ Small straight pin. ^ Remote Starter Switch. ^ TFI Ignition Tester, Rotunda 105-00003. NOTES ^ A spark plug with a broken side electrode is not sufficient to check for spark and may lead to incorrect results. ^ When instructed to inspect a wiring harness, both a visual inspection and a continuity test should be performed. ^ When making measurements on a wiring harness or connector, it is good practice to wiggle the wires while measuring. ^ References to pin-in-line connector apply to shorting bar type connector used to set base timing. ^ This procedure is intended to identify faulty components or wiring while the fault is present. If the complaint is of an intermittent condition refer to Intermittent Diagnosis. Functional Schematic TFI-IV Closed Bowl Distributor The TFI-IV Closed Bowl Distributor system electrical schematic is shown below. For detailed information, refer to the vehicle wiring diagram. Ignition Coil Secondary Voltage - Crank Mode Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 4362 TFI-IV Closed Bowl Distributor Part 2 Test 1 & 2 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 4363 Ignition Coil Secondary Voltage - Run Mode TFI-IV Closed Bowl Distributor Part 2 Test 2 Wiring Harness Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 4364 TFI-IV Closed Bowl Distributor Part 2 Test 3 Stator Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 4365 TFI-IV Closed Bowl Distributor Part 2 Test 4, 5 & 6 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 4366 Stator TFI-IV Closed Bowl Distributor Part 2 Test 5 Stator TFI-IV Closed Bowl Distributor Part 2 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 4367 Test 6 TFI Module TFI-IV Closed Bowl Distributor Part 2 Test 7 Ignition Coil, Primary & Secondary Ignition Coil Primary Resistance TFI-IV Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 4368 Closed Bowl Distributor Part 2 Test 8 Ignition Coil Secondary Resistance TFI-IV Closed Bowl Distributor Part 2 Test 9 EEC IV - Wiring Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 4369 TFI-IV Closed Bowl Distributor Part 2 Test 10 Wiring Harness Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 4370 TFI IV Closed Bowl Distributor Part 2 Test 11 Ignition Coil, TFI & Stator Voltage Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 4371 Ignition Coil Supply Voltage TFI IV Closed Bowl Distributor Part 2 Test 12 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 4372 TFI Supply Voltage TFI-IV Closed Bowl Distributor Part 2 Test 13 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 4373 Stator Supply Voltage TFI IV Closed Bowl Distributor Part 2 Test 14 Wiring Harness Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 4374 TFI IV Closed Bowl Distributor Part 2 Test 15 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 87720 > Apr > 87 > Tape Player - Ignition Noise Through Speakers Ignition Control Module: All Technical Service Bulletins Tape Player - Ignition Noise Through Speakers RADIO - IGNITION NOISE THROUGH FACTORY Article No. TAPE PLAYER - 4.9L - WITH TSB MODIFICATION87-3-20 87-7-20 LIGHT TRUCK: 1984-86 F SERIES, BRONCO ISSUE: Ignition noise through the radio speakers when operating the radio in the tape player mode may result if a new multispark ignition module was installed to correct a rough idle condition per TSB 87-3-20. ACTION: To correct this, modify the multi-spark ignition module wire harness as outlined in the following service procedure. 1. Shorten the heavy gauge BLACK wire on the module to 14 inches (357 mm). Crimp on a new solderless lug and hook up wire directly to negative terminal of battery. 2. Perform TSB 86-24-26 to eliminate the radio noise. OTHER APPLICABLE ARTICLES: 86-24-26, 87-3-20 WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual OPERATION: SP870720A TIME: 0.3 Hr. DLR. CODING: Basic Part No. 12A199 Code: 85 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 87610 > Mar > 87 > Engine - Stalling and/or A No Start Condition Ignition Control Module: All Technical Service Bulletins Engine - Stalling and/or A No Start Condition ^ STALL - THICK FILM IGNITION (TFI) MODULE - Article No. EEC IV VEHICLES 87-6-10 ^ STALL/NO START - THICK FILM IGNITION (TFI) MODULE - EEC IV VEHICLES FORD 1984-87 ALL LINCOLN-MERCURY 1984-87 ALL MERKUR 1985-87 XR4Ti LIGHT TRUCK 1984-87 ALL ISSUE: Stalling and/or a no-start condition on vehicles with EEC IV and certain TFI modules may be caused by moisture or salt splash entering at the upper right hand mounting hole of the TFI module housing. This condition will result in a service code 14. ACTION: To correct this, use the following diagnostic and service procedure to seal the hole and prevent further concerns. NOTE: The distributor does not have to be removed to perform this repair. 1. Check to see if the TFI-IV module part number suffix is A2A and the date code is 6K08 or prior, (mounting hole was sealed after 6K08). If the suffix is not A2A, use normal diagnostic procedures and do not perform Steps 2 and 3. 2. Thoroughly clean and dry upper right hand mounting hole of the TFI module with a clean paper towel. 3. Fill the cleaned hole with silicone grease (D7AZ-19A331-A). 4. Clear service code 14 from memory. PART NUMBER PART NAME CLASS D7AZ-19A331-A Silicone Grease AM OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual OPERATION: SP870610A TIME: 1.0 Hr. DLR. CODING: Basic Part No. 12A297 - Code: 09 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 86219 > Jan > 86 > Ignition System Resistance - Manual Revision Ignition Control Module: All Technical Service Bulletins Ignition System Resistance - Manual Revision Article No. 86-2-19 IGNITION SYSTEM - RESISTANCE TESTS - SHOP MANUAL REVISION EMISSION DIAGNOSIS MANUAL FORD 1982-86 ESCORT, EXP; 1983-86 LTD, THUNDERBIRD, CROWN VICTORIA, MUSTANG; 1984-86 TEMPO; 1986 TAURUS LINCOLN-MERCURY 1982-83 LN7; 1982-86 LYNX; 1983-86 MARQUIS, COUGAR, MERCURY, CONTINENTAL, MARK VII, LINCOLN; 1984-86 TOPAZ; 1986 SABLE LIGHT TRUCK 1983-86 EAND F-SERIES, BRONCO, RANGER; 1984-86 BRONCO II; 1986 AEROSTAR If your voltmeter has a high impedance, it will not draw enough current to show a voltage drop when testing TFI power circuits for resistive connections. To assure an accurate test, attach a test light between the circuit being tested and ground as shown. The light will draw current through the connection and allow measurement of the voltage drop so a resistive connection can be identified. IMPORTANT Do not use a test light while monitoring the PIP or SPOUT signal. The test light draws more current than the signal circuit can supply. The test light should be used only on power circuits. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 86220 > Jan > 86 > Ignition System - Weak/No Spark Ignition Control Module: All Technical Service Bulletins Ignition System - Weak/No Spark Article No. 86-2-20 IGNITION SYSTEM - TFI - WEAK OR NO SPARK - DIAGNOSTIC TIP FORD 1982-86 ESCORT, EXP; 1983-86 THUNDERBIRD, LTD, CROWN VICTORIA, MUSTANG; 1984-86 TEMPO; 1986 TAURUS LINCOLN-MERCURY 1982-83 LN7; 1982-86 LYNX; 1983-86 COUGAR, MERCURY, GRAND MARQUIS, CONTINENTAL, MARK VII, LINCOLN; 1984-86 TOPAZ; 1986 SABLE LIGHT TRUCK 1983-86 EAND F-SERIES, RANGER, BRONCO; 1984-86 BRONCO II; 1986 AEROSTAR CALIBRATIONS: All with TFI Systems If the TFI module fails and causes a short to ground, the primary winding of the ignition coil can be damaged. The TFI diagnostic procedure published in the Shop Manual will not identify this condition. When servicing a weak or no spark condition, perform the following: 1. Check for spark using the procedures found in the Manual Information, Computerized Engine, Quick Test Section, Test 1. 2. If there is no spark, test the coil primary resistance using Rotunda digital volt-ohmmeter 007-00001, as shown. 3. If the coil primary resistance is O.K., continue with the diagnostic procedure in Test 1. 4. If the coil primary resistance is not O.K., replace the coil and recheck for weak or no spark. If the spark is now O.K., the problem is resolved. 5. If the spark is still NOT O.K., continue with normal diagnostic procedure in Test 1. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Wiring Harness TFI-IV Part 2 Test 5 TEST EQUIPMENT: VOM, STRAIGHT PIN TEST PROCEDURE 1. Separate wiring harness connector from ignition module. Inspect for dirt, corrosion, and damage. NOTE: PUSH connector tabs to separate. 2. Disconnect wire at S terminal of starter relay. 3. Attach negative (-) VOM, Rotunda Number 007-00001, lead to distributor base. 4. Measure battery voltage. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 86220 > Jan > 86 > Ignition System - Weak/No Spark > Page 4391 5. Following table below, measure connector terminal voltage by attaching VOM to small straight pin inserted into connector terminal and turning ignition switch to position shown. CAUTION: Do not allow straight pin to contact electrical ground. CONNECTOR IGNITION SWITCH TERMINAL WIRE/CIRCUIT TEST POSITION #2 TO IGNITION RUN COIL (-) TERMINAL #3 RUN CIRCUIT RUN AND START #4 START CIRCUIT START 6. Turn ignition switch to Off position. 7. Remove straight pin. 8. Reconnect wire to S terminal of starter relay. TEST RESULT TEST RESOLUTION 90 percent of ^ Test result OK. battery ^ Go to Part 2, Test 6. voltage minimum Less than 90 ^ Inspect for faults in wiring percent of harness and connectors. battery ^ Refer to vehicle wiring voltage diagram for appropriate circuit. ^ Damaged or worn ignition switch, Refer to Shop Manual, Group 33. Primary Circuit Continuity TFI-IV Part 2 Test 8 TEST EQUIPMENT: VOM, STRAIGHT PIN TEST PROCEDURE 1. Separate wiring harness connector from ignition module. Inspect for dirt, corrosion, and damage. NOTE: PUSH connector tabs to separate. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 86220 > Jan > 86 > Ignition System - Weak/No Spark > Page 4392 2. Attach negative (-) VOM, Rotunda Number 007-00001, lead to distributor base. 3. Measure battery voltage. 4. Attach VOM to small straight pin inserted into connector terminal No. 2. CAUTION: Do not allow straight pin to contact electrical ground. 5. Turn ignition switch to Run position and measure terminal No. 2 voltage. 6. Turn ignition switch to Off position. 7. Remove straight pin. TEST RESULT TEST RESOLUTION 90 percent of ^ Go to Part 2, Test 5. battery voltage minimum Less than 90 ^ Go to Part 2, Test 9. percent of battery voltage Ignition Coil Primary Resistance TFI-IV Part 2 Test 3 TEST EQUIPMENT: VOM TEST PROCEDURE 1. Turn ignition switch to Off. 2. Disconnect ignition coil connector. Inspect for dirt, corrosion, and damage. 3. Measure resistance from positive (+) to negative (-) terminal of ignition coil, using Rotunda digital volt-ohmmeter 007-00001. TEST RESULT TEST RESOLUTION 0.3 to 1.0 ^ Test result OK. ohm ^ Go to Test 4. Less than ^ Replace ignition coil. 0.3 ohm or greater than 1.0 ohm Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure Technical Service Bulletin # 872110 Date: 871021 TFI Module/PIP Sensor - New Diagnostic Procedure EEC IV - TFI MODULE AND PIP SENSOR - Article No. NEW DIAGNOSTIC PROCEDURE 87-21-10 FORD: 1983-88 ESCORT/EXP, MUSTANG, THUNDERBIRD, FORD 1984-88 TEMPO 1986-88 TAURUS LINCOLN-MERCURY: 1983 MARK VI 1983-86 CAPRI 1983-87 LYNX 1983-88 COUGAR, MERCURY, CONTINENTAL, LINCOLN TOWN CAR 1984-88 TOPAZ, MARK VII 1986-88 SABLE MERKUR: 1985-88 XR4Ti 1988 SCORPIO LIGHT TRUCK: 1983-88 ALL LIGHT TRUCK LINES ISSUE: A new diagnostic procedure for testing the TFI module and PIP sensor has been developed. This new procedure allows the technician to take a direct path when testing the TFI module and PIP sensor with the use of the new TFI IV diagnostic tester (Rotunda No. 105-00003). ACTION: If service is required, use the diagnostic procedures on pages 29 through 60 of this TSB. Insert these pages in the Engine/Emission Diagnosis Manual, Volume H, Section 15. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Preliminary Checkout, Equipment & Notes CHECKOUT ^ Visually inspect the engine compartment to ensure all vacuum hoses and spark plug wires are properly routed and securely connected. ^ Examine all wiring harnesses and connectors for insulation damage, burned, overheated, loose or broken conditions. ^ Check that the TFI module is securely fastened to the distributor base. ^ Be certain the battery is fully charged. ^ All accessories should be off during diagnosis. EQUIPMENT Obtain the following test equipment or an equivalent: ^ Spark Tester, Special Service Tool D81P-6666-A. See note. ^ Volt/Ohm Meter Rotunda 014-00407. ^ 12 Volt Test Light. ^ Small straight pin. ^ Remote Starter Switch. ^ TFI Ignition Tester, Rotunda 105-00002. NOTES ^ A spark plug with a broken side electrode is not sufficient to check for spark and may lead to incorrect results. ^ When instructed to inspect a wiring harness, both a visual inspection and a continuity test should be performed. ^ When making measurements on a wiring harness or connector, it is good practice to wiggle the wires while measuring. ^ References to pin-in-line connector apply to a shorting bar type connector used to set base timing. ^ This procedure is intended to identify faulty components or wiring while the fault is present. If the complaint is of an intermittent condition, refer to Intermittent Diagnosis. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 4398 Functional Schematic TFI-IV The TFI-IV system electrical schematic is shown below. For detailed information, refer to the vehicle wiring diagram. Ignition Coil Secondary Voltage (Crank Mode) TFI-IV Part 2 Test 1 & 2 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 4399 Ignition Coil Secondary Voltage (Run Mode) TFI-IV Part 2 Test 2 Wiring Harness Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 4400 TFI-IV Part 2 Test 3 Stator - TFI Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 4401 TFI-IV Part 2 Test 4 & 5 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 4402 Stator - TFI-IV TFI-IV Part 2 Test 5 TFI Module TFI-IV Part 2 Test 6 Ignition Coils - Secondary & Primary Resistance Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 4403 Ignition Coil Primary Resistance TFI-IV Part 2 Test 7 & 8 Ignition Coil Secondary Resistance TFI-IV Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 4404 Part 2 Test 8 EEC-IV - TFI-IV TFI-IV Part 2 Test 9 Ignition Coil Supply Voltage Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 4405 TFI-IV Part 2 Test 10 Wiring Harness Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 4406 TFI-IV Part 2 Test 11 Preliminary Checkout, Equipment & Notes CHECKOUT ^ Visually inspect the engine compartment to ensure all vacuum hoses and spark plug wires are properly routed and securely connected. ^ Examine all wiring harnesses and connectors for insulation damage, burned, overheated, loose, or broken conditions. ^ Be certain the battery is fully charged. ^ All accessories should be off during diagnosis. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 4407 EQUIPMENT Obtain the following test equipment or an equivalent: ^ Spark Tester, Special Service Tool D81P-6666-A. See note. ^ Volt/Ohm Meter Rotunda 014-00407. ^ 12 Volt Test Light. ^ Small straight pin. ^ Remote Starter Switch. ^ TFI Ignition Tester, Rotunda 105-00003. NOTES ^ A spark plug with a broken side electrode is not sufficient to check for spark and may lead to incorrect results. ^ When instructed to inspect a wiring harness, both a visual inspection and a continuity test should be performed. ^ When making measurements on a wiring harness or connector, it is good practice to wiggle the wires while measuring. ^ References to pin-in-line connector apply to shorting bar type connector used to set base timing. ^ This procedure is intended to identify faulty components or wiring while the fault is present. If the complaint is of an intermittent condition refer to Intermittent Diagnosis. Functional Schematic TFI-IV Closed Bowl Distributor The TFI-IV Closed Bowl Distributor system electrical schematic is shown below. For detailed information, refer to the vehicle wiring diagram. Ignition Coil Secondary Voltage - Crank Mode Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 4408 TFI-IV Closed Bowl Distributor Part 2 Test 1 & 2 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 4409 Ignition Coil Secondary Voltage - Run Mode TFI-IV Closed Bowl Distributor Part 2 Test 2 Wiring Harness Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 4410 TFI-IV Closed Bowl Distributor Part 2 Test 3 Stator Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 4411 TFI-IV Closed Bowl Distributor Part 2 Test 4, 5 & 6 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 4412 Stator TFI-IV Closed Bowl Distributor Part 2 Test 5 Stator TFI-IV Closed Bowl Distributor Part 2 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 4413 Test 6 TFI Module TFI-IV Closed Bowl Distributor Part 2 Test 7 Ignition Coil, Primary & Secondary Ignition Coil Primary Resistance TFI-IV Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 4414 Closed Bowl Distributor Part 2 Test 8 Ignition Coil Secondary Resistance TFI-IV Closed Bowl Distributor Part 2 Test 9 EEC IV - Wiring Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 4415 TFI-IV Closed Bowl Distributor Part 2 Test 10 Wiring Harness Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 4416 TFI IV Closed Bowl Distributor Part 2 Test 11 Ignition Coil, TFI & Stator Voltage Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 4417 Ignition Coil Supply Voltage TFI IV Closed Bowl Distributor Part 2 Test 12 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 4418 TFI Supply Voltage TFI-IV Closed Bowl Distributor Part 2 Test 13 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 4419 Stator Supply Voltage TFI IV Closed Bowl Distributor Part 2 Test 14 Wiring Harness Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 4420 TFI IV Closed Bowl Distributor Part 2 Test 15 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 86219 > Jan > 86 > Ignition System Resistance - Manual Revision Ignition Control Module: All Technical Service Bulletins Ignition System Resistance - Manual Revision Article No. 86-2-19 IGNITION SYSTEM - RESISTANCE TESTS - SHOP MANUAL REVISION EMISSION DIAGNOSIS MANUAL FORD 1982-86 ESCORT, EXP; 1983-86 LTD, THUNDERBIRD, CROWN VICTORIA, MUSTANG; 1984-86 TEMPO; 1986 TAURUS LINCOLN-MERCURY 1982-83 LN7; 1982-86 LYNX; 1983-86 MARQUIS, COUGAR, MERCURY, CONTINENTAL, MARK VII, LINCOLN; 1984-86 TOPAZ; 1986 SABLE LIGHT TRUCK 1983-86 EAND F-SERIES, BRONCO, RANGER; 1984-86 BRONCO II; 1986 AEROSTAR If your voltmeter has a high impedance, it will not draw enough current to show a voltage drop when testing TFI power circuits for resistive connections. To assure an accurate test, attach a test light between the circuit being tested and ground as shown. The light will draw current through the connection and allow measurement of the voltage drop so a resistive connection can be identified. IMPORTANT Do not use a test light while monitoring the PIP or SPOUT signal. The test light draws more current than the signal circuit can supply. The test light should be used only on power circuits. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > Page 4425 Ignition Control Module: Locations LH Inner Fender Well Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > Page 4426 Ignition Control Module: Description and Operation Typical Ignition System The Ignition Module shuts off the primary circuit each time it receives a pulse from the magnetic pick-up Fig. 9. A timing circuit in the ignition module turns the primary current back on after a short period of time. High voltage is created each time the magnetic field is built up and collapsed. The red ignition module wire provides operating voltage for the module's electronic components in the Run mode. The white module wire and start bypass provide increased voltage for the module and coil during Start mode. Ignition Modules Dura Spark II systems with UIM (Universal Ignition Module) Fig. 10 can respond to another control signal from either an Ignition Barometric Pressure Switch, Ignition Timing Vacuum Switch, or the Microprocessor Control Unit (MCU), depending on the engine calibration. Responding to this second signal, the UIM provides additional spark timing control for certain operating conditions by shutting off the ignition coil current flow at a different time than with just the distributor pick-up signal. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > Page 4427 Module Identification Chart For proper ignition module identification refer to Fig. 1. The modules are not interchangeable, Dura Spark II has 6 wire connector while Dura Spark III has a 5 wire connector. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > Page 4428 Ignition Control Module: Service and Repair Open Bowl Distributor 1. Remove distributor cap and adapter. Position cap and wires aside. 2. Disconnect TFI wiring. 3. Remove distributor from engine using tool T82L-12270-A or equivalent to remove security-type hold-down bolt, if equipped. 4. Place distributor on workbench and remove 2 TFI module screws, Fig. 2. 5. Pull right side of module down distributor mounting flange and then back up to disengage module terminals from connector in distributor base. Module may then be pulled toward flange and away from distributor. Do not attempt to lift module from mounting surface before moving entire TFI module toward distributor flange, as pins at distributor/module connector will break otherwise. 6. Coat metal base plate of TFI ignition module with 1/32 inch thick layer of silicone grease D7AZ-19A331-A, or equivalent. 7. Place TFI module on distributor base mounting flange. Carefully position TFI module assembly toward distributor bowl and securely engage 3 distributor connector pins. 8. Install 2 TFI module mounting screws and torque to 9---35 inch lbs. 9. Install distributor on engine. 10. Install distributor cap and adapter. 11. Connect TFI wiring. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > Page 4429 12. Check and, if necessary adjust engine timing according to decal. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Camshaft Position Sensor: Diagram Information and Instructions Symbol Identification Wire Color Code Identification Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4435 NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Crankshaft Position Sensor: Diagram Information and Instructions Symbol Identification Wire Color Code Identification Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4440 NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Description and Operation Hall Effect Sensor: Description and Operation Profile Ignition Pickup The PIP signal is created in the Hall Effect and Stator assembly and indicates crankshaft position and engine RPM Fig. 21. The PIP signal is fed to both the TFI module and the ECA. PIP Sensor COMPONENTS The Hall Effect device is made up of a voltage regulator, a Hall voltage generator, Darlington amplifier, Schmitt trigger, and an open collector output stage integrated in a single monolithic silicon chip Fig. 22. A signal is produced when a ferrous material is passed through the opening and the flux lines decrease. The Hall generator (Hall device) sends a sine wave signal to the Darlington amplifier. The Darlington amplifier inverts the signal. When the signal is low the output is high. When the signal is high the output is low. This output then goes to the Schmitt trigger. The Schmitt trigger shapes the signal into a square wave (digital high) signal. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Description and Operation > Page 4444 PIP Signal Operation OPERATION The output signal to the Darlington amplifier is high when the window (on the armature) allows the magnetic field to reach the Hall device (switch off) Fig. 23. When the TAB shunts the magnetic field (closes) away from the Hall device the signal is low to the Darlington amplifier (switch on). Hall Effect Sensor In other words when one of the windows or openings is in the gap between the Hall device and the permanent magnet, the field stays strong and the voltage is high since the magnetic path is complete from the magnet, through the Hall device, and back to the magnet. In this case the switch is off and the Hall Effect does not send a signal. When the TAB enters the gap, the armature cuts off the magnetic path to the Hall device and its voltage drops. In this case the switch is on and the Hall Effect device sends a signal. The signal is switched On and Off as long as the armature is rotating (distributor is turning) and opening and closing the magnetic path. This is the signal used by the ECA to interpret crankshaft position and engine RPM. The signal can also be used by the TFI module if the SPOUT signal from the ECA is lost. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Description and Operation > Page 4445 Signature PIP SIGNATURE PIP Some Electronic Engine Control (EEC) vehicles are equipped with a signature profile ignition pickup signal. The regular type armature used for the PIP signal has the same size tabs and windows. In a signature PIP signal armature, one of the tabs is narrower than the others Fig. 25. The narrower tab provides a different signal to the ECA when it passes through the Hall Effect switch. When the ECA sees the narrow tab it knows when to properly pulse the fuel injectors. This system is used on cars and trucks where the ECA needs to know when to pulse certain injectors. For example, on sequential electronic fuel injection (SEFI) systems, each injector is pulsed to coincide with its intake valve opening. With the signature PIP, the ECA knows when the No. 1 cylinder needs to be supplied with fuel. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Description and Operation > Page 4446 Hall Effect Sensor: Service and Repair Removal Do not attempt to replace stator without an arbor press. 1. Remove distributor. Remove rotor, then the TFI module. 2. If distributor uses push on type rotor, remove two retaining screws holding armature, then the armature. Hold gear to loosen armature screws, do not hold armature. 3. Mark stator, armature, gear and collar with felt tip pen to aid in reassembly. 4. Remove and discard pins in gear and collar if equipped. 5. Invert distributor and place in Axle Bearing Seal Plate and press off gear using Bearing Removal Tool. 6. Deburr and polish shaft with emery paper and wipe clean so that shaft slides out freely from distributor base. 7. Remove shaft assembly, then the thrust washer from shaft. Next remove octane rod. 8. Remove stator assembly screws, then the stator assembly from top of bowl. 9. Inspect base bushing for wear of signs of excess heat concentration, replace distributor assembly if damaged. 10. Inspect base O-ring for cuts or damage and replace as necessary. 11. Inspect base for cracks and wear, replace distributor assembly if damage is found. Installation 1. Place stator assembly over bushing and press down to seat. 2. Place stator connector in position, tab should fit in notch on base with fastening eyelets aligned with screw holes. 3. Install stator screws and Torque to 15-35 inch lbs. Next install octane rod. 4. Install thrust washer on top of bushing, then apply lubricant to distributor shaft below armature. Do not over lubricate. 5. Insert shaft through base bushing, then place collar, if equipped, over shaft and line up mark on armature and collar to aid alignment with original drill hole. Use a suitable drift punch to assure proper alignment. 6. Drill holes through shaft and collar should align on both sides of shaft. If holes do not align, collar may be 180 degrees out of alignment on shaft. Rotate collar on shaft one half rotation, then check. 7. Insert new roll pin through collar and shaft, pin should be flush with both sides of collar when seated. 8. If distributor uses push on type rotor, place a 1/2 inch deep well socket over shaft, invert and place on arbor plate. 9. If distributor uses screw down type rotor, invert and place on arbor plate. 10. Place distributor gear on shaft and line up marks on armature and gear. Hole in shaft and gear must line up as accurately as possible to assure ease of roll pin insertion. 11. Place a 5/8 inch deep well socket over shaft and gear, then press gear to align with original drill hole. 12. If gear holes do not align, gear must be removed and repressed on. Drift punch will not align holes, as in collar, holes should align. 13. Insert new roll pin through gear and shaft, pin should extrude evenly on both sides. 14. Install armature, if removed, and Torque screws to 25-35 inch lbs. 15. Install TFI module, rotor, then distributor. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Technical Service Bulletins > Customer Interest for Ignition Switch: > 932410 > Nov > 93 > Instrument Cluster Warning Lights - Dimly Lit Ignition Switch: Customer Interest Instrument Cluster Warning Lights - Dimly Lit Article No. 93-24-10 11/24/93 ^ LAMP - MALFUNCTION OF FOUR PIN LOW OIL LEVEL RELAY - VEHICLES BUILT AFTER 8/1/92 OR 1983-1993 VEHICLES THAT HAVE HAD SERVICE REPLACEMENT IGNITION SWITCHES AFTER 8/1/92 ^ LAMPS - INSTRUMENT CLUSTER WARNING LIGHTS DIMLY LIT - VEHICLES BUILT AFTER 8/1/92 OR 1983-1993 VEHICLES THAT HAVE HAD SERVICE REPLACEMENT IGNITION SWITCHES AFTER 8/1/92 FORD: 1983 FAIRMONT 1983-89 CROWN VICTORIA, ESCORT 1983-93 MUSTANG, THUNDERBIRD 1983-94 PROBE 1984-86 LTD 1984-94 TEMPO LINCOLN-MERCURY: 1983 LN7, ZEPHYR 1983-87 CONTINENTAL, LYNX 1983-89 GRAND MARQUIS, TOWN CAR 1983-93 COUGAR 1984-86 CAPRI, MARQUIS 1984-94 TOPAZ LIGHT TRUCK: 1983-91 BRONCO 1983-93 ECONOLINE, F-150-350 SERIES, RANGER 1986-91 AEROSTAR 1991-93 EXPLORER ISSUE: The instrument cluster warning light(s) may be dimly lit or there may be a malfunction of the four pin low oil relay on vehicles so equipped. This could be due to the ignition switch. ACTION: If the vehicle displays the subject symptoms and meets the following conditions, replace the ignition switch. Refer to the appropriate Car or Light Truck Service Manual (Section 13-04 for 1983-1990 Cars, Section 11-04 for 1991-1993 Cars and Section 13-05 for 1983-1990 Light Trucks, Section 11-05 for 1991-1993 Light Trucks) for removal and installation procedures. Refer to the Parts Block in this article for correct parts usage. CONDITIONS ^ The vehicle has 14401 wiring attached to the P2 terminal of the ignition switch. Refer to the wiring schematic and/or Electrical And Vacuum Troubleshooting Manual (EVTM) for the concern vehicle. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Technical Service Bulletins > Customer Interest for Ignition Switch: > 932410 > Nov > 93 > Instrument Cluster Warning Lights - Dimly Lit > Page 4455 ^ The vehicle is equipped with one of the ignition switches identified in the Ignition Switch Part Number Chart. NOTE: THE SERVICE PART NUMBERS FOR THE REPLACEMENT IGNITION SWITCHES WILL HAVE THE SAME PART NUMBERS AS THOSE REPLACED. THE NEW SWITCH HAS BEEN IMPROVED TO CORRECT THE SUBJECT ISSUE. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of The Bumper To Bumper For 1992/93 Models, Basic Warranty Coverage For All Other Models Except Lincolns. Major Component Warranty Coverage For Lincolns OPERATION DESCRIPTION TIME 932410A Replace Ignition Switch - 0.5 Hr. All Light and Compact Trucks DEALER CODING BASIC PART NO. CONDITION CODE 11572 X1 OASIS CODES: 201000, 201100, 206000 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch: > 932410 > Nov > 93 > Instrument Cluster Warning Lights - Dimly Lit Ignition Switch: All Technical Service Bulletins Instrument Cluster Warning Lights - Dimly Lit Article No. 93-24-10 11/24/93 ^ LAMP - MALFUNCTION OF FOUR PIN LOW OIL LEVEL RELAY - VEHICLES BUILT AFTER 8/1/92 OR 1983-1993 VEHICLES THAT HAVE HAD SERVICE REPLACEMENT IGNITION SWITCHES AFTER 8/1/92 ^ LAMPS - INSTRUMENT CLUSTER WARNING LIGHTS DIMLY LIT - VEHICLES BUILT AFTER 8/1/92 OR 1983-1993 VEHICLES THAT HAVE HAD SERVICE REPLACEMENT IGNITION SWITCHES AFTER 8/1/92 FORD: 1983 FAIRMONT 1983-89 CROWN VICTORIA, ESCORT 1983-93 MUSTANG, THUNDERBIRD 1983-94 PROBE 1984-86 LTD 1984-94 TEMPO LINCOLN-MERCURY: 1983 LN7, ZEPHYR 1983-87 CONTINENTAL, LYNX 1983-89 GRAND MARQUIS, TOWN CAR 1983-93 COUGAR 1984-86 CAPRI, MARQUIS 1984-94 TOPAZ LIGHT TRUCK: 1983-91 BRONCO 1983-93 ECONOLINE, F-150-350 SERIES, RANGER 1986-91 AEROSTAR 1991-93 EXPLORER ISSUE: The instrument cluster warning light(s) may be dimly lit or there may be a malfunction of the four pin low oil relay on vehicles so equipped. This could be due to the ignition switch. ACTION: If the vehicle displays the subject symptoms and meets the following conditions, replace the ignition switch. Refer to the appropriate Car or Light Truck Service Manual (Section 13-04 for 1983-1990 Cars, Section 11-04 for 1991-1993 Cars and Section 13-05 for 1983-1990 Light Trucks, Section 11-05 for 1991-1993 Light Trucks) for removal and installation procedures. Refer to the Parts Block in this article for correct parts usage. CONDITIONS ^ The vehicle has 14401 wiring attached to the P2 terminal of the ignition switch. Refer to the wiring schematic and/or Electrical And Vacuum Troubleshooting Manual (EVTM) for the concern vehicle. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch: > 932410 > Nov > 93 > Instrument Cluster Warning Lights - Dimly Lit > Page 4461 ^ The vehicle is equipped with one of the ignition switches identified in the Ignition Switch Part Number Chart. NOTE: THE SERVICE PART NUMBERS FOR THE REPLACEMENT IGNITION SWITCHES WILL HAVE THE SAME PART NUMBERS AS THOSE REPLACED. THE NEW SWITCH HAS BEEN IMPROVED TO CORRECT THE SUBJECT ISSUE. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of The Bumper To Bumper For 1992/93 Models, Basic Warranty Coverage For All Other Models Except Lincolns. Major Component Warranty Coverage For Lincolns OPERATION DESCRIPTION TIME 932410A Replace Ignition Switch - 0.5 Hr. All Light and Compact Trucks DEALER CODING BASIC PART NO. CONDITION CODE 11572 X1 OASIS CODES: 201000, 201100, 206000 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Technical Service Bulletins > Page 4462 Ignition Switch: Service and Repair Fig. 3 Ignition switch replacement 1. Disconnect battery ground cable. 2. Remove steering column shroud and lower the steering column. 3. Disconnect electrical connector from switch, then remove 2 switch attaching nuts. 4. Lift switch up to disengage actuator rod, then remove switch from vehicle, Fig. 3. 5. Reverse procedure to install. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Description and Operation Knock Sensor: Description and Operation The Knock Sensor, is a piezoelectric accelerometer with the sensor designed to resonate at approximately the same frequency as the engine knock frequency. The sensor uses the resonant frequency to mechanically amplify the vibrations. This method allows relatively large signals to be achieved without electrical amplification and with small package size. The sensor has a thin circular piezoelectric ceramic disk which is bonded to a metal diaphragm. Electrical connections are made through a two pin integral connector. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Description and Operation > Page 4466 Knock Sensor: Testing and Inspection Ford provides trouble code/symptom driven diagnostics for this component. For complete diagnosis and pinpoint testing, refer to Computers and Control Systems, Testing and Inspection. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Technical Service Bulletins > Engine - Lack of Power/No Start Diagnosis Spark Plug: Technical Service Bulletins Engine - Lack of Power/No Start Diagnosis Article No. 91-12-11 06/12/91 LACK OF POWER 7.5L, 5.8L, 5.0L, 4.9L - CATALYTIC CONVERTER DIAGNOSTIC TIPS LIGHT TRUCK: 1986-91 BRONCO, ECONOLINE, F-150-350 SERIES 1988-91 F SUPER DUTY, F47 ISSUE: Lack of power or a no start condition may be diagnosed as an exhaust restriction caused by a plugged catalytic converter. A plugged catalytic converter (internal deterioration) is usually caused by abnormal engine operation. ACTION: Diagnose the catalytic converter to confirm internal failure. Refer to the Catalyst and Exhaust System Diagnostic Section, in the Engine/Emissions Diagnostic Shop Manual and the following procedures for service details. 1. Lack of proper HEGO operation may cause, or be the result of a rich or lean fuel condition, which could cause additional heat in the catalyst. Perform self test KOEO and KOER, service any codes. NOTE: IF TWO DIGIT CODES 41, 42, 85 OR THREE DIGIT CODES 171, 172, 173, 179, 181, 182, 183 AND 565 ARE RECEIVED, CHECK FOR PROPER HEGO GROUND. If the HEGO ground is good, the following areas may be at fault: ^ Ignition Coil ^ Distributor Cap ^ Distributor Rotor ^ Fouled Spark Plug ^ Spark Plug Wires ^ Air Filter ^ Stuck Open Injector ^ Fuel Contamination Engine OIL ^ Manifold Leaks Intake/ Exhaust ^ Fuel Pressure ^ Poor Power Ground ^ Engine Not At Normal Operating Temperature ^ HEGO Sensor 2. Spark timing that is retarded from specification may increase exhaust gas temperature and shorten catalyst life. Refer to the following procedure for service details. a. Check spark timing. Check base timing with spout disconnected. Set base timing to the specification on the vehicle emission decal. b. Check computed timing with spout connected. NOTE: COMPUTED TIMING IS EQUAL TO BASE TIMING PLUS 20~ BTDC +/- 3~. 3. Misfiring spark plugs may cause an unburned fuel air mixture to pass through the catalyst, which could cause higher than normal catalyst temperatures. Refer to the following procedure for service details. a. Check secondary ignition, hook the vehicle up to an engine analyzer and check for a secondary ignition misfire. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Technical Service Bulletins > Engine - Lack of Power/No Start Diagnosis > Page 4471 NOTE: SERVICE ANY ITEM THAT IS NOT PERFORMING AT PROPER SPECIFICATIONS BEFORE CONTINUING. 4. Fuel pressure that is too high may cause rich air fuel mixtures to pass through the catalyst which could cause higher than normal catalyst temperatures. Refer to the following procedure for service details. a. Check fuel pressure, install fuel pressure gauge, start and run the engine at idle. Fuel pressures between 28 and 34 PSI are typical (4.9L typically is 15 PSI higher). b. Disconnect the vacuum line going to the fuel pressure regulator. Fuel pressure typically jumps to 40 PSI +/- 3 PSI (4.9L typically is 15 PSI higher). Visually inspect vacuum line for raw fuel. NOTE: FUEL PRESSURES ABOVE THESE VALUES SHOULD BE CORRECTED. HOWEVER, THIS MAY NOT BE THE CAUSE OF THE CONCERN. SERVICE AS NECESSARY. 5. Throttle plates in the throttle body not returning to the proper closed position may cause excessive catalyst temperatures during downhill grades. Refer to the following procedure for service details. a. Visually inspect the throttle body and linkage for: ^ Binding or sticking throttle linkage. ^ Tight speed control linkage or cable. ^ Vacuum line interference. ^ Electrical harness interference. NOTE: AFTERMARKET GOVERNORS, THROTTLE LINKAGE AND CABLES ASSOCIATED WITH POWER TAKE-OFF UNITS, MAY ALSO INTERFERE WITH PROPER THROTTLE RETURN. SERVICE AS NECESSARY. 6. It is extremely important that all systems related to the engine and emission systems operate properly. a. Visually inspect the engine compartment to make sure all vacuum hoses and spark plug wires are properly routed and securely connected. b. Inspect all wiring harnesses and connectors for insulation damage, burned, overheated, loose or broken conditions. c. Verify proper operation of the thermactor system. Thermactor systems that fail to dump thermactor air to the atmosphere properly or at the correct time can cause high catalyst temperatures. d. Visually inspect thermactor system for damaged or kinked hoses and perform a function test on following components: air control valve, check valve, silencer, filter and the air bypass solenoid. e. Verify proper operation of the engine cooling system thermostat. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under Basic Warranty Coverage, Emissions Warranty Coverage OPERATION DESCRIPTION TIME 911211A Diagnostics - Perform 0.5 Hrs. KOEO And KOER Self Tests 911211B Timing - Check Or Adjust 0.5 Hrs. Spark Timing, Check Computed Timing And Check Secondary Ignition System With Engine Analyzer. 911211C Check - Fuel Pressure And 0.2 Hrs. Inspect Vacuum Line For Raw Fuel. 911211D Inspect - Throttle Body And 0.1 Hrs. Linkage. 911211E Inspect - Vacuum Hoses, 0.1 Hrs. Electrical Harnesses, Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Technical Service Bulletins > Engine - Lack of Power/No Start Diagnosis > Page 4472 Connectors And Spark Plug Wires For Routing Damage. 911211F Thermactor System - 0.3 Hrs. Inspect For Proper Operation And Damaged Component. Includes Function Check Of Air Control Valve, Thermactor Air Bypass Solenoid, Check Valves, Silencer And Filter. 911211G Thermostat - Check For 0.2 Hrs. Proper Operation. DEALER CODING BASIC PART NO. CONDITION CODE 5E212 25 OASIS CODES: 403000, 603300, 614000 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Technical Service Bulletins > Page 4473 Spark Plug: Specifications SPARK PLUGS Gap ...................................................................................................................................................... ............................................................ 0.044 in Torque ...................................................................... ................................................................................................................. 9-20 Nm (7-15 ft-lbs) Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Technical Service Bulletins > Page 4474 Spark Plug: Service and Repair REMOVAL - Remove the wire from each spark plug by grasping the molded boot with tool T74P-6666-A or equivalent. Twist the boot until it loosens and then pull it off the spark plug. Do not pull on the wire, as the connection may become damaged. - Any wire damaged must be replaced. Each original spark plug wire is numbered for the cylinder to which it is designated. If wires are not numbered, each wire should be numbered as to the plug from which it was removed. - Clean the area around each spark plug port with compressed air. - Using the proper size spark plug socket remove the spark plugs. INSTALLATION Check the gap on each new spark plug and set to specification. See: Specifications - Install each spark plug and tighten to 9-20 Nm (7-15 ft-lbs). Cylinder Numbering And Distributor Location Location On Distributor - Coat the inside of each spark plug boot with silicone dielectric compound. Connect each spark plug wire to the plug from which it was removed. Be sure each wire is fully depressed on each plug and molded boot is firmly in place. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Vacuum Restrictor > Component Information > Description and Operation Vacuum Restrictor: Description and Operation This orifice-type flow restrictor (Fig. 1) is used in several emission calibrations to control the flow rate and/or timing inactions to the following emission component systems: a. EGR valve timing-opening and closing. b. Part throttle spark advance c. Purge system d. Thermactor system Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Ignition System > Vacuum Restrictor > Component Information > Description and Operation > Page 4478 Vacuum Restrictor: Testing and Inspection The flow rate through the restrictor is the same in both directions. If it is blocked, replace it. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Locations Four Wheel Drive Indicator Lamp: Locations LH Quarter Panel Area (F150-350) On Transfer Case Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions Four Wheel Drive Indicator Lamp: Diagram Information and Instructions Symbol Identification Wire Color Code Identification Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 4487 NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 4488 Fig. 25 Four Wheel Drive Indicator Lamp Wiring Circuit Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > A L L Diagnostic Trouble Codes - Trans and Drivetrain > System Information > System Diagnosis A L L Diagnostic Trouble Codes - Trans and Drivetrain: Testing and Inspection For Transmission related codes, proceed to Computers and Control Systems. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band, A/T > Component Information > Technical Service Bulletins > A/T - AOD New Overdrive Band Anchor Pin Band: Technical Service Bulletins A/T - AOD New Overdrive Band Anchor Pin Article No. TRANSMISSION - AUTOMATIC OVERDRIVE 87-22-13 (AOD) - NEW OVERDRIVE BAND ANCHOR PIN - VEHICLES BUILT BEFORE 09/30/86 FORD: 1980-87 MUSTANG, THUNDERBIRD, FORD LINCOLN-MERCURY: 1980-83 MARK VI 1980-87 COUGAR, MERCURY, CONTINENTAL, LINCOLN TOWN CAR LIGHT TRUCK: 1980-87 E SERIES, F SERIES, BRONCO ISSUE: A new overdrive band anchor pin, with a stepped diameter, is available for service. The old pin may have caused overdrive band wear or anchor pin leakage on vehicles built before 09/30/86. NOTE: AOD transmissions built after 09/30/86 have the new design overdrive band anchor pin. This pin is NOT serviceable on transmissions built after 09/30/86. If replacement is required, a new transmission case must be installed. Figure 10 ACTION: If service is required, use the appropriate Car or Light Truck Shop Manual, Section 17-20, for installation of the new overdrive band anchor pin, Figure 10. PART NUMBER PART NAME CLASS E2AZ-7F295-A Anchor Pin C E0AZ-19554-BA Ford Stud and B Bearing Mount OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band, A/T > Component Information > Adjustments > C5 Transmission Band: Adjustments C5 Transmission Intermediate Band Intermediate Band Adjustment 1. Clean all the dirt from the band adjusting screw area. Remove and discard the locknut 2. Install a new locknut on the adjustment screw. 3. Tighten the adjusting screw using Band Adjusting Ratchet T71 P-77370-H and Socket T71 P-77370-D or equivalent. Tool T71 P-77370-H or equivalent, is a pre-set torque wrench which will click when the torque on the adjusting screw reaches 13.5 Nm (10 lb-ft). 4. Back off the adjusting screw exactly 4 1/4 turns. 5. Hold the adjusting screw from turning and tighten the locknut to 54 Nm (40 lb-ft). Low/Reverse Band Low Reverse Band Adjustment 1. Clean all the dirt from the band adjusting screw area. Remove and discard the locknut. 2. Install a new locknut on the adjusting screw. 3. Tighten the adjusting screw using Band Adjusting Ratchet T71 P-77370-H and Socket T71 P-77370-D or equivalent. Tool T71 P-77370-H or equivalent, is a pre-set torque wrench which will click when the torque on the adjusting screw reaches 13.5 Nm (10 lb-ft). Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band, A/T > Component Information > Adjustments > C5 Transmission > Page 4500 4. Back off the adjusting screw exactly 3 turns. 5. Hold the adjusting screw from turning and tighten locknut to 54 Nm (40 lb-ft). Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band, A/T > Component Information > Adjustments > C5 Transmission > Page 4501 Band: Adjustments C6 Transmission INTERMEDIATE BAND ADJUSTMENT NOTE: When making the intermediate band adjustment, the locknut must be discarded and a new one installed each time the band is adjusted. Refer to service bulletins section for additional information on this procedure. 1. Clean dirt from the band adjusting screw. Remove and discard locknut. 2. Install a new locknut and tighten the adjusting screw to 14 Nm (10 ft lbs). 3. Back the screw off exactly 1.5 turns. 4. Hold the adjusting screw from turning and torque the locknut to 48-61 Nm(35-40 ft lbs). Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Technical Service Bulletins > A/T - AOD Case Thread Update Case: Technical Service Bulletins A/T - AOD Case Thread Update TRANSMISSION - AOD - CASE BOLT HOLE SIZE CHANGE Article No. 89-9-12 FORD: 1986-88 CROWN VICTORIA 1986 LTD 1986-88 MUSTANG, THUNDERBIRD LINCOLN-MERCURY: 1986 CAPRI 1986-87 CONTINENTAL 1986-88 COUGAR, GRAND MARQUIS, MARK VII 1986 MARQUIS 1986-88 TOWN CAR LIGHT TRUCK: 1986-88 BRONCO, ECONOLINE, F-150, F-250, F-350 ISSUE: The 1989 model year "AOD" transmission case threads are different from prior model year cases. Prior model year transmission cases use a 5/16"-18 thread. 1989 model year transmission cases use a M10-1.5 thread. The larger M10-1.5 bolts will not pass through the prior model year converter plate, transmission brace or engine cover plate. FIGURE 1 ACTION: If a transmission case replacement is required on a past model vehicle, the bolt holes for the car's transmission brace and converter cover plate will need to be enlarged with a 1/2" drill. On light trucks, enlarge the converter cover plate and engine cover plate with a 1/2" drill. Refer to Figure 1 for the bolt hole locations. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 5800 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > Customer Interest: > 861117 > Jun > 86 > A/T - Synthetic Fluid Availability Fluid - A/T: Customer Interest A/T - Synthetic Fluid Availability Article No. 86-11-17 TRANSMISSION - AUTOMATIC - NEW SYNTHETIC DEXRON II ALL WEATHER AUTOMATIC TRANSMISSION FLUID FORD 1986 and PRIOR ESCORT, EXP, FORD, LTD, THUNDERBIRD, MUSTANG, TEMPO; 1986 TAURUS LINCOLN-MERCURY 1982-83 LN7; 1986 and PRIOR LYNX, MERCURY, MARQUIS, COUGAR, CAPRI, TOPAZ, LINCOLN, MARK, CONTINENTAL; 1986 SABLE LIGHT TRUCK 1986 and PRIOR E, F SERIES, BRONCO, BRONCO II, RANGER A new synthetic Dexron II automatic transmission fluid specification number ESR-M2C163-A2, part number E6AZ-19582-B is now available. This fluid will maintain a more constant viscosity through a wider range of temperatures. In the event a vehicle will be operated in extremely cold temperatures for an extended period of time, remove all existing fluid from the transmission (using the procedure shown in the applicable 1986 Car or Light Truck Shop Manual) and replace with the new synthetic Dexron II fluid, E6AZ-19582-B. The synthetic fluid is year 'round fluid and will not require replacement for warmer weather. CAUTION: DO NOT use synthetic Dexron II fluid in transmissions designed to use Type "F" fluid. PART NUMBER PART NAME CLASS E6AZ-19582-B Synthetic Dexron Oil V Automatic Transmission Oil OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid - A/T: > 06-14-4 > Jul > 06 > A/T Mercon V ATF Usage Fluid - A/T: All Technical Service Bulletins A/T - Mercon V ATF Usage TSB 06-14-4 07/24/06 MERCON ATF IS BEING REPLACED BY MERCON V ATF AS A SERVICE FLUID. FORD: 1980-1997 Crown Victoria 1981-1997 Mustang, Thunderbird 1981-2003 Escort 1986-1993 Festiva 1986-1997 Taurus 1989-1997 Probe 1994-1997 Aspire 1995-2000 Contour 1980-1996 Bronco 1981-2003 F-150 1981-2004 E-Series, F-Super Duty 1983-1996 Ranger 1986-1996 Aerostar 1991-1997 Explorer 1993-2004 F-53 Motorhome Chassis 1995-1998 Windstar 1997-2004 Expedition 2000-2005 Excursion 2001-2007 Escape 1987-2000 F-B-Series 2000-2007 F-650, F-750 LINCOLN: 1980-1997 Town Car 1981-1997 Continental 1993-1997 Mark VIII 1998-2004 Navigator 2002-2003 Blackwood MERCURY: 1980-1997 Grand Marquis 1981-1997 Cougar 1986-1997 Sable 1987-1999 Tracer 1995-2000 Mystique 1999-2002 Cougar 1993-2002 Villager 1997 Mountaineer 2005-2007 Mariner MERKUR: 1985-1989 XR4TI This article supersedes TSB 01-15-7 to update the vehicle application chart. ISSUE MERCON(R) Automatic Transmission Fluid is being replaced by MERCON(R) V as a service fluid. ACTION Beginning immediately all automatic transmission / transaxle applications requiring MERCON(R) can now be serviced using MERCON(R) V or MERCON(R) Automatic Transmission Fluid or dual usage fluids labeled MERCON(R) / MERCON(R) V. After July 1, 2007, MERCON(R) Automatic Transmission Fluid will no longer be manufactured, therefore, availability of this fluid will only continue for however long it takes to deplete what remains in inventory. SERVICE PROCEDURE Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid - A/T: > 06-14-4 > Jul > 06 > A/T Mercon V ATF Usage > Page 4519 Service automatic transmissions requiring MERCON(R) with MERCON(R) V or MERCON(R) Automatic Transmission Fluid or dual usage fluids labeled MERCON(R) / MERCON(R) V For proper fluid application on current and past model vehicles equipped with automatic transmissions I transaxles refer to the fluid usage chart. (Figure 1) CAUTION AUTOMATIC TRANSMISSIONS / TRANSAXLES THAT REQUIRE MERCON® V SHOULD STILL ONLY USE MERCON(R) V OR DUAL USAGE FLUID LABELED MERCON(R) / MERCON(R) V. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid - A/T: > 06-14-4 > Jul > 06 > A/T Mercon V ATF Usage > Page 4520 CAUTION MERCON(R) SP, MOTORCRAFT PREMIUM AUTOMATIC TRANSMISSION FLUID AND MOTORCRAFT M5 ATFS ARE UNIQUE FLUIDS AND MUST BE USED IN APPLICATIONS RECOMMENDING THAT PARTICULAR FLUID. USE OF ANY OTHER FLUID MAY CAUSE REDUCED FUNCTIONALITY OR TRANSMISSION DAMAGE. CAUTION THE FUNCTIONAL CHARACTERISTICS OF FLUIDS FOR CVT TRANSMISSIONS ARE VERY DIFFERENT THAN THOSE OF OTHER AUTOMATIC TRANSMISSION FLUIDS (ATFS). USE OF A FLUID OTHER THAN MOTORCRAFT CONTINUOUSLY VARIABLE CHAIN TYPE TRANSMISSION FLUID OR ONE LABELED AS MEETING MERCON(R) C WILL CAUSE FUNCTIONALITY CONCERNS AND INTERNAL TRANSMISSION DAMAGE. CAUTION DO NOT USE AUTOMATIC TRANSMISSION FLUID SUPPLEMENTS, ADDITIVES, TREATMENTS OR CLEANING AGENTS. Parts Block WARRANTY STATUS: Information Only Disclaimer Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid - A/T: > 871814 > Sep > 87 > A/T, M/T New `Mercon' Transmission Fluid Fluid - A/T: All Technical Service Bulletins A/T, M/T - New `Mercon' Transmission Fluid TRANSMISSION - AUTOMATIC/MANUAL - Article No. NEW FLUID AND USAGE CHART 87-18-14 FORD: 1986 And Prior LTD 1988 And Prior ESCORT, TEMPO, MUSTANG, TAURUS, THUNDERBIRD, FORD LINCOLN-MERCURY: 1986 And Prior CAPRI, MARQUIS 1987 And Prior LYNX 1988 And Prior TOPAZ, SABLE, COUGAR, MERCURY, MARK VII, CONTINENTAL, LINCOLN TOWN CAR MERKUR: 1985-88 XR4Ti 1988 SCORPIO LIGHT TRUCK: 1988 And Prior E SERIES, F SERIES, BRONCO, RANGER, BRONCO II, AEROSTAR ISSUE: A new Transmission Fluid, MERCON (Ford Specification "MERCON") (XT-2- QDX, Quart), (XT-2-DDX, 55 Gallon Drum) is available for service. Use of the Motorcraft "MERCON" transmission fluid, where specified, will improve cold weather shift effort and synchronized operation. ACTION: The chart on page 44 of this TSB gives transmission fluid applications for automatic transmissions and certain manual transmissions for Ford, Lincoln-Mercury, and Merkur vehicles. NOTE: The use of MERCON is NOT RECOMMENDED for power steering systems. The manual transmission lubricant for the 1985 Merkur XR4Ti is a semi-synthetic oil. When adding oil to the transmission, use only E5RY-19C547-A (Ford Specification ESD-M2C175-A) or equivalent. PART NUMBER PART NAME CLASS XT-2-QDX MERCON - Quart V Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid - A/T: > 871814 > Sep > 87 > A/T, M/T New `Mercon' Transmission Fluid > Page 4525 XT-2-DDX MERCON - 55 Gallon V Drum E5RY-19C547-A Semi-Synthetic Oil B OTHER APPLICABLE ARTICLES: 82-9-9 Supersedes 85-1-15, 85-6-7 WARRANTY STATUS: "INFORMATION ONLY" Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid - A/T: > 861117 > Jun > 86 > A/T Synthetic Fluid Availability Fluid - A/T: All Technical Service Bulletins A/T - Synthetic Fluid Availability Article No. 86-11-17 TRANSMISSION - AUTOMATIC - NEW SYNTHETIC DEXRON II ALL WEATHER AUTOMATIC TRANSMISSION FLUID FORD 1986 and PRIOR ESCORT, EXP, FORD, LTD, THUNDERBIRD, MUSTANG, TEMPO; 1986 TAURUS LINCOLN-MERCURY 1982-83 LN7; 1986 and PRIOR LYNX, MERCURY, MARQUIS, COUGAR, CAPRI, TOPAZ, LINCOLN, MARK, CONTINENTAL; 1986 SABLE LIGHT TRUCK 1986 and PRIOR E, F SERIES, BRONCO, BRONCO II, RANGER A new synthetic Dexron II automatic transmission fluid specification number ESR-M2C163-A2, part number E6AZ-19582-B is now available. This fluid will maintain a more constant viscosity through a wider range of temperatures. In the event a vehicle will be operated in extremely cold temperatures for an extended period of time, remove all existing fluid from the transmission (using the procedure shown in the applicable 1986 Car or Light Truck Shop Manual) and replace with the new synthetic Dexron II fluid, E6AZ-19582-B. The synthetic fluid is year 'round fluid and will not require replacement for warmer weather. CAUTION: DO NOT use synthetic Dexron II fluid in transmissions designed to use Type "F" fluid. PART NUMBER PART NAME CLASS E6AZ-19582-B Synthetic Dexron Oil V Automatic Transmission Oil OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid - A/T: > 06-14-4 > Jul > 06 > A/T - Mercon V ATF Usage Fluid - A/T: All Technical Service Bulletins A/T - Mercon V ATF Usage TSB 06-14-4 07/24/06 MERCON ATF IS BEING REPLACED BY MERCON V ATF AS A SERVICE FLUID. FORD: 1980-1997 Crown Victoria 1981-1997 Mustang, Thunderbird 1981-2003 Escort 1986-1993 Festiva 1986-1997 Taurus 1989-1997 Probe 1994-1997 Aspire 1995-2000 Contour 1980-1996 Bronco 1981-2003 F-150 1981-2004 E-Series, F-Super Duty 1983-1996 Ranger 1986-1996 Aerostar 1991-1997 Explorer 1993-2004 F-53 Motorhome Chassis 1995-1998 Windstar 1997-2004 Expedition 2000-2005 Excursion 2001-2007 Escape 1987-2000 F-B-Series 2000-2007 F-650, F-750 LINCOLN: 1980-1997 Town Car 1981-1997 Continental 1993-1997 Mark VIII 1998-2004 Navigator 2002-2003 Blackwood MERCURY: 1980-1997 Grand Marquis 1981-1997 Cougar 1986-1997 Sable 1987-1999 Tracer 1995-2000 Mystique 1999-2002 Cougar 1993-2002 Villager 1997 Mountaineer 2005-2007 Mariner MERKUR: 1985-1989 XR4TI This article supersedes TSB 01-15-7 to update the vehicle application chart. ISSUE MERCON(R) Automatic Transmission Fluid is being replaced by MERCON(R) V as a service fluid. ACTION Beginning immediately all automatic transmission / transaxle applications requiring MERCON(R) can now be serviced using MERCON(R) V or MERCON(R) Automatic Transmission Fluid or dual usage fluids labeled MERCON(R) / MERCON(R) V. After July 1, 2007, MERCON(R) Automatic Transmission Fluid will no longer be manufactured, therefore, availability of this fluid will only continue for however long it takes to deplete what remains in inventory. SERVICE PROCEDURE Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid - A/T: > 06-14-4 > Jul > 06 > A/T - Mercon V ATF Usage > Page 4535 Service automatic transmissions requiring MERCON(R) with MERCON(R) V or MERCON(R) Automatic Transmission Fluid or dual usage fluids labeled MERCON(R) / MERCON(R) V For proper fluid application on current and past model vehicles equipped with automatic transmissions I transaxles refer to the fluid usage chart. (Figure 1) CAUTION AUTOMATIC TRANSMISSIONS / TRANSAXLES THAT REQUIRE MERCON® V SHOULD STILL ONLY USE MERCON(R) V OR DUAL USAGE FLUID LABELED MERCON(R) / MERCON(R) V. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid - A/T: > 06-14-4 > Jul > 06 > A/T - Mercon V ATF Usage > Page 4536 CAUTION MERCON(R) SP, MOTORCRAFT PREMIUM AUTOMATIC TRANSMISSION FLUID AND MOTORCRAFT M5 ATFS ARE UNIQUE FLUIDS AND MUST BE USED IN APPLICATIONS RECOMMENDING THAT PARTICULAR FLUID. USE OF ANY OTHER FLUID MAY CAUSE REDUCED FUNCTIONALITY OR TRANSMISSION DAMAGE. CAUTION THE FUNCTIONAL CHARACTERISTICS OF FLUIDS FOR CVT TRANSMISSIONS ARE VERY DIFFERENT THAN THOSE OF OTHER AUTOMATIC TRANSMISSION FLUIDS (ATFS). USE OF A FLUID OTHER THAN MOTORCRAFT CONTINUOUSLY VARIABLE CHAIN TYPE TRANSMISSION FLUID OR ONE LABELED AS MEETING MERCON(R) C WILL CAUSE FUNCTIONALITY CONCERNS AND INTERNAL TRANSMISSION DAMAGE. CAUTION DO NOT USE AUTOMATIC TRANSMISSION FLUID SUPPLEMENTS, ADDITIVES, TREATMENTS OR CLEANING AGENTS. Parts Block WARRANTY STATUS: Information Only Disclaimer Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid - A/T: > 871814 > Sep > 87 > A/T, M/T New `Mercon' Transmission Fluid Fluid - A/T: All Technical Service Bulletins A/T, M/T - New `Mercon' Transmission Fluid TRANSMISSION - AUTOMATIC/MANUAL - Article No. NEW FLUID AND USAGE CHART 87-18-14 FORD: 1986 And Prior LTD 1988 And Prior ESCORT, TEMPO, MUSTANG, TAURUS, THUNDERBIRD, FORD LINCOLN-MERCURY: 1986 And Prior CAPRI, MARQUIS 1987 And Prior LYNX 1988 And Prior TOPAZ, SABLE, COUGAR, MERCURY, MARK VII, CONTINENTAL, LINCOLN TOWN CAR MERKUR: 1985-88 XR4Ti 1988 SCORPIO LIGHT TRUCK: 1988 And Prior E SERIES, F SERIES, BRONCO, RANGER, BRONCO II, AEROSTAR ISSUE: A new Transmission Fluid, MERCON (Ford Specification "MERCON") (XT-2- QDX, Quart), (XT-2-DDX, 55 Gallon Drum) is available for service. Use of the Motorcraft "MERCON" transmission fluid, where specified, will improve cold weather shift effort and synchronized operation. ACTION: The chart on page 44 of this TSB gives transmission fluid applications for automatic transmissions and certain manual transmissions for Ford, Lincoln-Mercury, and Merkur vehicles. NOTE: The use of MERCON is NOT RECOMMENDED for power steering systems. The manual transmission lubricant for the 1985 Merkur XR4Ti is a semi-synthetic oil. When adding oil to the transmission, use only E5RY-19C547-A (Ford Specification ESD-M2C175-A) or equivalent. PART NUMBER PART NAME CLASS XT-2-QDX MERCON - Quart V Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid - A/T: > 871814 > Sep > 87 > A/T, M/T New `Mercon' Transmission Fluid > Page 4541 XT-2-DDX MERCON - 55 Gallon V Drum E5RY-19C547-A Semi-Synthetic Oil B OTHER APPLICABLE ARTICLES: 82-9-9 Supersedes 85-1-15, 85-6-7 WARRANTY STATUS: "INFORMATION ONLY" Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Refill Capacity Fluid - A/T: Specifications TYPE MA CAPACITY, Initial Refill*: C-6 5.0 qt (US) With the engine at operating temperature, shift transmission through all gears. Check fluid level in PARK and add fluid as needed Others 3.0 qt (US) Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Refill Capacity > Page 4544 Fluid - A/T: Specifications Fluid Capacity 11.8 qt (US) Note: 4 x 4 models, 13.4 qts. Approximate. Make final check with dipstick. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Technical Service Bulletins > Torque Converter - Cleaning and Replacement Guidelines Technical Service Bulletin # 962612 Date: 961216 Torque Converter - Cleaning and Replacement Guidelines Article No. 96-26-12 12/16/96 ^ TRANSAXLE - TORQUE CONVERTER REPLACEMENT GUIDELINES AND TORQUE CONVERTER/TRANSAXLE COOLING SYSTEM CLEANING PROCEDURES - SERVICE TIP ^ TRANSMISSION - TORQUE CONVERTER REPLACEMENT GUIDELINES AND TORQUE CONVERTER/TRANSMISSION COOLING SYSTEM CLEANING PROCEDURES - SERVICE TIP FORD: 1985-86 LTD 1985-88 EXP 1985-94 TEMPO 1985-97 CROWN VICTORIA, ESCORT, MUSTANG, THUNDERBIRD 1986-97 TAURUS 1988-93 FESTIVA 1989-97 PROBE 1994-97 ASPIRE 1995-97 CONTOUR LINCOLN-MERCURY: 1985-86 MARQUIS 1985-87 LN7, LYNX 1985-92 MARK VII 1985-94 TOPAZ 1985-97 CONTINENTAL, COUGAR, GRAND MARQUIS, TOWN CAR 1986-97 SABLE 1987-89 TRACER 1991-94 CAPRI 1991-97 TRACER 1993-97 MARK VIII 1995-97 MYSTIQUE MERKUR: 1985-89 XR4TI 1988-90 SCORPIO LIGHT TRUCK: 1985-90 BRONCO II 1985-96 BRONCO 1985-97 ECONOLINE, F-150-350 SERIES, RANGER 1986-97 AEROSTAR 1988-97 F SUPER DUTY 1991-97 EXPLORER 1993-97 VILLAGER 1995-97 WINDSTAR 1997 EXPEDITION, MOUNTAINEER ISSUE: Torque converter replacement guidelines and torque converter/transmission (or transaxle) cooling-system cleaning procedures are now available to reduce repeat repairs. ACTION: Refer to the following guideline to properly diagnose and service torque converters and to properly clean the torque converter and transmission cooling system using forward flushing/backflushing. For diagnosis, service and cleaning, refer to to the appropriate model/year Service Manual, Sections 07-01, 07-02, 03-03, 307-01, 307-02, or 303-03. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Technical Service Bulletins > Torque Converter - Cleaning and Replacement Guidelines > Page 4549 OASIS CODES: 501000, 502000, 503000, 504000 Diagnostic Procedure Prior to torque converter replacement, all diagnostic procedures must be followed. This is to prevent the unnecessary replacement of good torque converters. Only after a complete diagnostic evaluation can the decision be made to replace the torque converter. The normal diagnostic procedure is as follows: 1. Preliminary inspection. 2. Know and understand the customers concern. 3. Verify the concern: - Perform the Torque Converter Clutch Operation Test 4. Perform diagnostic procedures: a. Run On-Board Diagnostics - Repair all non-transmission-related Diagnostic Trouble Codes (DTCs) first. - Repair all transmission DTCs. - Rerun On-Board Diagnostic to verify repair. b. Perform Line Pressure Test c. Perform Stall Speed Test d. Diagnosis by Symptom Routines - Use the index to locate the appropriate routine that best describes the symptom(s). The routine will list all possible components that may cause or contribute to the symptom. Check each component listed, diagnose and service as required, before servicing the torque converter. Replacement The torque converter must be replaced if one or more of the following statements are true: ^ A torque converter malfunction has been determined based on completed diagnostic procedures ^ A converter stud(s), impeller hub or bushing is damaged ^ If there is discoloration of the torque converter (due to overheating) ^ The torque converter is found to be out of specification when performing the following checks (as applicable): 1. Torque Converter One-way Clutch Check 2. End Play Check 3. Stator-to-Turbine Interference Check 4. Converter Leakage Check 5. Stator-to-Impeller Interference Check ^ If there is evidence of transmission assembly or fluid contamination due to the following failure modes: Torque converter Replacement Policy Failure Modes Major metallic failure Multiple clutches or clutch plate failures Sufficient component wear which results in metallic contamination Torque Converter & Transmission Cooling System Cleaning Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Technical Service Bulletins > Torque Converter - Cleaning and Replacement Guidelines > Page 4550 When the torque converter is replaced, the following actions must take place: 1. All cooler lines must be thoroughly cleaned by Back and Forward Flushing using Service Manual procedure. 2. All coolers (in-tank and auxiliary) must be thoroughly cleaned by Back and Forward Flushing using Service Manual procedure. 3. All Cooler By-Pass Valves (CBV), it equipped, must be removed and thoroughly cleaned using Service Manual procedures. Replace rubber coated sealing washers prior to reinstalling CBV. Replace CBV if damaged or plugged. 4. Perform Transmission Cooler Flow Test - If the Transmission Cooling System fails the Flow Test, the coolers, CBVs or lines must be replaced. If the coolers are to be replaced, use only factory approved service parts. If the torque converter is not being replaced, the following actions must take place: 1. The torque convener must be thoroughly cleaned: a. Torque converters with drain plugs can be cleaned using the Rotunda Torque Converter Cleaner Follow the instructions included with the equipment. b. Torque converters without drain plugs can be cleaned by hand. Partially fill the converter using clean transmission fluid (as recommended for the particular transmission). Hand agitate the converter and then thoroughly drain the fluid. Refill with new fluid, specified for the transmission, and reinstall. 2. All cooler lines must be thoroughly cleaned by Back and Forward Flushing using Service Manual procedure. 3. All coolers (in-tank and auxiliary) must be thoroughly cleaned by Back and Forward Flushing using Service Manual procedure. 4. All Cooler By-Pass Valves (CBV), if equipped, must be removed and thoroughly cleaned using Service Manual procedures. Replace rubber coated sealing washers prior to reinstalling CBV. Replace CBV if damaged or plugged. 5. Perform Transmission Cooler Flow Test - If the Transmission Cooling System fails the Flow Test, the coolers, CBVs or lines must be replaced. If the coolers are to be replaced, use only factory approved service parts. Required Tools Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > A/T - AOD Main Control Valve Body Gasket Seals and Gaskets: Technical Service Bulletins A/T - AOD Main Control Valve Body Gasket Article No. 86-13-17 TRANSMISSION - AUTOMATIC - AOD - MAIN CONTROL VALVE BODY GASKETS FORD 1980-86 FORD, THUNDERBIRD, LTD, MUSTANG LINCOLN-MERCURY 1980-83 MARK VI; 1980-86 MERCURY, COUGAR, MARQUIS, CAPRI, LINCOLN, CONTINENTAL; 1984-86 MARK VII LIGHT TRUCK 1981-86 E SERIES, F SERIES, BRONCO Figure 11 Figure 12 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > A/T - AOD Main Control Valve Body Gasket > Page 4555 New upper and lower main control valve body gaskets have been released for service. The new gasket has an additional slot, which reduces the chance for contamination of the 3-4 shift valve (refer to Figures 11 and 12). The new gaskets can be used on all AOD main control valve bodies produced for the 1980-86 model years. Old upper and lower main control valve body gaskets (EOAZ-7D100-B and EOAZ-7C155-A) may still be used on certain applications. To identify the correct application, the middle letter of the main control valve body's three-letter I.D. code is necessary. Refer to the following service usage chart for the correct gasket applications. SERVICE USAGE CHART FOR AOD MAIN CONTROL VALVE BODY GASKETS AOD Valve Body Old Gaskets New Gaskets I.D. Codes EOAZ-7D100-B E6AZ-7D100-A (Middle Letter) EOAZ-7C155-A E6AZ-7C155-A A, B, C, D, E Acceptable Acceptable T, U, V, W, X, Y, Z All other than above Must NOT Use Must Use (For example: main controls with middle letter I.D. code F, G, H, . . . Q, R, S) OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Technical Service Bulletins > A/T Torque Converter - Leak Test Procedure Torque Converter: Technical Service Bulletins A/T Torque Converter - Leak Test Procedure Article No. 96-24-9 11/18/96 TORQUE CONVERTER - LEAK TEST PROCEDURE - SERVICE TIP FORD: 1984-94 TEMPO 1984-97 CROWN VICTORIA, ESCORT, MUSTANG, THUNDERBIRD 1986-97 TAURUS 1988-93 FESTIVA 1989-97 PROBE 1994-97 ASPIRE 1995-97 CONTOUR LINCOLN-MERCURY: 1984-92 MARK VII 1984-94 TOPAZ 1984-97 CONTINENTAL, COUGAR, GRAND MARQUIS, TOWN CAR 1986-97 SABLE 1991-94 CAPRI 1991-97 TRACER 1993-97 MARK VIII 1995-97 MYSTIQUE LIGHT TRUCK: 1984-90 BRONCO II 1984-96 BRONCO 1984-97 ECONOLINE, F-150-350 SERIES, RANGER 1986-97 AEROSTAR 1988-97 F SUPER DUTY 1991-97 EXPLORER 1993-97 VILLAGER 1995-97 WINDSTAR 1997 EXPEDITION, MOUNTAINEER ISSUE: A new torque converter leak test tool has been released. The current leak test tool has been discontinued by the manufacturer. The new tool will be available to all dealers in 1997. ACTION: When using the new leak test tool, a new procedure must be followed. Refer to the following Service Procedure and/or the 1997 Service/Workshop Manuals when using the new leak test tool. NEW TOOL NUMBER Description Tool Number Torque converter Leak Test Tool and Gasket 014-R1075 SERVICE PROCEDURE 1. Clean the outside surface of the torque converter. CAUTION: BE CAREFUL NOT TO DAMAGE THE CONVERTER HUB FINISH WHEN INSTALLING THE TOOL. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Technical Service Bulletins > A/T Torque Converter - Leak Test Procedure > Page 4560 2. Install the Torque Converter Leak Test Tool and Gasket (O14-R1075) into the converter hub. Figure 1. WARNING: ALWAYS USE PROPER SAFETY PROCEDURES WHILE USING PRESS. CAUTION: DO NOT DAMAGE THE CONVERTER BY APPLYING EXCESSIVE FORCE FROM THE PRESS. USE ONLY ENOUGH FORCE TO SEAL TOOL INTO THE CONVERTER. 3. Place the torque converter with the tool installed into press and apply enough force to seal tool into the converter. Figure 2. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Technical Service Bulletins > A/T Torque Converter - Leak Test Procedure > Page 4561 4. Using clean, dry shop air only, apply air pressure of 552 kPa (80 psi) maximum to the valve on the tool. Refer to Figure 3. 5. With air pressure applied to the valve, inspect for any air leaks at the studs, seams and pilot hub. A soap bubble solution may be applied around those areas to aid in diagnosis. If any leaks are present, replace the converter. 6. Disconnect the air line and release the air pressure from the tool by pulling on the release ring and then slowly releasing the press. Refer to Figure 4. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Technical Service Bulletins > A/T Torque Converter - Leak Test Procedure > Page 4562 7. Turn the torque converter and tool upside down and reinstall into the press. Repeat Steps 2-6 to check for leaks on the opposite side. Refer to Figure 5. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 501000, 502000, 504000, 510000 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Technical Service Bulletins > A/T Torque Converter - Leak Test Procedure > Page 4563 Technical Service Bulletin # 962612 Date: 961216 Torque Converter - Cleaning and Replacement Guidelines Article No. 96-26-12 12/16/96 ^ TRANSAXLE - TORQUE CONVERTER REPLACEMENT GUIDELINES AND TORQUE CONVERTER/TRANSAXLE COOLING SYSTEM CLEANING PROCEDURES - SERVICE TIP ^ TRANSMISSION - TORQUE CONVERTER REPLACEMENT GUIDELINES AND TORQUE CONVERTER/TRANSMISSION COOLING SYSTEM CLEANING PROCEDURES - SERVICE TIP FORD: 1985-86 LTD 1985-88 EXP 1985-94 TEMPO 1985-97 CROWN VICTORIA, ESCORT, MUSTANG, THUNDERBIRD 1986-97 TAURUS 1988-93 FESTIVA 1989-97 PROBE 1994-97 ASPIRE 1995-97 CONTOUR LINCOLN-MERCURY: 1985-86 MARQUIS 1985-87 LN7, LYNX 1985-92 MARK VII 1985-94 TOPAZ 1985-97 CONTINENTAL, COUGAR, GRAND MARQUIS, TOWN CAR 1986-97 SABLE 1987-89 TRACER 1991-94 CAPRI 1991-97 TRACER 1993-97 MARK VIII 1995-97 MYSTIQUE MERKUR: 1985-89 XR4TI 1988-90 SCORPIO LIGHT TRUCK: 1985-90 BRONCO II 1985-96 BRONCO 1985-97 ECONOLINE, F-150-350 SERIES, RANGER 1986-97 AEROSTAR 1988-97 F SUPER DUTY 1991-97 EXPLORER 1993-97 VILLAGER 1995-97 WINDSTAR 1997 EXPEDITION, MOUNTAINEER ISSUE: Torque converter replacement guidelines and torque converter/transmission (or transaxle) cooling-system cleaning procedures are now available to reduce repeat repairs. ACTION: Refer to the following guideline to properly diagnose and service torque converters and to properly clean the torque converter and transmission cooling system using forward flushing/backflushing. For diagnosis, service and cleaning, refer to to the appropriate model/year Service Manual, Sections 07-01, 07-02, 03-03, 307-01, 307-02, or 303-03. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Technical Service Bulletins > A/T Torque Converter - Leak Test Procedure > Page 4564 OASIS CODES: 501000, 502000, 503000, 504000 Diagnostic Procedure Prior to torque converter replacement, all diagnostic procedures must be followed. This is to prevent the unnecessary replacement of good torque converters. Only after a complete diagnostic evaluation can the decision be made to replace the torque converter. The normal diagnostic procedure is as follows: 1. Preliminary inspection. 2. Know and understand the customers concern. 3. Verify the concern: - Perform the Torque Converter Clutch Operation Test 4. Perform diagnostic procedures: a. Run On-Board Diagnostics - Repair all non-transmission-related Diagnostic Trouble Codes (DTCs) first. - Repair all transmission DTCs. - Rerun On-Board Diagnostic to verify repair. b. Perform Line Pressure Test c. Perform Stall Speed Test d. Diagnosis by Symptom Routines - Use the index to locate the appropriate routine that best describes the symptom(s). The routine will list all possible components that may cause or contribute to the symptom. Check each component listed, diagnose and service as required, before servicing the torque converter. Replacement The torque converter must be replaced if one or more of the following statements are true: ^ A torque converter malfunction has been determined based on completed diagnostic procedures ^ A converter stud(s), impeller hub or bushing is damaged ^ If there is discoloration of the torque converter (due to overheating) ^ The torque converter is found to be out of specification when performing the following checks (as applicable): 1. Torque Converter One-way Clutch Check 2. End Play Check 3. Stator-to-Turbine Interference Check 4. Converter Leakage Check 5. Stator-to-Impeller Interference Check ^ If there is evidence of transmission assembly or fluid contamination due to the following failure modes: Torque converter Replacement Policy Failure Modes Major metallic failure Multiple clutches or clutch plate failures Sufficient component wear which results in metallic contamination Torque Converter & Transmission Cooling System Cleaning Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Technical Service Bulletins > A/T Torque Converter - Leak Test Procedure > Page 4565 When the torque converter is replaced, the following actions must take place: 1. All cooler lines must be thoroughly cleaned by Back and Forward Flushing using Service Manual procedure. 2. All coolers (in-tank and auxiliary) must be thoroughly cleaned by Back and Forward Flushing using Service Manual procedure. 3. All Cooler By-Pass Valves (CBV), it equipped, must be removed and thoroughly cleaned using Service Manual procedures. Replace rubber coated sealing washers prior to reinstalling CBV. Replace CBV if damaged or plugged. 4. Perform Transmission Cooler Flow Test - If the Transmission Cooling System fails the Flow Test, the coolers, CBVs or lines must be replaced. If the coolers are to be replaced, use only factory approved service parts. If the torque converter is not being replaced, the following actions must take place: 1. The torque convener must be thoroughly cleaned: a. Torque converters with drain plugs can be cleaned using the Rotunda Torque Converter Cleaner Follow the instructions included with the equipment. b. Torque converters without drain plugs can be cleaned by hand. Partially fill the converter using clean transmission fluid (as recommended for the particular transmission). Hand agitate the converter and then thoroughly drain the fluid. Refill with new fluid, specified for the transmission, and reinstall. 2. All cooler lines must be thoroughly cleaned by Back and Forward Flushing using Service Manual procedure. 3. All coolers (in-tank and auxiliary) must be thoroughly cleaned by Back and Forward Flushing using Service Manual procedure. 4. All Cooler By-Pass Valves (CBV), if equipped, must be removed and thoroughly cleaned using Service Manual procedures. Replace rubber coated sealing washers prior to reinstalling CBV. Replace CBV if damaged or plugged. 5. Perform Transmission Cooler Flow Test - If the Transmission Cooling System fails the Flow Test, the coolers, CBVs or lines must be replaced. If the coolers are to be replaced, use only factory approved service parts. Required Tools Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > Torque Converter - Cleaning and Replacement Guidelines Technical Service Bulletin # 962612 Date: 961216 Torque Converter - Cleaning and Replacement Guidelines Article No. 96-26-12 12/16/96 ^ TRANSAXLE - TORQUE CONVERTER REPLACEMENT GUIDELINES AND TORQUE CONVERTER/TRANSAXLE COOLING SYSTEM CLEANING PROCEDURES - SERVICE TIP ^ TRANSMISSION - TORQUE CONVERTER REPLACEMENT GUIDELINES AND TORQUE CONVERTER/TRANSMISSION COOLING SYSTEM CLEANING PROCEDURES - SERVICE TIP FORD: 1985-86 LTD 1985-88 EXP 1985-94 TEMPO 1985-97 CROWN VICTORIA, ESCORT, MUSTANG, THUNDERBIRD 1986-97 TAURUS 1988-93 FESTIVA 1989-97 PROBE 1994-97 ASPIRE 1995-97 CONTOUR LINCOLN-MERCURY: 1985-86 MARQUIS 1985-87 LN7, LYNX 1985-92 MARK VII 1985-94 TOPAZ 1985-97 CONTINENTAL, COUGAR, GRAND MARQUIS, TOWN CAR 1986-97 SABLE 1987-89 TRACER 1991-94 CAPRI 1991-97 TRACER 1993-97 MARK VIII 1995-97 MYSTIQUE MERKUR: 1985-89 XR4TI 1988-90 SCORPIO LIGHT TRUCK: 1985-90 BRONCO II 1985-96 BRONCO 1985-97 ECONOLINE, F-150-350 SERIES, RANGER 1986-97 AEROSTAR 1988-97 F SUPER DUTY 1991-97 EXPLORER 1993-97 VILLAGER 1995-97 WINDSTAR 1997 EXPEDITION, MOUNTAINEER ISSUE: Torque converter replacement guidelines and torque converter/transmission (or transaxle) cooling-system cleaning procedures are now available to reduce repeat repairs. ACTION: Refer to the following guideline to properly diagnose and service torque converters and to properly clean the torque converter and transmission cooling system using forward flushing/backflushing. For diagnosis, service and cleaning, refer to to the appropriate model/year Service Manual, Sections 07-01, 07-02, 03-03, 307-01, 307-02, or 303-03. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > Torque Converter - Cleaning and Replacement Guidelines > Page 4570 OASIS CODES: 501000, 502000, 503000, 504000 Diagnostic Procedure Prior to torque converter replacement, all diagnostic procedures must be followed. This is to prevent the unnecessary replacement of good torque converters. Only after a complete diagnostic evaluation can the decision be made to replace the torque converter. The normal diagnostic procedure is as follows: 1. Preliminary inspection. 2. Know and understand the customers concern. 3. Verify the concern: - Perform the Torque Converter Clutch Operation Test 4. Perform diagnostic procedures: a. Run On-Board Diagnostics - Repair all non-transmission-related Diagnostic Trouble Codes (DTCs) first. - Repair all transmission DTCs. - Rerun On-Board Diagnostic to verify repair. b. Perform Line Pressure Test c. Perform Stall Speed Test d. Diagnosis by Symptom Routines - Use the index to locate the appropriate routine that best describes the symptom(s). The routine will list all possible components that may cause or contribute to the symptom. Check each component listed, diagnose and service as required, before servicing the torque converter. Replacement The torque converter must be replaced if one or more of the following statements are true: ^ A torque converter malfunction has been determined based on completed diagnostic procedures ^ A converter stud(s), impeller hub or bushing is damaged ^ If there is discoloration of the torque converter (due to overheating) ^ The torque converter is found to be out of specification when performing the following checks (as applicable): 1. Torque Converter One-way Clutch Check 2. End Play Check 3. Stator-to-Turbine Interference Check 4. Converter Leakage Check 5. Stator-to-Impeller Interference Check ^ If there is evidence of transmission assembly or fluid contamination due to the following failure modes: Torque converter Replacement Policy Failure Modes Major metallic failure Multiple clutches or clutch plate failures Sufficient component wear which results in metallic contamination Torque Converter & Transmission Cooling System Cleaning Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > Torque Converter - Cleaning and Replacement Guidelines > Page 4571 When the torque converter is replaced, the following actions must take place: 1. All cooler lines must be thoroughly cleaned by Back and Forward Flushing using Service Manual procedure. 2. All coolers (in-tank and auxiliary) must be thoroughly cleaned by Back and Forward Flushing using Service Manual procedure. 3. All Cooler By-Pass Valves (CBV), it equipped, must be removed and thoroughly cleaned using Service Manual procedures. Replace rubber coated sealing washers prior to reinstalling CBV. Replace CBV if damaged or plugged. 4. Perform Transmission Cooler Flow Test - If the Transmission Cooling System fails the Flow Test, the coolers, CBVs or lines must be replaced. If the coolers are to be replaced, use only factory approved service parts. If the torque converter is not being replaced, the following actions must take place: 1. The torque convener must be thoroughly cleaned: a. Torque converters with drain plugs can be cleaned using the Rotunda Torque Converter Cleaner Follow the instructions included with the equipment. b. Torque converters without drain plugs can be cleaned by hand. Partially fill the converter using clean transmission fluid (as recommended for the particular transmission). Hand agitate the converter and then thoroughly drain the fluid. Refill with new fluid, specified for the transmission, and reinstall. 2. All cooler lines must be thoroughly cleaned by Back and Forward Flushing using Service Manual procedure. 3. All coolers (in-tank and auxiliary) must be thoroughly cleaned by Back and Forward Flushing using Service Manual procedure. 4. All Cooler By-Pass Valves (CBV), if equipped, must be removed and thoroughly cleaned using Service Manual procedures. Replace rubber coated sealing washers prior to reinstalling CBV. Replace CBV if damaged or plugged. 5. Perform Transmission Cooler Flow Test - If the Transmission Cooling System fails the Flow Test, the coolers, CBVs or lines must be replaced. If the coolers are to be replaced, use only factory approved service parts. Required Tools Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Vacuum Diaphragm, A/T > Component Information > Technical Service Bulletins > A/T Vacuum Diaphragm - Return Vacuum Diaphragm: Technical Service Bulletins A/T Vacuum Diaphragm - Return Number: 61286 To: All Ford and Lincoln-Mercury Dealers Subject: Request for Return of Diaphragm Assy, E5TZ-7A377-B (TM-73) Because the subject part may not meet Ford's high quality requirements, it should be withdrawn from all inventories. All unused E5TZ-7A377-B should be returned to your facing PDC within 30 days from the date of this letter. Use the least expensive mode of transportation for your return. Replacement stock of the same part number is available for ordering immediately. You are requested to complete a separate FPS-340 form in accordance with the instructions on the front of the form. Annotate "Returned Per FPSD Instructions Purge No. PN 1020" in the Customer's Detail Explanation section and use Reason Code J (Unsatisfactory Service Stock). You will receive full credit in your parts statement for the price of each unused part returned, plus the prepaid transportation cost. In order to receive return credit, all parts must be received at the Parts Distribution Center within 30 days from the date of this letter. Material other than E5TZ-7A377-B received on this return will be sent back to you freight collect. Any questions should be referred to your Zone Manager or facing PDC Manager. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > A/T - AOD Separator Plate Gasket Changes Valve Body: Technical Service Bulletins A/T - AOD Separator Plate Gasket Changes TRANSMISSION - AOD - MAIN CONTROL GASKET CHANGES AFFECTING USAGE OF SERVICE KITS Article No. 89-23-7 FORD: 1980-90 CROWN VICTORIA 1980-86 LTD 1980-90 THUNDERBIRD 1985-90 MUSTANG LINCOLN-MERCURY: 1980-87 CONTINENTAL 1980-90 COUGAR, GRAND MARQUIS 1980-83 MARK VI 1980-90 TOWN CAR 1984-90 MARK VII 1985 CAPRI, MARQUIS LIGHT TRUCK: 1981-90 BRONCO, ECONOLINE, F-150, F-250 ISSUE: The separator plate lower gasket from the current gasket service kit (7153) and overhaul service kit (7C391) cannot be used on any 1990 model vehicles. ACTION: When servicing 1990 AOD transmissions the separator plate lower gasket found in the current kits must be thrown away and replaced with a new gasket (F0AZ-7D100-A). This new gasket can only be used on 1990 vehicles. CAUTION: USE OF THE SEPARATOR PLATE LOWER GASKET CONTAINED IN THE CURRENT KITS ON 1990 VEHICLES COULD CAUSE A REDUCTION IN THROTTLE VALVE PRESSURE. THIS CAN RESULT IN POSSIBLE TRANSMISSION FAILURES. In the near future, gasket and overhaul kits will no longer contain any main control gaskets. Two main control lower separator plate gasket items will be available. Refer to the following gasket application chart for correct service part usage. PART NUMBER PART NAME CLASS E9AZ-7D100-B Main Control Gasket Kit B FOAZ-7D100-A Separator Plate Lower Gasket B E9SZ-7C155-A Main Control Upper Separator B Plate Gasket OTHER APPLICABLE ARTICLES: none SUPERSEDES: 88-13-6 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 5100, 5101, 5102, 5200, 5300, 5500, 5800 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > A/T - AOD Separator Plate Gasket Changes > Page 4580 Valve Body: Technical Service Bulletins A/T - AOD Main Control Valve Body Gasket Article No. 86-13-17 TRANSMISSION - AUTOMATIC - AOD - MAIN CONTROL VALVE BODY GASKETS FORD 1980-86 FORD, THUNDERBIRD, LTD, MUSTANG LINCOLN-MERCURY 1980-83 MARK VI; 1980-86 MERCURY, COUGAR, MARQUIS, CAPRI, LINCOLN, CONTINENTAL; 1984-86 MARK VII LIGHT TRUCK 1981-86 E SERIES, F SERIES, BRONCO Figure 11 Figure 12 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > A/T - AOD Separator Plate Gasket Changes > Page 4581 New upper and lower main control valve body gaskets have been released for service. The new gasket has an additional slot, which reduces the chance for contamination of the 3-4 shift valve (refer to Figures 11 and 12). The new gaskets can be used on all AOD main control valve bodies produced for the 1980-86 model years. Old upper and lower main control valve body gaskets (EOAZ-7D100-B and EOAZ-7C155-A) may still be used on certain applications. To identify the correct application, the middle letter of the main control valve body's three-letter I.D. code is necessary. Refer to the following service usage chart for the correct gasket applications. SERVICE USAGE CHART FOR AOD MAIN CONTROL VALVE BODY GASKETS AOD Valve Body Old Gaskets New Gaskets I.D. Codes EOAZ-7D100-B E6AZ-7D100-A (Middle Letter) EOAZ-7C155-A E6AZ-7C155-A A, B, C, D, E Acceptable Acceptable T, U, V, W, X, Y, Z All other than above Must NOT Use Must Use (For example: main controls with middle letter I.D. code F, G, H, . . . Q, R, S) OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Disc, M/T > Component Information > Description and Operation Clutch Disc: Description and Operation DESCRIPTION AND OPERATION The purpose of the clutch is to connect and disconnect a manually operated transmission and the remainder of the power-transmission system from the engine. This permits starting and stopping the vehicle, shifting and changing speeds that correspond to the engine speed through gear reductions for both forward and reverse directions. The clutch consists of a driven plate (clutch disc) splined for the input shaft of the transmission and the clutch housing (pressure plate). This forms a continuous system by which rotation of the engine is connected to the transmission by solid member when engaged (clutch assembly). For power at the output shaft of the transmission or rear wheel rotation (forward or reverse), the driven plate is a metal disc, faced on both sides with woven friction materials. The pressure plate is a metal member bolted on the flywheel which houses the driven plate held in position by the transmission input shaft. A clutch sleeve mounted over the input shaft of the transmission carries a release bearing that is pressed against the fingers of the clutch that pushes it away from the driven plate causing disengagement-breaking the connection between the engine (flywheel) and the clutch. Reverse action or the release of the bearing engages the clutch. The release lever is actuated by a hydraulic system. Other internal clutch parts are a pilot bearing mounted in the crankshaft which supports the end of the input shaft. Bearings are designed for long life and require no lubrication. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Disc, M/T > Component Information > Service and Repair > With Warner Transmission Clutch Disc: Service and Repair With Warner Transmission Single-Disc-Type Clutch Standard Disc and Pressure Plate Assembly10.0 lnch/11.0 lnch/12.0 Inch Removal 1. Disconnect the battery negative cable. 2. Remove clutch slave cylinder, or the hydraulic line quick disconnect using quick disconnect tool T88T-70522-A. 3. Remove the release lever if so equipped. 4. Remove the dust cover it so equipped. 5. Remove transmission. 6. Mark the assembled position of the pressure plate and cover to the flywheel (for re-assembly). 7. Remove the pressure plate and cover assembly and the clutch disc from the flywheel. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Disc, M/T > Component Information > Service and Repair > With Warner Transmission > Page 4588 Installation 1. Position the clutch disc on the flywheel so that the Clutch Alignment Shaft D79T-7550-A or equivalent can enter the clutch pilot bearing and align the disc. 2. When re-installing the original pressure plate and cover assembly, align the assembly and flywheel according to the marks made during the removal operations. Position the pressure plate and cover assembly on the flywheel, align the pressure plate and disc, and install the retaining bolts that fasten the assembly to the flywheel. Tighten the bolts to specification and remove the clutch disc pilot tool. 3. Clean and lubricate the release lever pivot stud. 4. Reinstall the transmission. 5. Correctly position the release lever (if so equipped) in its release bearing hub, and align with the pivot stud. Push inward on the lever until it snaps into position. 6. Reinstall the external slave cylinder, or attach the hydraulic tube quick connect fitting. 7. Install the dust boot if so equipped. 8. Install the starter motor. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Disc, M/T > Component Information > Service and Repair > With Warner Transmission > Page 4589 Clutch Disc: Service and Repair Without Warner Transmission Single-Disc-Type Clutch Standard Disc and Pressure Plate Assembly10.0 lnch/11.0 lnch/12.0 Inch Removal 1. Disconnect the battery negative cable. 2. Remove clutch slave cylinder, or the hydraulic line quick disconnect using quick disconnect tool T88T-70522-A. 3. Remove the release lever if so equipped. 4. Remove the dust cover it so equipped. 5. Remove transmission. 6. Mark the assembled position of the pressure plate and cover to the flywheel (for re-assembly). 7. Remove the pressure plate and cover assembly and the clutch disc from the flywheel. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Disc, M/T > Component Information > Service and Repair > With Warner Transmission > Page 4590 Installation 1. Position the clutch disc on the flywheel so that the Clutch Alignment Shaft D79T-7550-A or equivalent can enter the clutch pilot bearing and align the disc. 2. When re-installing the original pressure plate and cover assembly, align the assembly and flywheel according to the marks made during the removal operations. Position the pressure plate and cover assembly on the flywheel, align the pressure plate and disc, and install the retaining bolts that fasten the assembly to the flywheel. Tighten the bolts to specification and remove the clutch disc pilot tool. 3. Clean and lubricate the release lever pivot stud. 4. Reinstall the transmission. 5. Correctly position the release lever (if so equipped) in its release bearing hub, and align with the pivot stud. Push inward on the lever until it snaps into position. 6. Reinstall the external slave cylinder, or attach the hydraulic tube quick connect fitting. 7. Install the dust boot if so equipped. 8. Install the starter motor. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Master Cylinder > Component Information > Technical Service Bulletins > Customer Interest for Clutch Master Cylinder: > 90167 > Aug > 90 > M/T - Clutch Fluid Leaks/Incomplete Release Technical Service Bulletin # 90167 Date: 900801 M/T - Clutch Fluid Leaks/Incomplete Release Article No. 90-16-7 ^ CRACKS - DASH (ENGINE COMPARTMENT BULKHEAD) - CLUTCH MASTER CYLINDER AREA - VEHICLES BUILT BEFORE 6/15/90 ^ CLUTCH - HIGH EFFORT - DASH CRACKED IN CLUTCH MASTER CYLINDER AREA VEHICLES BUILT BEFORE 6/15/90 LIGHT TRUCK: 1984-90 BRONCO, F-150, F-250, F-350 1988-90 F SUPER DUTY ISSUE: Incomplete clutch release and/or hydraulic fluid leaking into the cab from the clutch master cylinder may be caused by the reinforcement plate on the clutch master cylinder separating from the dash panel. The separation of the reinforcement plate reduces the clutch master cylinder pushrod travel. Reinforcement plate separation can also cause deflection of the clutch master cylinder that results in a misalignment of the pushrod to the clutch master cylinder. Misalignment causes the "O" ring in front of the secondary seal to leak hydraulic fluid. ACTION: Inspect the truck and, if necessary, use the following service procedure to install a reinforcement kit. Inspection Procedure 1. If the truck is a 1988 or later model, confirm that the starter interlock switch operates (the engine can be started) with the clutch pedal at least 0.5" (12.7 mm) from the floor. 2. Test drive the truck and check for good clutch release. There should be no grinding of the gears, particularly when shifting from neutral to reverse gear. 3. If the truck passes these tests, go to the Small Reinforcement Installation Procedure Section of this article. 4. If either of the above conditions are not met, check the hydraulic system for air. Refer to the Suggested Bleeding Procedure at the end of this article. 5. Test drive the truck and check for improved clutch release. 6. If there is no improvement, proceed as follows: a. Remove the clutch master cylinder pushrod from the release lever pin on the release lever. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Master Cylinder > Component Information > Technical Service Bulletins > Customer Interest for Clutch Master Cylinder: > 90167 > Aug > 90 > M/T - Clutch Fluid Leaks/Incomplete Release > Page 4600 Figure 1 b. Make sure the hole in the pushrod lines up with the pin, for those units requiring a minimal force for installation, Figure 1. c. If it does not line up correctly, install an adjustable pushrod (except 1988 and later models) or replace the clutch release lever (required on 1988 and later models), cutting a new seat on the cross shaft splines. 7. Test drive the truck again, checking for improved clutch release. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Master Cylinder > Component Information > Technical Service Bulletins > Customer Interest for Clutch Master Cylinder: > 90167 > Aug > 90 > M/T - Clutch Fluid Leaks/Incomplete Release > Page 4601 Figure 2 8. If there is no improvement, inspect the truck for adequate release bearing travel. ^ It should be 11 mm or greater for full pedal travel. ^ Pedal travel at the center of the pedal pad should be 6.75" (171 mm minimum) or more, Figure 2. 9. Release bearing travel and gear grinding noise may indicate the following concerns. ^ If the release bearing is 11 mm or greater and there is grinding of one or two gears only, the concern is probably with the transmission. ^ If all gears grind, the concern may be with the clutch and/or pilot bearing which will need replacing. ^ If the release travel is less than 11 mm, check the clutch hydraulic system for air and bleed as necessary. 10. If the release travel is still less than 11 mm, with all of the above items eliminated, proceed as follows: a. Raise the hood, while an assistant operates the clutch pedal. b. Watch the clutch master cylinder for significant deflection. Figure 3 c. Look for the dash reinforcement moving away from the dash, Figure 3. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Master Cylinder > Component Information > Technical Service Bulletins > Customer Interest for Clutch Master Cylinder: > 90167 > Aug > 90 > M/T - Clutch Fluid Leaks/Incomplete Release > Page 4602 d. On 1987 and earlier models, look down inside the cowl cover at the cowl where it is attached to the dash reinforcement. Check for pulled spot welds. 11. If there is significant movement of the dash or clutch master cylinder, proceed as follows: a. Remove the steering column and its dash toe plate and seal. Refer to the appropriate Light Truck Shop Manual, Section 13-07 for service details. b. Inspect the dash inside the cab and look for: ^ Pulled spotwelds and cracked or torn sheet metal. ^ Cracks in the brake and clutch pedal support Figure 4 ^ Missing Y-brace fasteners and a broken or detached Y-brace, Figure 4. 12. Check the cross shaft bushings for wear if the brake pedal moves when the clutch is depressed and vise versa. Replace them as required. NOTE: GENERALLY, TRUCKS WITH SIGNIFICANTLY LESS THAN 11 MM CLUTCH RELEASE BEARING TRAVEL (AFTER COMPLETING THE INSPECTION PROCEDURE AND CORRECTING WHERE NECESSARY) WILL HAVE SIGNIFICANT DASH DAMAGE FROM PULLED SPOTWELDS AND TORN METAL. THESE TRUCKS WILL REQUIRE EXTENSIVE REPAIR. THEREFORE, GO TO THE LARGE REINFORCEMENT INSTALLATION PROCEDURE. Small Reinforcement Installation Procedure Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Master Cylinder > Component Information > Technical Service Bulletins > Customer Interest for Clutch Master Cylinder: > 90167 > Aug > 90 > M/T - Clutch Fluid Leaks/Incomplete Release > Page 4603 Figure 5 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Master Cylinder > Component Information > Technical Service Bulletins > Customer Interest for Clutch Master Cylinder: > 90167 > Aug > 90 > M/T - Clutch Fluid Leaks/Incomplete Release > Page 4604 Figure 6 There are two small reinforcement kits. One for 1988 and later models and one for 1987 and prior models. This is necessary because a new hydraulic clutch master cylinder mounting pattern was introduced for 1988 models. 1987 And Prior Trucks Use reinforcement kit E3TZ-7K509-A on these trucks, Figure 5. Comprehensive installation instructions are included in this kit. 1988 And Later Trucks Use reinforcement kit E8TZ-7K509-A on these trucks. The only part in this kit is the special reinforcement for these trucks. To install it, proceed as follows: 1. Remove the two clutch master cylinder attaching nuts (13 mm) from inside the truck. 2. Position the reinforcement in place over the clutch master cylinder studs. 3. Re-install the two master cylinder nuts, Figure 6. Tighten to 9.5 - 14.9 N-m. Large Reinforcement Installation Procedure Figure 7 Use reinforcement kit E3TZ-7K509-B on all 1983-1991 Bronco/F-Series trucks with hydraulic clutch controls. The kit consists of the following items: ^ A main reinforcement or doubler, with a plate having two studs to clamp the doubler through the cowl inner ^ Two additional pieces with three threaded holes: Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Master Cylinder > Component Information > Technical Service Bulletins > Customer Interest for Clutch Master Cylinder: > 90167 > Aug > 90 > M/T - Clutch Fluid Leaks/Incomplete Release > Page 4605 One plate helps attach the main doubler through the dash inner tunnel. The other large piece is placed inside the front of the cowl, with bolts driven through from the engine compartment side of the dash reinforcement, see Figure 7. Installation Figure 1 1. Remove the insulating material. a. On earlier models, remove the instrument panel lower sound insulator assembly. b. For later diesel powered trucks, remove the fasteners holding the engine compartment dash insulation in place. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Master Cylinder > Component Information > Technical Service Bulletins > Customer Interest for Clutch Master Cylinder: > 90167 > Aug > 90 > M/T - Clutch Fluid Leaks/Incomplete Release > Page 4606 c. Pull the dash insulation back out of the way. d. Disconnect the battery ground cable. 2. Disconnect the clutch master cylinder pushrod from the lever, removing the pushrod retention clip on older models, Figure 1. 3. Remove the two nuts attaching the clutch master cylinder to the dash panel. a. Pull the master cylinder into the engine compartment. b. For, 1988 and later trucks, it will be necessary to disconnect the wiring harness connector from the pushrod switch. c. Rotate the master cylinder to get it past the switch through the dash opening. 4. Remove the steering column and dash toe plate by removing the five (5) fasteners. 5. Disconnect the brake master cylinder pushrod from the brake pedal. 6. On F-Super Duty, proceed to Step 7. On all units except F-Super Duty, proceed as follows: a. Remove the four brake booster attaching nuts. b. Move the brake booster to one side. Figure 4 c. Loosen the two (2) fasteners attaching the brake and clutch pedal support to the Y-brace, Figure 4. 7. Check for cracks. a. Pull back the floor covering and dash sound insulator. (it may be helpful to remove the accelerator pedal.) b. Inspect the area for pulled welds and torn dash sheet metal. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Master Cylinder > Component Information > Technical Service Bulletins > Customer Interest for Clutch Master Cylinder: > 90167 > Aug > 90 > M/T - Clutch Fluid Leaks/Incomplete Release > Page 4607 Figure 8 c. If there are cracks that have not run out, stop them by drilling a 2-3 mm hole at the end, Figure 8. NOTE: WELDING OR BRAZING IS NOT RECOMMENDED, BECAUSE IT COULD BE A SOURCE OF FUTURE BLIND SIDE CORROSION. Figure 4 8. Thoroughly inspect the brake and clutch support again for cracks in the casting and worn bushings. Also, inspect the "Y" brace for cracks and missing fasteners. Replace as necessary, Figure 4. 9. Remove excess body sealer in the area of the clutch master cylinder, inside the dash. 10. Carefully remove the cowl top cover 12 fasteners (7 in front, 5 in rear). NOTE: IT MAY BE NECESSARY TO REMOVE THE RADIO ANTENNA AND REPOSITION THE HOOD TO ACHIEVE THIS. IF THE HOOD IS REMOVED, MARK THE LOCATION OF THE HINGES WITH A WAX PENCIL, PRIOR TO LOOSENING. 11. Place the main reinforcement in position. a. Locate positively, using the lower steering column toe plate fastener and a bolt and nut (8 mm or 5/16") through the upper clutch master Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Master Cylinder > Component Information > Technical Service Bulletins > Customer Interest for Clutch Master Cylinder: > 90167 > Aug > 90 > M/T - Clutch Fluid Leaks/Incomplete Release > Page 4608 cylinder stud hole. NOTE: THE SHEET METAL VARIES FROM TRUCK TO TRUCK AND IT MAY BE NECESSARY TO BEND THE REINFORCEMENT TO GET A GOOD FIT. b. Tighten the upper nut and bolt securely to compress any distortion in the four sheet metal laminations in this area. 12. Drill the holes for the reinforcement plate. a. Using a 3/8" (9.5 mm) drill bit, with the reinforcement as a template, drill two holes up into the cowl inner and three holes into the inner side of the dash. b. De-burr the outside of the holes as necessary. c. Remove any excess sealant in the area and clean up the drill chips inside the truck and cowl. 13. Attach the smaller plate via the three threaded holes into the engine compartment side of the dash inner panel. a. Use three 8 mm bolts passed through the main reinforcement, from inside the cab. b. Install the rubber cap (N804118) onto the end of the uppermost screw from under the dash. c. Position the plate with the two studs attached inside the cowl, through the two holes drilled from below. d. Attach two 8 mm nuts from the inside of the cab. 14. Using the paper template provided in the kit, proceed as follows: Figure 9 a. Center punch and drill three 3/8" (9.5 mm) holes into the dash reinforcement and through the cowl, from the engine compartment side, Figure 9. NOTE: DRILLING WILL BE EASIER IF THERE ARE NO SPOTWELDS VISIBLE THROUGH THE THREE HOLES. b. If necessary, move the pattern outboard slightly to avoid any visible spotwelds. c. De-burr the holes inside the cowl as necessary and clean up the drill chips inside the cowl. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Master Cylinder > Component Information > Technical Service Bulletins > Customer Interest for Clutch Master Cylinder: > 90167 > Aug > 90 > M/T - Clutch Fluid Leaks/Incomplete Release > Page 4609 Figure 10 15. Place the larger three holed plate from the kit inside the cowl. Attach it with three 8 mm bolts through the dash reinforcement, from the engine compartment side, Figure 10. 16. Inspect the seam between the cowl inner and outer, inside the cowl, for cracks in the sealant. If necessary, add sealant. 17. Replace the cowl top. a. If the hood was removed, locate the hinges to the wax pencil marks and tighten the fasteners. b. Replace the radio antenna and windshield washer tube. 18. Re-install the brake booster and stoplight switch, if removed. Tighten the brace bolts. 19. Install the clutch master cylinder. a. Inspect the clutch master cylinder for leaks in the area of the pushrod. Replace it if there is evidence of leaking. b. Remove the nut and bolt from the top of the reinforcement. c. Install the clutch master cylinder. d. Inspect the position of the clutch master cylinder pushrod hole. The pushrod hole should go onto the lever pin with no force required while the pedal is against the upstop. NOTE: ALTHOUGH THIS WAS SPECIFIED IN THE INSPECTION PROCEDURE, REPAIR MAY HAVE CHANGED THE SETTING. e. If the pushrod hole is not in position, install and adjust an adjustable clutch master cylinder pushrod (1987 and prior models) or install a new lever (7A554). Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Master Cylinder > Component Information > Technical Service Bulletins > Customer Interest for Clutch Master Cylinder: > 90167 > Aug > 90 > M/T - Clutch Fluid Leaks/Incomplete Release > Page 4610 Figure 1 NOTE: THE NEW LEVER IS TIGHTENED INTO PLACE WHILE THE MASTER CYLINDER PUSHROD IS ATTACHED, TO SET THE CORRECT POSITION, FIGURE 1. 20. Remove the toe plate fastener from the bottom of the reinforcement and reinstall the steering column and five (5) fasteners. 21. Complete reassembly. a. Re-install the dash sound deadener material and the instrument panel sound insulator. b. Re-install the engine compartment sound insulator on diesel models. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Master Cylinder > Component Information > Technical Service Bulletins > Customer Interest for Clutch Master Cylinder: > 90167 > Aug > 90 > M/T - Clutch Fluid Leaks/Incomplete Release > Page 4611 c. Connect the battery ground terminal. Final Inspection If the truck has been driven for a long period of time with the broken dash and resulting poor clutch release, the clutch disc could be excessively worn or buckled. Test drive the truck, evaluating the clutch for clean release. If the release is not satisfactory, measure the release bearing travel. ^ If it has the required 12 mm at full clutch pedal stroke, then the clutch may need to be replaced. ^ If the release bearing has less than the required release travel, then the hydraulic system probably needs to be bled. Suggested Bleeding Procedure - External Slave Cylinder Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Master Cylinder > Component Information > Technical Service Bulletins > Customer Interest for Clutch Master Cylinder: > 90167 > Aug > 90 > M/T - Clutch Fluid Leaks/Incomplete Release > Page 4612 Figure 11 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Master Cylinder > Component Information > Technical Service Bulletins > Customer Interest for Clutch Master Cylinder: > 90167 > Aug > 90 > M/T - Clutch Fluid Leaks/Incomplete Release > Page 4613 Figure 12 If the truck is a 1987 or prior model, 1988 model with a 7.3L Diesel, 7.5L EFI gas engine or the smaller family of engines with a Warner T-18 four speed transmission, proceed as follows: 1. Remove the master cylinder reservoir cap and diaphragm. 2. Check the fluid level to be sure it is at the step diameter of the reservoir. Do not over fill. 3. From below the truck, push the release lever slowly towards the front of the truck several times. Figures 11 & 12. 4. If it will not move, the master cylinder pushrod is not set correctly. See repair Step # 19. 5. Check the fluid level and replace the diaphragm and cap. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Master Cylinder > Component Information > Technical Service Bulletins > Customer Interest for Clutch Master Cylinder: > 90167 > Aug > 90 > M/T - Clutch Fluid Leaks/Incomplete Release > Page 4614 Suggested Bleeding Proc - Internal Concentric Slave CYL. Figure 13 If the truck has a concentric slave cylinder, proceed as follows: 1. Operate the clutch pedal at full stroke, 10-20 times. 2. Check the fluid level at the change in diameter part of the reservoir. Do not over fill. 3. Have an assistant depress the clutch pedal slowly and hold it down. 4. Open the slave cylinder bleed screw and watch for escaping air, Figure 13. 5. Close the bleed screw and have the assistant release pedal. 6. Repeat this cycle several times until there is no sign of air. Be sure to keep the reservoir topped to the correct level. 7. Replace the diaphragm and reservoir cover. 8. Operate the clutch pedal at full stroke 10-20 times. Misc. Information OTHER APPLICABLE ARTICLES: 86-20-10 WARRANTY STATUS: Eligible Under Basic Warranty Coverage, Powertrain Warranty Coverage OPERATION DESCRIPTION TIME 901607A Inspect & Adjust 0.5 Hr. 901607B Install Reinforcement 2.9 Hr. DEALER CODING BASIC PART NO. CONDITION CODE 7050 50 OASIS CODES: 111000, 505000, 505200, 506000, 590000 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Master Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Master Cylinder: > 90167 > Aug > 90 > M/T - Clutch Fluid Leaks/Incomplete Release Technical Service Bulletin # 90167 Date: 900801 M/T - Clutch Fluid Leaks/Incomplete Release Article No. 90-16-7 ^ CRACKS - DASH (ENGINE COMPARTMENT BULKHEAD) - CLUTCH MASTER CYLINDER AREA - VEHICLES BUILT BEFORE 6/15/90 ^ CLUTCH - HIGH EFFORT - DASH CRACKED IN CLUTCH MASTER CYLINDER AREA VEHICLES BUILT BEFORE 6/15/90 LIGHT TRUCK: 1984-90 BRONCO, F-150, F-250, F-350 1988-90 F SUPER DUTY ISSUE: Incomplete clutch release and/or hydraulic fluid leaking into the cab from the clutch master cylinder may be caused by the reinforcement plate on the clutch master cylinder separating from the dash panel. The separation of the reinforcement plate reduces the clutch master cylinder pushrod travel. Reinforcement plate separation can also cause deflection of the clutch master cylinder that results in a misalignment of the pushrod to the clutch master cylinder. Misalignment causes the "O" ring in front of the secondary seal to leak hydraulic fluid. ACTION: Inspect the truck and, if necessary, use the following service procedure to install a reinforcement kit. Inspection Procedure 1. If the truck is a 1988 or later model, confirm that the starter interlock switch operates (the engine can be started) with the clutch pedal at least 0.5" (12.7 mm) from the floor. 2. Test drive the truck and check for good clutch release. There should be no grinding of the gears, particularly when shifting from neutral to reverse gear. 3. If the truck passes these tests, go to the Small Reinforcement Installation Procedure Section of this article. 4. If either of the above conditions are not met, check the hydraulic system for air. Refer to the Suggested Bleeding Procedure at the end of this article. 5. Test drive the truck and check for improved clutch release. 6. If there is no improvement, proceed as follows: a. Remove the clutch master cylinder pushrod from the release lever pin on the release lever. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Master Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Master Cylinder: > 90167 > Aug > 90 > M/T - Clutch Fluid Leaks/Incomplete Release > Page 4620 Figure 1 b. Make sure the hole in the pushrod lines up with the pin, for those units requiring a minimal force for installation, Figure 1. c. If it does not line up correctly, install an adjustable pushrod (except 1988 and later models) or replace the clutch release lever (required on 1988 and later models), cutting a new seat on the cross shaft splines. 7. Test drive the truck again, checking for improved clutch release. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Master Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Master Cylinder: > 90167 > Aug > 90 > M/T - Clutch Fluid Leaks/Incomplete Release > Page 4621 Figure 2 8. If there is no improvement, inspect the truck for adequate release bearing travel. ^ It should be 11 mm or greater for full pedal travel. ^ Pedal travel at the center of the pedal pad should be 6.75" (171 mm minimum) or more, Figure 2. 9. Release bearing travel and gear grinding noise may indicate the following concerns. ^ If the release bearing is 11 mm or greater and there is grinding of one or two gears only, the concern is probably with the transmission. ^ If all gears grind, the concern may be with the clutch and/or pilot bearing which will need replacing. ^ If the release travel is less than 11 mm, check the clutch hydraulic system for air and bleed as necessary. 10. If the release travel is still less than 11 mm, with all of the above items eliminated, proceed as follows: a. Raise the hood, while an assistant operates the clutch pedal. b. Watch the clutch master cylinder for significant deflection. Figure 3 c. Look for the dash reinforcement moving away from the dash, Figure 3. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Master Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Master Cylinder: > 90167 > Aug > 90 > M/T - Clutch Fluid Leaks/Incomplete Release > Page 4622 d. On 1987 and earlier models, look down inside the cowl cover at the cowl where it is attached to the dash reinforcement. Check for pulled spot welds. 11. If there is significant movement of the dash or clutch master cylinder, proceed as follows: a. Remove the steering column and its dash toe plate and seal. Refer to the appropriate Light Truck Shop Manual, Section 13-07 for service details. b. Inspect the dash inside the cab and look for: ^ Pulled spotwelds and cracked or torn sheet metal. ^ Cracks in the brake and clutch pedal support Figure 4 ^ Missing Y-brace fasteners and a broken or detached Y-brace, Figure 4. 12. Check the cross shaft bushings for wear if the brake pedal moves when the clutch is depressed and vise versa. Replace them as required. NOTE: GENERALLY, TRUCKS WITH SIGNIFICANTLY LESS THAN 11 MM CLUTCH RELEASE BEARING TRAVEL (AFTER COMPLETING THE INSPECTION PROCEDURE AND CORRECTING WHERE NECESSARY) WILL HAVE SIGNIFICANT DASH DAMAGE FROM PULLED SPOTWELDS AND TORN METAL. THESE TRUCKS WILL REQUIRE EXTENSIVE REPAIR. THEREFORE, GO TO THE LARGE REINFORCEMENT INSTALLATION PROCEDURE. Small Reinforcement Installation Procedure Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Master Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Master Cylinder: > 90167 > Aug > 90 > M/T - Clutch Fluid Leaks/Incomplete Release > Page 4623 Figure 5 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Master Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Master Cylinder: > 90167 > Aug > 90 > M/T - Clutch Fluid Leaks/Incomplete Release > Page 4624 Figure 6 There are two small reinforcement kits. One for 1988 and later models and one for 1987 and prior models. This is necessary because a new hydraulic clutch master cylinder mounting pattern was introduced for 1988 models. 1987 And Prior Trucks Use reinforcement kit E3TZ-7K509-A on these trucks, Figure 5. Comprehensive installation instructions are included in this kit. 1988 And Later Trucks Use reinforcement kit E8TZ-7K509-A on these trucks. The only part in this kit is the special reinforcement for these trucks. To install it, proceed as follows: 1. Remove the two clutch master cylinder attaching nuts (13 mm) from inside the truck. 2. Position the reinforcement in place over the clutch master cylinder studs. 3. Re-install the two master cylinder nuts, Figure 6. Tighten to 9.5 - 14.9 N-m. Large Reinforcement Installation Procedure Figure 7 Use reinforcement kit E3TZ-7K509-B on all 1983-1991 Bronco/F-Series trucks with hydraulic clutch controls. The kit consists of the following items: ^ A main reinforcement or doubler, with a plate having two studs to clamp the doubler through the cowl inner ^ Two additional pieces with three threaded holes: Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Master Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Master Cylinder: > 90167 > Aug > 90 > M/T - Clutch Fluid Leaks/Incomplete Release > Page 4625 One plate helps attach the main doubler through the dash inner tunnel. The other large piece is placed inside the front of the cowl, with bolts driven through from the engine compartment side of the dash reinforcement, see Figure 7. Installation Figure 1 1. Remove the insulating material. a. On earlier models, remove the instrument panel lower sound insulator assembly. b. For later diesel powered trucks, remove the fasteners holding the engine compartment dash insulation in place. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Master Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Master Cylinder: > 90167 > Aug > 90 > M/T - Clutch Fluid Leaks/Incomplete Release > Page 4626 c. Pull the dash insulation back out of the way. d. Disconnect the battery ground cable. 2. Disconnect the clutch master cylinder pushrod from the lever, removing the pushrod retention clip on older models, Figure 1. 3. Remove the two nuts attaching the clutch master cylinder to the dash panel. a. Pull the master cylinder into the engine compartment. b. For, 1988 and later trucks, it will be necessary to disconnect the wiring harness connector from the pushrod switch. c. Rotate the master cylinder to get it past the switch through the dash opening. 4. Remove the steering column and dash toe plate by removing the five (5) fasteners. 5. Disconnect the brake master cylinder pushrod from the brake pedal. 6. On F-Super Duty, proceed to Step 7. On all units except F-Super Duty, proceed as follows: a. Remove the four brake booster attaching nuts. b. Move the brake booster to one side. Figure 4 c. Loosen the two (2) fasteners attaching the brake and clutch pedal support to the Y-brace, Figure 4. 7. Check for cracks. a. Pull back the floor covering and dash sound insulator. (it may be helpful to remove the accelerator pedal.) b. Inspect the area for pulled welds and torn dash sheet metal. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Master Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Master Cylinder: > 90167 > Aug > 90 > M/T - Clutch Fluid Leaks/Incomplete Release > Page 4627 Figure 8 c. If there are cracks that have not run out, stop them by drilling a 2-3 mm hole at the end, Figure 8. NOTE: WELDING OR BRAZING IS NOT RECOMMENDED, BECAUSE IT COULD BE A SOURCE OF FUTURE BLIND SIDE CORROSION. Figure 4 8. Thoroughly inspect the brake and clutch support again for cracks in the casting and worn bushings. Also, inspect the "Y" brace for cracks and missing fasteners. Replace as necessary, Figure 4. 9. Remove excess body sealer in the area of the clutch master cylinder, inside the dash. 10. Carefully remove the cowl top cover 12 fasteners (7 in front, 5 in rear). NOTE: IT MAY BE NECESSARY TO REMOVE THE RADIO ANTENNA AND REPOSITION THE HOOD TO ACHIEVE THIS. IF THE HOOD IS REMOVED, MARK THE LOCATION OF THE HINGES WITH A WAX PENCIL, PRIOR TO LOOSENING. 11. Place the main reinforcement in position. a. Locate positively, using the lower steering column toe plate fastener and a bolt and nut (8 mm or 5/16") through the upper clutch master Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Master Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Master Cylinder: > 90167 > Aug > 90 > M/T - Clutch Fluid Leaks/Incomplete Release > Page 4628 cylinder stud hole. NOTE: THE SHEET METAL VARIES FROM TRUCK TO TRUCK AND IT MAY BE NECESSARY TO BEND THE REINFORCEMENT TO GET A GOOD FIT. b. Tighten the upper nut and bolt securely to compress any distortion in the four sheet metal laminations in this area. 12. Drill the holes for the reinforcement plate. a. Using a 3/8" (9.5 mm) drill bit, with the reinforcement as a template, drill two holes up into the cowl inner and three holes into the inner side of the dash. b. De-burr the outside of the holes as necessary. c. Remove any excess sealant in the area and clean up the drill chips inside the truck and cowl. 13. Attach the smaller plate via the three threaded holes into the engine compartment side of the dash inner panel. a. Use three 8 mm bolts passed through the main reinforcement, from inside the cab. b. Install the rubber cap (N804118) onto the end of the uppermost screw from under the dash. c. Position the plate with the two studs attached inside the cowl, through the two holes drilled from below. d. Attach two 8 mm nuts from the inside of the cab. 14. Using the paper template provided in the kit, proceed as follows: Figure 9 a. Center punch and drill three 3/8" (9.5 mm) holes into the dash reinforcement and through the cowl, from the engine compartment side, Figure 9. NOTE: DRILLING WILL BE EASIER IF THERE ARE NO SPOTWELDS VISIBLE THROUGH THE THREE HOLES. b. If necessary, move the pattern outboard slightly to avoid any visible spotwelds. c. De-burr the holes inside the cowl as necessary and clean up the drill chips inside the cowl. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Master Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Master Cylinder: > 90167 > Aug > 90 > M/T - Clutch Fluid Leaks/Incomplete Release > Page 4629 Figure 10 15. Place the larger three holed plate from the kit inside the cowl. Attach it with three 8 mm bolts through the dash reinforcement, from the engine compartment side, Figure 10. 16. Inspect the seam between the cowl inner and outer, inside the cowl, for cracks in the sealant. If necessary, add sealant. 17. Replace the cowl top. a. If the hood was removed, locate the hinges to the wax pencil marks and tighten the fasteners. b. Replace the radio antenna and windshield washer tube. 18. Re-install the brake booster and stoplight switch, if removed. Tighten the brace bolts. 19. Install the clutch master cylinder. a. Inspect the clutch master cylinder for leaks in the area of the pushrod. Replace it if there is evidence of leaking. b. Remove the nut and bolt from the top of the reinforcement. c. Install the clutch master cylinder. d. Inspect the position of the clutch master cylinder pushrod hole. The pushrod hole should go onto the lever pin with no force required while the pedal is against the upstop. NOTE: ALTHOUGH THIS WAS SPECIFIED IN THE INSPECTION PROCEDURE, REPAIR MAY HAVE CHANGED THE SETTING. e. If the pushrod hole is not in position, install and adjust an adjustable clutch master cylinder pushrod (1987 and prior models) or install a new lever (7A554). Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Master Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Master Cylinder: > 90167 > Aug > 90 > M/T - Clutch Fluid Leaks/Incomplete Release > Page 4630 Figure 1 NOTE: THE NEW LEVER IS TIGHTENED INTO PLACE WHILE THE MASTER CYLINDER PUSHROD IS ATTACHED, TO SET THE CORRECT POSITION, FIGURE 1. 20. Remove the toe plate fastener from the bottom of the reinforcement and reinstall the steering column and five (5) fasteners. 21. Complete reassembly. a. Re-install the dash sound deadener material and the instrument panel sound insulator. b. Re-install the engine compartment sound insulator on diesel models. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Master Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Master Cylinder: > 90167 > Aug > 90 > M/T - Clutch Fluid Leaks/Incomplete Release > Page 4631 c. Connect the battery ground terminal. Final Inspection If the truck has been driven for a long period of time with the broken dash and resulting poor clutch release, the clutch disc could be excessively worn or buckled. Test drive the truck, evaluating the clutch for clean release. If the release is not satisfactory, measure the release bearing travel. ^ If it has the required 12 mm at full clutch pedal stroke, then the clutch may need to be replaced. ^ If the release bearing has less than the required release travel, then the hydraulic system probably needs to be bled. Suggested Bleeding Procedure - External Slave Cylinder Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Master Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Master Cylinder: > 90167 > Aug > 90 > M/T - Clutch Fluid Leaks/Incomplete Release > Page 4632 Figure 11 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Master Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Master Cylinder: > 90167 > Aug > 90 > M/T - Clutch Fluid Leaks/Incomplete Release > Page 4633 Figure 12 If the truck is a 1987 or prior model, 1988 model with a 7.3L Diesel, 7.5L EFI gas engine or the smaller family of engines with a Warner T-18 four speed transmission, proceed as follows: 1. Remove the master cylinder reservoir cap and diaphragm. 2. Check the fluid level to be sure it is at the step diameter of the reservoir. Do not over fill. 3. From below the truck, push the release lever slowly towards the front of the truck several times. Figures 11 & 12. 4. If it will not move, the master cylinder pushrod is not set correctly. See repair Step # 19. 5. Check the fluid level and replace the diaphragm and cap. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Master Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Master Cylinder: > 90167 > Aug > 90 > M/T - Clutch Fluid Leaks/Incomplete Release > Page 4634 Suggested Bleeding Proc - Internal Concentric Slave CYL. Figure 13 If the truck has a concentric slave cylinder, proceed as follows: 1. Operate the clutch pedal at full stroke, 10-20 times. 2. Check the fluid level at the change in diameter part of the reservoir. Do not over fill. 3. Have an assistant depress the clutch pedal slowly and hold it down. 4. Open the slave cylinder bleed screw and watch for escaping air, Figure 13. 5. Close the bleed screw and have the assistant release pedal. 6. Repeat this cycle several times until there is no sign of air. Be sure to keep the reservoir topped to the correct level. 7. Replace the diaphragm and reservoir cover. 8. Operate the clutch pedal at full stroke 10-20 times. Misc. Information OTHER APPLICABLE ARTICLES: 86-20-10 WARRANTY STATUS: Eligible Under Basic Warranty Coverage, Powertrain Warranty Coverage OPERATION DESCRIPTION TIME 901607A Inspect & Adjust 0.5 Hr. 901607B Install Reinforcement 2.9 Hr. DEALER CODING BASIC PART NO. CONDITION CODE 7050 50 OASIS CODES: 111000, 505000, 505200, 506000, 590000 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Pedal Assembly > Component Information > Technical Service Bulletins > Customer Interest for Clutch Pedal Assembly: > 871615 > Aug > 87 > M/T - Gear Clash and Hard Shifting Clutch Pedal Assembly: Customer Interest M/T - Gear Clash and Hard Shifting ^ CLUTCH (HYDRAULIC) - PEDAL DOES NOT Article No. FULLY RETURN - DIAGNOSTIC TIPS 87-16-15 ^ TRANSMISSION - MANUAL - GEAR CLASH AND HARD SHIFTING ^ SPEED CONTROL - INOPERATIVE - LOW CLUTCH PEDAL ALLOWS SWITCH CIRCUIT TO REMAIN OPEN LIGHT TRUCK: 1984-87 F-150/350, BRONCO ISSUE: A clutch pedal not fully returning to contact the rubber bumper at the "up" stop may result in any of the following conditions. ^ Transmission gear clash or hard shifting or failure to release into or from gear (particularly reverse and 1st gear) because clutch pedal stroke length is decreased, causing low pedal reserve. ^ Clutch pedal may sometimes stick near the TOP of the stroke, requiring driver to "tip" the pedal with his/her foot in order to get pedal to further return. ^ Speed control is inoperative, due to pedal not returning and permitting "shut off" switch circuit to remain in the open position, i.e., clutch disengaged mode. ACTION: To determine if a new cross-shaft lever is required, use the following diagnostic and servicing procedure. 1. Check under the dash area to be certain that the clutch pedal system has no wiring looms which interfere with pedal return, at the interlock switch rod and the end of the master cylinder pushrod. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Pedal Assembly > Component Information > Technical Service Bulletins > Customer Interest for Clutch Pedal Assembly: > 871615 > Aug > 87 > M/T - Gear Clash and Hard Shifting > Page 4643 Figure 7 2. Determine if the clutch master cylinder pushrod and lever pin are correctly aligned by disconnecting the pushrod and seeing if it will reassemble to the pin WITHOUT DEPRESSING THE PUSHROD OR DEPRESSING THE CLUTCH PEDAL. (When the pushrod is disconnected from the pin, the clutch master cylinder piston is fully retracted (rearward) and the clutch pedal blade is contacting the rubber bumper stop), see Figure 7. 3. If the two components are not in alignment, perform the following IN THIS EXACT SEQUENCE: a. Loosen the clutch pedal attaching nut (left hand side). Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Pedal Assembly > Component Information > Technical Service Bulletins > Customer Interest for Clutch Pedal Assembly: > 871615 > Aug > 87 > M/T - Gear Clash and Hard Shifting > Page 4644 b. Reinstall the clutch master cylinder pushrod to the cross-shaft lever pin. c. Tighten the clutch pedal attaching nut (left hand side). d. Stroke the clutch pedal several times to reset the position of the shaft to the pedal slot, THIS STEP IS REQUIRED! e. Again, remove the clutch master cylinder pushrod from the lever pin and check the alignment. If the two (2) components are still not in alignment, replace the crossshaft lever. NOTE: If the pushrod is aligned with the pin, no further action is required. Cross-Shaft Lever Replacement Removal 1. Disconnect the master cylinder pushrod from the cross-shaft lever pin. 1984-86 Vehicles Remove the clevis pin. Carefully pull the pushrod from the lever. 1987 Vehicles Disconnect the snap-in bushing by wedging a small screwdriver or putty knife between the lever and the bushing. When the bushing tangs are free at the pin groove, carefully pull the pushrod from the lever. 2. Remove the attaching nut. 3. Remove the lever from the cross-shaft, using a pry tool or puller. Installation NOTE: The proper position of clutch master cylinder pushrod relative to the crossshaft lever (7A554) pin is controlled by this installation PROCEDURE. Therefore, ONLY the following steps should be used. 1. Install the new lever (pin) to the clutch master cylinder pushrod bushing. 2. Install the lever onto the cross-shaft. 3. Install the attaching nut, finger tight. 4. Inspect pedal position to make sure it is against the "up" stop. 5. Tighten the attaching nut. This will permit the knurled teeth on the shaft to cut matching teeth in lever, which then results in the correct positioning of the two (2) components. NOTE: The above procedure is the preferred method of "adjusting" master cylinder pushrod length. Frequently, the master cylinder is replaced or adjustable pushrods are installed to obtain the required pushrod to lever positioning. Cross-shaft lever replacement is a more efficient method and eliminates the potential of pushrod mis-adjustment and introducing air or contamination into the hydraulic system. CROSS-SHAFT LEVER APPLICATION Model Year Truck Series Part Number 1984-86 F Series, Bronco E4TZ-7A554-A 1987 F Series, Bronco E7TZ-7A554-A PART NUMBER PART NAME CLASS E4TZ-7A554-A Cross-Shaft Lever B E7TZ-7A554-A Cross-Shaft Lever B OTHER APPLICABLE ARTICLES: 85-1-20, 85-5-24, 85-5-26 WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual OPERATION: SP871615A Align clutch master cylinder pushrod and cross-shaft lever pin Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Pedal Assembly > Component Information > Technical Service Bulletins > Customer Interest for Clutch Pedal Assembly: > 871615 > Aug > 87 > M/T - Gear Clash and Hard Shifting > Page 4645 TIME: 0.4 Hr. - 6.9L diesel 0.3 Hr. - All others OPERATION: SP871615B - Replace cross-shaft lever (includes time to perform previous alignment) TIME: 0.6 Hr. - 6.9L diesel 0.5 Hr. - All others DLR. CODING: Basic Part No. 7A554 - Code: 07 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Pedal Assembly > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Pedal Assembly: > 871615 > Aug > 87 > M/T - Gear Clash and Hard Shifting Clutch Pedal Assembly: All Technical Service Bulletins M/T - Gear Clash and Hard Shifting ^ CLUTCH (HYDRAULIC) - PEDAL DOES NOT Article No. FULLY RETURN - DIAGNOSTIC TIPS 87-16-15 ^ TRANSMISSION - MANUAL - GEAR CLASH AND HARD SHIFTING ^ SPEED CONTROL - INOPERATIVE - LOW CLUTCH PEDAL ALLOWS SWITCH CIRCUIT TO REMAIN OPEN LIGHT TRUCK: 1984-87 F-150/350, BRONCO ISSUE: A clutch pedal not fully returning to contact the rubber bumper at the "up" stop may result in any of the following conditions. ^ Transmission gear clash or hard shifting or failure to release into or from gear (particularly reverse and 1st gear) because clutch pedal stroke length is decreased, causing low pedal reserve. ^ Clutch pedal may sometimes stick near the TOP of the stroke, requiring driver to "tip" the pedal with his/her foot in order to get pedal to further return. ^ Speed control is inoperative, due to pedal not returning and permitting "shut off" switch circuit to remain in the open position, i.e., clutch disengaged mode. ACTION: To determine if a new cross-shaft lever is required, use the following diagnostic and servicing procedure. 1. Check under the dash area to be certain that the clutch pedal system has no wiring looms which interfere with pedal return, at the interlock switch rod and the end of the master cylinder pushrod. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Pedal Assembly > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Pedal Assembly: > 871615 > Aug > 87 > M/T - Gear Clash and Hard Shifting > Page 4651 Figure 7 2. Determine if the clutch master cylinder pushrod and lever pin are correctly aligned by disconnecting the pushrod and seeing if it will reassemble to the pin WITHOUT DEPRESSING THE PUSHROD OR DEPRESSING THE CLUTCH PEDAL. (When the pushrod is disconnected from the pin, the clutch master cylinder piston is fully retracted (rearward) and the clutch pedal blade is contacting the rubber bumper stop), see Figure 7. 3. If the two components are not in alignment, perform the following IN THIS EXACT SEQUENCE: a. Loosen the clutch pedal attaching nut (left hand side). Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Pedal Assembly > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Pedal Assembly: > 871615 > Aug > 87 > M/T - Gear Clash and Hard Shifting > Page 4652 b. Reinstall the clutch master cylinder pushrod to the cross-shaft lever pin. c. Tighten the clutch pedal attaching nut (left hand side). d. Stroke the clutch pedal several times to reset the position of the shaft to the pedal slot, THIS STEP IS REQUIRED! e. Again, remove the clutch master cylinder pushrod from the lever pin and check the alignment. If the two (2) components are still not in alignment, replace the crossshaft lever. NOTE: If the pushrod is aligned with the pin, no further action is required. Cross-Shaft Lever Replacement Removal 1. Disconnect the master cylinder pushrod from the cross-shaft lever pin. 1984-86 Vehicles Remove the clevis pin. Carefully pull the pushrod from the lever. 1987 Vehicles Disconnect the snap-in bushing by wedging a small screwdriver or putty knife between the lever and the bushing. When the bushing tangs are free at the pin groove, carefully pull the pushrod from the lever. 2. Remove the attaching nut. 3. Remove the lever from the cross-shaft, using a pry tool or puller. Installation NOTE: The proper position of clutch master cylinder pushrod relative to the crossshaft lever (7A554) pin is controlled by this installation PROCEDURE. Therefore, ONLY the following steps should be used. 1. Install the new lever (pin) to the clutch master cylinder pushrod bushing. 2. Install the lever onto the cross-shaft. 3. Install the attaching nut, finger tight. 4. Inspect pedal position to make sure it is against the "up" stop. 5. Tighten the attaching nut. This will permit the knurled teeth on the shaft to cut matching teeth in lever, which then results in the correct positioning of the two (2) components. NOTE: The above procedure is the preferred method of "adjusting" master cylinder pushrod length. Frequently, the master cylinder is replaced or adjustable pushrods are installed to obtain the required pushrod to lever positioning. Cross-shaft lever replacement is a more efficient method and eliminates the potential of pushrod mis-adjustment and introducing air or contamination into the hydraulic system. CROSS-SHAFT LEVER APPLICATION Model Year Truck Series Part Number 1984-86 F Series, Bronco E4TZ-7A554-A 1987 F Series, Bronco E7TZ-7A554-A PART NUMBER PART NAME CLASS E4TZ-7A554-A Cross-Shaft Lever B E7TZ-7A554-A Cross-Shaft Lever B OTHER APPLICABLE ARTICLES: 85-1-20, 85-5-24, 85-5-26 WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual OPERATION: SP871615A Align clutch master cylinder pushrod and cross-shaft lever pin Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Pedal Assembly > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Pedal Assembly: > 871615 > Aug > 87 > M/T - Gear Clash and Hard Shifting > Page 4653 TIME: 0.4 Hr. - 6.9L diesel 0.3 Hr. - All others OPERATION: SP871615B - Replace cross-shaft lever (includes time to perform previous alignment) TIME: 0.6 Hr. - 6.9L diesel 0.5 Hr. - All others DLR. CODING: Basic Part No. 7A554 - Code: 07 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Pedal Assembly > Component Information > Technical Service Bulletins > Page 4654 Clutch Pedal Assembly: Adjustments No clutch linkage or pedal travel adjustments are required. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Pedal Position Switch <--> [Clutch Switch] > Component Information > Testing and Inspection Clutch Pedal Position Switch: Testing and Inspection Manual Transmission Vehicles Only This switch functions magnetically. Do not use magnetized tools near this switch. 1. If the switch is open when the clutch pedal is released, speed control will not operate. This must be corrected before making any other tests. Use only a multimeter of 5000 ohm/volt rating or higher when performing the clutch switch test. 2. Disconnect switch pigtail connector from speed control harness connector and connect an ohmmeter to the two switch connector terminals. 3. With clutch pedal in the fully released position, the resistance should be less than 5 ohms. With clutch pedal fully depressed, the circuit should be open. 4. If switch does not function as described, remove and replace switch. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Pressure Plate > Component Information > Service and Repair > With Warner Transmission Pressure Plate: Service and Repair With Warner Transmission Single-Disc-Type Clutch Standard Disc and Pressure Plate Assembly10.0 lnch/11.0 lnch/12.0 Inch Removal 1. Disconnect the battery negative cable. 2. Remove clutch slave cylinder, or the hydraulic line quick disconnect using quick disconnect tool T88T-70522-A. 3. Remove the release lever if so equipped. 4. Remove the dust cover it so equipped. 5. Remove transmission. 6. Mark the assembled position of the pressure plate and cover to the flywheel (for re-assembly). 7. Remove the pressure plate and cover assembly and the clutch disc from the flywheel. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Pressure Plate > Component Information > Service and Repair > With Warner Transmission > Page 4662 Installation 1. Position the clutch disc on the flywheel so that the Clutch Alignment Shaft D79T-7550-A or equivalent can enter the clutch pilot bearing and align the disc. 2. When re-installing the original pressure plate and cover assembly, align the assembly and flywheel according to the marks made during the removal operations. Position the pressure plate and cover assembly on the flywheel, align the pressure plate and disc, and install the retaining bolts that fasten the assembly to the flywheel. Tighten the bolts to specification and remove the clutch disc pilot tool. 3. Clean and lubricate the release lever pivot stud. 4. Reinstall the transmission. 5. Correctly position the release lever (if so equipped) in its release bearing hub, and align with the pivot stud. Push inward on the lever until it snaps into position. 6. Reinstall the external slave cylinder, or attach the hydraulic tube quick connect fitting. 7. Install the dust boot if so equipped. 8. Install the starter motor. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Pressure Plate > Component Information > Service and Repair > With Warner Transmission > Page 4663 Pressure Plate: Service and Repair Without Warner Transmission Single-Disc-Type Clutch Standard Disc and Pressure Plate Assembly10.0 lnch/11.0 lnch/12.0 Inch Removal 1. Disconnect the battery negative cable. 2. Remove clutch slave cylinder, or the hydraulic line quick disconnect using quick disconnect tool T88T-70522-A. 3. Remove the release lever if so equipped. 4. Remove the dust cover it so equipped. 5. Remove transmission. 6. Mark the assembled position of the pressure plate and cover to the flywheel (for re-assembly). 7. Remove the pressure plate and cover assembly and the clutch disc from the flywheel. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Pressure Plate > Component Information > Service and Repair > With Warner Transmission > Page 4664 Installation 1. Position the clutch disc on the flywheel so that the Clutch Alignment Shaft D79T-7550-A or equivalent can enter the clutch pilot bearing and align the disc. 2. When re-installing the original pressure plate and cover assembly, align the assembly and flywheel according to the marks made during the removal operations. Position the pressure plate and cover assembly on the flywheel, align the pressure plate and disc, and install the retaining bolts that fasten the assembly to the flywheel. Tighten the bolts to specification and remove the clutch disc pilot tool. 3. Clean and lubricate the release lever pivot stud. 4. Reinstall the transmission. 5. Correctly position the release lever (if so equipped) in its release bearing hub, and align with the pivot stud. Push inward on the lever until it snaps into position. 6. Reinstall the external slave cylinder, or attach the hydraulic tube quick connect fitting. 7. Install the dust boot if so equipped. 8. Install the starter motor. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Carrier > Carrier Bearings > Component Information > Testing and Inspection > Bearing Cups Carrier Bearings: Testing and Inspection Bearing Cups Check bearing cups for rings, spalling, galling or erratic wear patterns. The bearing cups must be solidly seated. Check by attempting to insert .0015 inch feeler gauge between cups and bottoms of bores. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Carrier > Carrier Bearings > Component Information > Testing and Inspection > Bearing Cups > Page 4671 Carrier Bearings: Testing and Inspection Cone & Roller Assemblies When operated in the cups, the cone and roller assemblies must turn without any roughness. Examine roller ends for wear. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Carrier > Carrier Bearings > Component Information > Testing and Inspection > Bearing Cups > Page 4672 Carrier Bearings: Testing and Inspection Differential Bearing Adjusters Test fit of bearing adjusters in their threads with bearing caps installed. Ensure that bearing caps are on sides that they were machined to fit. The faces of the adjusters that contact the bearing cups must be smooth and square. Examine threads in carrier if their fit is not proper and replace any adjuster with a damaged face or threads. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Carrier > Carrier Side Gears > Component Information > Testing and Inspection Carrier Side Gears: Testing and Inspection Examine drive pinion and ring gear teeth for scoring or signs of excessive wear. Worn gears cannot be rebuilt to correct a noisy condition. Gear scoring and flaking are the result of excessive shock loading or the use of improper lubricant. Scored gears cannot be reused. Examine teeth and thrust surfaces of differential gears. Wear on hub of differential side gears may cause a chucking noise known as chuckle, when the vehicle is operated at low speeds. Wear of splines, thrust surfaces or thrust washers may contribute to excessive drive line backlash. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Technical Service Bulletins > Customer Interest for Differential Case: > 871218 > Jun > 87 > Front Drive Axle - Leaks Lubricant From Vent Differential Case: Customer Interest Front Drive Axle - Leaks Lubricant From Vent Article No. ^ AXLE - FRONT - LEAKS LUBRICANT FROM AXLE 87-12-18 VENT - DANA MODEL 44 IFS AND 50 IFS CARRIERS ^ LEAKS - LUBRICANT - FRONT AXLE VENT - DANA MODEL 44 IFS AND 50 IFS CARRIERS LIGHT TRUCK: 1980-87 F SERIES, BRONCO ISSUE: Lubricant leaking from the axle vent on Dana Model 44 IFS or 50 IFS front drive axle carriers may be caused by an obstructed or mislocated axle vent or vent hose. ACTION: To correct this, check to make sure the axle vent and the vent hose is not blocked. If they are clear, modify and/or relocate the axle vent using the following service procedure. 1. Remove vent hose from axle vent. 2. Remove axle vent from carrier assembly. 3. Drill out the existing 1/16" axle vent hole in axle vent with a 1/8" drill. 4. Reassemble axle vent to carrier assembly. Reconnect rubber vent hose to axle vent. NOTE: Make sure vent hose is not plugged. 5. Test drive vehicle. If lubricant leaks continue after performing Steps 1 through 4, relocate the axle vent as described in Part 11. 6. Remove carrier assembly from vehicle and support arm. Refer to the appropriate Light Truck Shop Manual. 7. Remove right hand axle shaft and differential case assembly from carrier. Remove right hand trunnion seal and right hand needle bearing assembly. Figure 29 - Article 87-12-18 8. Drill an 11/32" (.343) diameter hole in right hand trunnion (passenger side) of carrier. Locate hole as shown in Figure 29. 9. Tap hole with a .125-27 NPSF Dryseal thread. CAUTION: DURING DRILLING AND TAPPING OPERATION, CARE SHOULD BE USED TO MAKE SURE THAT ALL METAL CHIPS ARE REMOVED FROM THE CARRIER AND THAT THEY DO NOT ENTER OTHER COMPONENTS, (e.g., bearings and oil seals). 10. Install a .125-27 NPSF pipe plug in old vent hole. 11. Reassemble differential case assembly into carrier. Assemble new axle shaft bearing and seal in carrier trunnion. Assemble remaining components Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Technical Service Bulletins > Customer Interest for Differential Case: > 871218 > Jun > 87 > Front Drive Axle - Leaks Lubricant From Vent > Page 4684 and install in vehicle. 12. Install axle vent into new hole that was drilled and tapped in the above steps. Reconnect rubber vent hose to axle vent. NOTE: Make sure vent hose is not plugged. 13. Fill axle assembly with Hypoid Gear Lubricant (C6AZ-19580-E). NOTE: Make sure vehicle is level. Do not overfill axle assembly. ONLY GL6 (C6AZ-19850-E) Lubricant should be, used. Use of lesser quality lubricants (i.e., GL4, GL5) may cause premature wear of the axle carrier. Limited slip carriers must have friction modifier added. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual OPERATION: SP871218A - Steps 1-5 TIME: 0.6 Hr. OPERATION: SP871218B - Steps 6-13 TIME: 2.8 Hrs. Use "M" time for auxiliary equipment such as snow plow frames. DLR. CODING: Basic Part No. 3010 - Code: 77 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Technical Service Bulletins > Customer Interest for Differential Case: > 862223 > Nov > 86 > Axle - Rear Axle Hub Seals Leak Differential Case: Customer Interest Axle - Rear Axle Hub Seals Leak Article No. 86-22-23 AXLE (10.25") - REAR - HUB SEALS LEAK - VENT PLUGGED LIGHT TRUCK 1985-86 F-250/350 A plugged rear axle vent may cause water to be sucked in through the seals and grease to be pushed out. This happens when pressures rise and fall inside the axle during various driving conditions and temperatures. The purpose of the vent is to relieve those pressures. If the vent is plugged with mud or other foreign materials, the axle cannot "breathe". To eliminate this concern, perform the following procedure: Figure 17 1. Remove the vent from the axle (Figure 17). 2. Place the vent in a vise so as not to damage the threads. 3. Drill out the vent using a 3/16 inch drill bit. Clean all shavings from vent. 4. Install vent. 5. Make sure entire vent hose is clear of dirt and mud, etc. 6. Install hose. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION: SP4022A86 TIME: 0.5 Hr. DLR. CODING: Basic Part No. 4022 - Code: 55 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Differential Case: > 871218 > Jun > 87 > Front Drive Axle - Leaks Lubricant From Vent Differential Case: All Technical Service Bulletins Front Drive Axle - Leaks Lubricant From Vent Article No. ^ AXLE - FRONT - LEAKS LUBRICANT FROM AXLE 87-12-18 VENT - DANA MODEL 44 IFS AND 50 IFS CARRIERS ^ LEAKS - LUBRICANT - FRONT AXLE VENT - DANA MODEL 44 IFS AND 50 IFS CARRIERS LIGHT TRUCK: 1980-87 F SERIES, BRONCO ISSUE: Lubricant leaking from the axle vent on Dana Model 44 IFS or 50 IFS front drive axle carriers may be caused by an obstructed or mislocated axle vent or vent hose. ACTION: To correct this, check to make sure the axle vent and the vent hose is not blocked. If they are clear, modify and/or relocate the axle vent using the following service procedure. 1. Remove vent hose from axle vent. 2. Remove axle vent from carrier assembly. 3. Drill out the existing 1/16" axle vent hole in axle vent with a 1/8" drill. 4. Reassemble axle vent to carrier assembly. Reconnect rubber vent hose to axle vent. NOTE: Make sure vent hose is not plugged. 5. Test drive vehicle. If lubricant leaks continue after performing Steps 1 through 4, relocate the axle vent as described in Part 11. 6. Remove carrier assembly from vehicle and support arm. Refer to the appropriate Light Truck Shop Manual. 7. Remove right hand axle shaft and differential case assembly from carrier. Remove right hand trunnion seal and right hand needle bearing assembly. Figure 29 - Article 87-12-18 8. Drill an 11/32" (.343) diameter hole in right hand trunnion (passenger side) of carrier. Locate hole as shown in Figure 29. 9. Tap hole with a .125-27 NPSF Dryseal thread. CAUTION: DURING DRILLING AND TAPPING OPERATION, CARE SHOULD BE USED TO MAKE SURE THAT ALL METAL CHIPS ARE REMOVED FROM THE CARRIER AND THAT THEY DO NOT ENTER OTHER COMPONENTS, (e.g., bearings and oil seals). 10. Install a .125-27 NPSF pipe plug in old vent hole. 11. Reassemble differential case assembly into carrier. Assemble new axle shaft bearing and seal in carrier trunnion. Assemble remaining components Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Differential Case: > 871218 > Jun > 87 > Front Drive Axle - Leaks Lubricant From Vent > Page 4694 and install in vehicle. 12. Install axle vent into new hole that was drilled and tapped in the above steps. Reconnect rubber vent hose to axle vent. NOTE: Make sure vent hose is not plugged. 13. Fill axle assembly with Hypoid Gear Lubricant (C6AZ-19580-E). NOTE: Make sure vehicle is level. Do not overfill axle assembly. ONLY GL6 (C6AZ-19850-E) Lubricant should be, used. Use of lesser quality lubricants (i.e., GL4, GL5) may cause premature wear of the axle carrier. Limited slip carriers must have friction modifier added. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual OPERATION: SP871218A - Steps 1-5 TIME: 0.6 Hr. OPERATION: SP871218B - Steps 6-13 TIME: 2.8 Hrs. Use "M" time for auxiliary equipment such as snow plow frames. DLR. CODING: Basic Part No. 3010 - Code: 77 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Differential Case: > 862223 > Nov > 86 > Axle - Rear Axle Hub Seals Leak Differential Case: All Technical Service Bulletins Axle - Rear Axle Hub Seals Leak Article No. 86-22-23 AXLE (10.25") - REAR - HUB SEALS LEAK - VENT PLUGGED LIGHT TRUCK 1985-86 F-250/350 A plugged rear axle vent may cause water to be sucked in through the seals and grease to be pushed out. This happens when pressures rise and fall inside the axle during various driving conditions and temperatures. The purpose of the vent is to relieve those pressures. If the vent is plugged with mud or other foreign materials, the axle cannot "breathe". To eliminate this concern, perform the following procedure: Figure 17 1. Remove the vent from the axle (Figure 17). 2. Place the vent in a vise so as not to damage the threads. 3. Drill out the vent using a 3/16 inch drill bit. Clean all shavings from vent. 4. Install vent. 5. Make sure entire vent hose is clear of dirt and mud, etc. 6. Install hose. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION: SP4022A86 TIME: 0.5 Hr. DLR. CODING: Basic Part No. 4022 - Code: 55 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Technical Service Bulletins > Page 4699 Differential Case: Testing and Inspection Ensure that hubs where bearings mount are smooth. Check fit of differential gears in the counterbores. Carefully examine thrust washers, which may be damaged when bearings are removed. If differential bearing assemblies do not seat firmly on hubs, failure is certain. Ensure that mating surfaces of the two parts of case and the face of the ring gear attaching flange are smooth and free from nicks and burrs. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Technical Service Bulletins > Page 4700 Differential Case: Adjustments 1. Attach ring gear to the differential case using new bolts. Torque bolts alternately and evenly to 50---60 ft. lbs. on except model 60 monobeam axle or 100-120 ft. lbs on model 60 monobeam axle. 2. Clean trunnions on the differential and install the master differential bearings on to differential case. Remove all burrs and nicks from hubs so master bearings rotate freely. 3. Place differential case into carrier (without pinion). The differential case should move freely in the carrier assembly. Position a suitable dial indicator against differential case flanges. Locate tip of the indicator on the flat surface of one ring gear bolt. Force the differential case toward the dial indicator as far as possible and zero dial indicator with force still applied. Dial indicator should have a minimum of .200 inch travel. Force differential case away from the dial indicator as far as it will go. Repeat this procedure until the same reading is obtained. Record dial indicator reading. This reading indicates the amount of shims needed behind the differential side bearings to take up total clearance between the differential bearing and case. This reading will be used during pinion and ring gear backlash adjustment. 4. Remove differential case from the carrier. Do not remove the master differential bearings at this time. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Technical Service Bulletins > Page 4701 Differential Case: Service and Repair For limited slip & locking differential assemblies, refer to ``Ford Drive Axle w/Integral Carrier'' section for assembly procedures. For adjustment procedures on these differentials, refer to step 9 in this procedure. 1. Install differential case in a vise, then apply suitable lubricant to side gear thrust washers and to hubs and thrust face of the new side gears. 2. Assemble both side gears and apply suitable lubricant to the spherical washers and pinion mate gears, then assemble pinion mate gears and washers. 3. Install both side gears and thrust washers, then the pinion mate gears and washers to hold side gears in position. 4. Rotate side gears until holes of washers and pinion gears line up with holes of the case. If gears cannot be rotated by hand, install one of the axle shafts into the side gear spline and use a pipe wrench to turn shaft. 5. Line up gear holes with those of the differential case using a suitable drift, then install pinion mate shaft. Ensure lock pin hole of shaft is lined up with lock pin hole of case. 6. Install lock pin, then peen metal of case over pin to lock in position. The semi-float shaft riding bearing design uses a locking pin that is installed using a suitable wrench. Use a new lock pin and assemble finger tight. This prevents differential side gears and differential pinion mate gears from rotating in the case and dropping out when servicing the carrier section. A new lock pin should be installed after assembling the axle shafts. 7. Install ring gear to case, then the ring gear attaching screws. Torque ring gear attaching screws alternately to approximately 115 ft. lbs. on except model 30 axle or 45---60 ft. lbs on model 30 axle. 8. Install differential bearings onto case using suitable tool. 9. Install differential case assembly into carrier, less pinion, then mount suitable dial indicator on face of housing. 10. Locate tip of indicator on flat surface of one of the ring gear screw spot faces, then force differential assembly as far as possible in the direction towards the indicator. With force still applied, set indicator at zero. 11. Force differential assembly as far as it will go in the opposite direction. Repeat this step until the same reading is obtained, then record this reading. This reading will be the total amount of shims required, less preload, and will be calculated later during assembly. 12. Remove indicator and differential assembly from housing. Do not remove bearings from differential case at this time. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Technical Service Bulletins > Front Drive Axle - Identification Tags Differential Axle Housing: Technical Service Bulletins Front Drive Axle - Identification Tags Article No. 92-5-14 February 26, 1992 AXLE - FRONT DRIVE AXLE IDENTIFICATION TAGS - 4X4 MODELS LIGHT TRUCK: 1985-90 BRONCO II 1985-92 BRONCO, F-150-350 SERIES, RANGER 1991-92 EXPLORER ISSUE: The 1991 and prior model front drive axles had identification information in the following three (3) places... ^ It was on a metal tag attached to a carrier cover mounting bolt. ^ It was stamped into the left side axle arm (tube) front face inboard of the U-Joint. ^ It was on a paper tape tag wrapped around the axle arm (tube). The 1992 model year axles use a glue-on label that replaces all three of the prior identification markings, Figure 1. The new label is on the rear face of the right hand arm (tube). ACTION: Since this glue-on label, Figure 1, is the only identification, be sure that the information on the label is recorded in a retrievable place before any service actions are taken which will damage/destroy or remove the label. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 509000 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Dana/Spicer Integral - Rear Axle Assembly Differential Axle Housing: Service and Repair Dana/Spicer Integral - Rear Axle Assembly 1. Raise vehicle from floor and support with stand jacks under frame side rails. 2. Remove rear wheels. 3. Split rear universal joint. 4. Disconnect parking brake cable from equalizer rod and unfasten brake cable brackets from frame crossmember. 5. Disconnect hydraulic brake line connection at rear axle housing. 6. Loosen and move shock absorbers out of the way. 7. While supporting axle housing with hydraulic jack, remove spring clips and lower axle assembly to the floor. 8. Reverse the foregoing procedure to install the rear axle assembly, being sure to bleed the brake system when the installation is completed. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Dana/Spicer Integral - Rear Axle Assembly > Page 4708 Differential Axle Housing: Service and Repair Ford Integral Carrier Axle Disassembly, Ford Integral Carrier Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Dana/Spicer Integral - Rear Axle Assembly > Page 4709 Fig. 1 Disassembled view of Ford 6 3/4 inch ring gear axle Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Dana/Spicer Integral - Rear Axle Assembly > Page 4710 Fig. 2 Disassembled view of Ford 7 1/2 inch ring gear axle Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Dana/Spicer Integral - Rear Axle Assembly > Page 4711 Fig. 3 Exploded view of 8.8 & 10.25 inch ring gear axles (except models w/anti-lock brakes). 8.8 inch ring gear axle shown, 10.25 inch ring gear axle similar Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Dana/Spicer Integral - Rear Axle Assembly > Page 4712 Fig. 4 Exploded view of 8.8 inch ring gear axles. Models w/anti-lock brakes 1. Remove axle cover, Figs. 1 through 4, then wipe lubricant from internal working parts and visually inspect parts for wear or damage. 2. Rotate gears to check for any roughness, which indicates damaged bearings or gears. 3. Check ring gear teeth for signs of scoring, abnormal wear, nicks or chips. 4. On models with 8.8 or 10.25 inch ring gear, proceed as follows: a. Using dial indicator, check ring gear backlash and ring gear back face runout. Backlash should be .008---.015 inch and back face runout should be under .004 inch. b. Do not use contact pattern as a guide to check for noise. Check for proper gear set assembly using pinion depth gauge tool to determine correct pinion shim required to ensure acceptable running condition. 5. On models with 6 3/4 or 7 1/2 inch ring gear, test ring gear runout as follows: a. Install suitable dial indicator and zero indicator, then rotate ring gear and record reading. b. If reading exceeds .003 inch, check for improper torque of ring gear bolts or dirt between ring and case. 6. If reading still exceeds .003 inch after step 5b, diagnose ring gear runout as follows: a. Remove ring gear. 1987 Bronco II models with anti-lock brakes use an exciter ring located on the ring gear assembly. Removal of the exciter ring is not necessary when removing ring gear on this model. b. On models with 6 3/4 inch ring gear, install left case on right and tap them together, then place differential cups on differential bearing cone and roller. c. On all models, place differential assembly in carrier casting. On models with 6 3/4 inch ring gear, two bolts and nuts must be installed to hold case halves together. d. Install .265 inch shim on left side as guide. e. Install left bearing cap and tighten bolts finger tight. f. Install progressively larger shims on right side until largest shim selected can be assembled with a slight drag feel. Apply pressure toward left side to ensure that bearing cup is seated. g. Install right side bearing cap and torque differential bearing cap bolts to 70---80 ft. lbs., then rotate assembly to ensure free rotation. h. Check runout of differential case flange with dial indicator. If runout is within .003 inch, install new ring and pinion gear. If runout exceeds specifications, trouble is due to either a damaged case or worn bearings. i. Remove differential case from carrier and the differential bearings from case. j. Install new differential bearings on case hubs and install differential assembly in carrier less ring gear. k. Check case runout. If runout is within .003 inch, use new bearings for reassembly. If runout is still excessive, case is damaged and must be replaced. 7. Remove axle shafts. 8. Mark relationship of driveshaft end yoke and axle companion flange for proper assembly, then disconnect driveshaft at rear axle universal joint. 9. Install inch pound torque wrench on pinion nut and record torque required to maintain rotation of pinion through several turns. 10. Using suitable tools, hold companion flange and remove pinion nut. 11. Clean area around oil seal and place drain pan under seal. 12. Mark relationship of companion flange to pinion shaft for proper assembly, then, using suitable puller, remove companion flange. 13. Using suitable tool, remove pinion oil seal. 14. Mark one differential bearing cap to ensure proper positioning of caps during assembly. Do not interchange left and right bearing caps. 15. Loosen differential bearing cap bolts and bearing caps, noting direction of triangles on bearing caps for proper assembly. 16. Pry differential case, bearing cups and shims out until they are loose in bearing caps, then remove bearing caps and pry differential assembly from carrier. When using pry bar, place a wood block between pry bar and axle housing to protect casting face from damage. 17. Using suitable mallet, drive pinion out of front bearing cone and remove through rear of carrier casting. 18. Using suitable tools, remove pinion rear cone and roller bearing assembly, then, using micrometer, measure and record thickness of shim found under bearing cone. 19. Remove damaged pinion bearing cups from carrier by tapping alternately with brass drift on opposite sides of cups to prevent cups from cocking in casting. Axle Housing, Replace, Ford Integral Carrier 1. Remove four backing plate nuts from each side of axle and wire backing plate aside. 2. Remove vent hose from vent and vent from brake junction block on rear axle housing. 3. Remove brake line from clips on axle housing and remove brake junction block. Do not open brake lines when removing junction box. 4. Support rear axle housing on suitable jack and remove U-bolt nuts and plates. 5. Disconnect lower bolts on shock absorber mounting bracket and remove housing from vehicle. 6. Reverse procedure to install. Torque U-bolt nuts to 75-100 ft. lbs. on 1983 F-100-350 & Bronco; 75-105 ft. lbs. on 1983 E-100-150 and 1984-87 E-250; 75-115 ft. lbs. on 1984-87 models exc. F-250 4 2 chassis cab and E series; 150-180 ft. lbs. on 1983 E-250 and 1983-87 E-350; and 150-210 ft. lbs. on 1983 and 1986-87 F-350 and 1984-87 F-250 4 2 chassis cab. Torque shock absorber lower bolts to 40-60 ft. lbs. on Econoline models, and 40-64 ft. lbs. on all other models. Torque backing brake attaching bolts to 20-40 ft. lbs. on F-100-150 models, and 50-70 ft. lbs. on E-250 & F-250 models with 4050 lb. axle. No gaskets are required on brake backing plate. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Dana/Spicer Integral - Rear Axle Assembly > Page 4713 Differential Axle Housing: Service and Repair Ford Removable Carrier 1. Raise and support vehicle. 2. Remove rear wheels and brake drums. 3. Remove rear wheel bearing retainer plate attaching nuts, then disconnect axle shafts from axle housing. 4. Mark driveshaft end yoke and U-joint flange for assembly reference, then disconnect driveshaft from flange. Mark position of cups to flange and remove driveshaft from transmission extension housing. Install a suitable seal installation tool into housing to prevent leakage. 5. Unfasten brake lines from retaining clips and disconnect vent tube, if equipped, from axle housing. 6. Remove brake backing plate assemblies from axle housing and wire aside. 7. Disconnect rear shock absorbers from lower mounts and position aside. 8. Lower axle slightly to reduce spring tension, then remove spring clips, U-bolt nuts and spring seat caps from each rear spring and lower axle assembly from vehicle. 9. On all models, reverse procedure to install. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Technical Service Bulletins > Customer Interest: > 86198 > Sep > 86 > Rear Locking Differential - Noise On Turns Fluid - Differential: Customer Interest Rear Locking Differential - Noise On Turns Article No. 86-19-8 AXLE - REAR - TRACTION-LOK 7.5" AND 8.8" - NOISE ON TURNS NOISE ON TURNS - REAR AXLE - TRACTION-LOK 7.5" AND 8.8" FORD 1986 MUSTANG, THUNDERBIRD, LTD, FORD LINCOLN-MERCURY 1986 CAPRI, COUGAR, MARQUIS, MERCURY, LINCOLN TOWN CAR, MARK VII, CONTINENTAL LIGHT TRUCK 1986 AEROSTAR, RANGER, BRONCO II, BRONCO, E SERIES, F SERIES Traction-Lok limited slip differentials may exhibit a slip stick noise on turns after extended highway driving. The noise may be caused by the lubricant (friction modifier) breaking down. This condition will not damage the internal parts of the axle. However, to correct, drain and refill the axle with E0AZ-19580-A or equivalent rear axle lubricant. Refer to the appropriate 1986 Shop Manual for fill capacities. After filling, add four ounces of friction modifier, C8AZ-19B546-A or equivalent. PART NUMBER PART NAME CLASS E0AZ-19580-A Rear Axle Lubricant A C8AZ-19B546-A Friction Modifier A OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION: 4036A - Passenger Car TIME: 0.4 Hr. OPERATION: 4036A - Light Truck TIME: 0.5 Hr. DLR. CODING: Basic Part No. 4209 - Code: 53 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid - Differential: > 89816 > Apr > 89 > Drivetrain - Lubricant Usage Fluid - Differential: All Technical Service Bulletins Drivetrain - Lubricant Usage Article No. 89-8-16 ^ DRIVETRAIN - LUBRICATION USAGE ^ TRANSMISSION - MANUAL - LUBRICATION USAGE LIGHT TRUCK: 1980-89 BRONCO, ECONOLINE, F-150, F-250, F-350 1983-89 RANGER 1984-89 BRONCO II 1986-89 AEROSTAR ISSUE: A quick reference manual transmission fluid usage chart and a quick reference drivetrain lubrication usage chart for light trucks has been put together to assist technicians in the event service is required. FIGURE 1 FIGURE 2 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid - Differential: > 89816 > Apr > 89 > Drivetrain - Lubricant Usage > Page 4727 ACTION: Refer to the transmission fluid application chart in Figure 1 for the correct fluid usage. Refer to the drivetrain lubrication application chart in Figure 2 for the correct lubricant usage. PART NUMBER PART NAME CLASS D8DZ-19C547-A Standard Transmission BG Lubricant - 5 gallons C1AZ-19590-BA Long Life Lubricant B (molybdenum disulfide) - 14.5 ounces DOAZ-19584-AA Multi-Purpose Grease - 4 ounce B tube D7AZ-19584-AA Multi-Purpose Grease - 15 B ounce aerosol can XT-2-QDX Transmission Fluid (Mercon) - V quart can (pkg. of 12) C6AZ-19580-E Gear Oil (Dana axle) - 1 gallon AG C8AZ-19B546-A Additive Friction Modifier - 4 AM ounce bottle D7AZ-19590-A Disc Brake Caliper Slide AM Grease - 4 ounce tube E8TZ-19590-A Grease - 14.5 ounces B E1TZ-19590-A Automatic Hublock Grease - 5 B ounce tube E5RY-19C547-A Merkur Synthetic Manual B Transmission Fluid OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 5970 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid - Differential: > 86198 > Sep > 86 > Rear Locking Differential - Noise On Turns Fluid - Differential: All Technical Service Bulletins Rear Locking Differential - Noise On Turns Article No. 86-19-8 AXLE - REAR - TRACTION-LOK 7.5" AND 8.8" - NOISE ON TURNS NOISE ON TURNS - REAR AXLE - TRACTION-LOK 7.5" AND 8.8" FORD 1986 MUSTANG, THUNDERBIRD, LTD, FORD LINCOLN-MERCURY 1986 CAPRI, COUGAR, MARQUIS, MERCURY, LINCOLN TOWN CAR, MARK VII, CONTINENTAL LIGHT TRUCK 1986 AEROSTAR, RANGER, BRONCO II, BRONCO, E SERIES, F SERIES Traction-Lok limited slip differentials may exhibit a slip stick noise on turns after extended highway driving. The noise may be caused by the lubricant (friction modifier) breaking down. This condition will not damage the internal parts of the axle. However, to correct, drain and refill the axle with E0AZ-19580-A or equivalent rear axle lubricant. Refer to the appropriate 1986 Shop Manual for fill capacities. After filling, add four ounces of friction modifier, C8AZ-19B546-A or equivalent. PART NUMBER PART NAME CLASS E0AZ-19580-A Rear Axle Lubricant A C8AZ-19B546-A Friction Modifier A OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION: 4036A - Passenger Car TIME: 0.4 Hr. OPERATION: 4036A - Light Truck TIME: 0.5 Hr. DLR. CODING: Basic Part No. 4209 - Code: 53 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid - Differential: > 89816 > Apr > 89 > Drivetrain - Lubricant Usage Fluid - Differential: All Technical Service Bulletins Drivetrain - Lubricant Usage Article No. 89-8-16 ^ DRIVETRAIN - LUBRICATION USAGE ^ TRANSMISSION - MANUAL - LUBRICATION USAGE LIGHT TRUCK: 1980-89 BRONCO, ECONOLINE, F-150, F-250, F-350 1983-89 RANGER 1984-89 BRONCO II 1986-89 AEROSTAR ISSUE: A quick reference manual transmission fluid usage chart and a quick reference drivetrain lubrication usage chart for light trucks has been put together to assist technicians in the event service is required. FIGURE 1 FIGURE 2 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid - Differential: > 89816 > Apr > 89 > Drivetrain - Lubricant Usage > Page 4737 ACTION: Refer to the transmission fluid application chart in Figure 1 for the correct fluid usage. Refer to the drivetrain lubrication application chart in Figure 2 for the correct lubricant usage. PART NUMBER PART NAME CLASS D8DZ-19C547-A Standard Transmission BG Lubricant - 5 gallons C1AZ-19590-BA Long Life Lubricant B (molybdenum disulfide) - 14.5 ounces DOAZ-19584-AA Multi-Purpose Grease - 4 ounce B tube D7AZ-19584-AA Multi-Purpose Grease - 15 B ounce aerosol can XT-2-QDX Transmission Fluid (Mercon) - V quart can (pkg. of 12) C6AZ-19580-E Gear Oil (Dana axle) - 1 gallon AG C8AZ-19B546-A Additive Friction Modifier - 4 AM ounce bottle D7AZ-19590-A Disc Brake Caliper Slide AM Grease - 4 ounce tube E8TZ-19590-A Grease - 14.5 ounces B E1TZ-19590-A Automatic Hublock Grease - 5 B ounce tube E5RY-19C547-A Merkur Synthetic Manual B Transmission Fluid OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 5970 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Specifications > Capacity Specifications Fluid - Differential: Capacity Specifications TYPE: Standard 90 HP Limited-Slip 90 HP* 8.8" & 10 1/4" has removable cover, 9.0" does not CAPACITY, Refill: Front: Dana 44 3.8 pt (US) LIMITED-SLIP OR TRACTION-LOK IDENTIFICATION: Label on door lock pillar shows letter and number Dana 50 4.0 pt (US) Dana 60 5.8 pt (US) Rear: Ford w/8.8" ring gear* 5.5 pt (US) 10 1/4 ring gear* 6.5 pt (US) Dana 60 & 61 6.0 pt (US) Dana 70 HD 7.4 pt (US) Dana 70 6.5 pt (US) Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Specifications > Capacity Specifications > Page 4740 Fluid - Differential: Fluid Type Specifications BL Self-adjusting Brake Lubricant EC Ethylene Glycol Coolant Mix 50/50 with water to at least -20°F (-29°C) protection EP Extreme Pressure Gear Lubricant Ford Part No. D8DZ-19C547-A FA Automatic Transmission Fluid, Type F GL-5 Gear Oil, API Service GL-5 HBH Hydraulic Brake Fluid, Extra Heavy-Duty HP Hypoid Gear Oil Ford Part No. E0AZ-19580-A HP* Hypoid Gear Oil for Limited-Slip or Traction-Lok Differential LM Lithium Grease, with Polyethylene LS Steering Gear Lubricant MA MERCONAutomatic Transmission Fluid MERCON(R) automatic Transmission Fluid is being replaced by MERCON(R) V as a service fluid, as per TSB 06-14-4. MH Manifold Heat Valve Solvent SG Motor Oil, API Service SG Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Bearing, Differential > Component Information > Testing and Inspection > Bearing Cups Pinion Bearing: Testing and Inspection Bearing Cups Check bearing cups for rings, galling or erratic wear patterns. The bearing cups must be solidly seated. Check by attempting to insert .0015 inch feeler gauge between cups and bottoms of bores. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Bearing, Differential > Component Information > Testing and Inspection > Bearing Cups > Page 4745 Pinion Bearing: Testing and Inspection Companion Flange Be sure that flat machined surfaces and the bearing cup sockets of the flange have not been damaged in removing driveshaft or in removing flange from axle. The edge of the flange that contacts the oil slinger or pinion front bearing must be smooth. Roughness aggravates backlash noises and causes wear on the slinger with a resultant loss in drive pinion bearing preload. The seal surface should be perfectly smooth or leakage will result. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Bearing, Differential > Component Information > Testing and Inspection > Bearing Cups > Page 4746 Pinion Bearing: Testing and Inspection Cone & Roller Assemblies When operated in the cups, the cone and roller assemblies must turn without any roughness. Examine roller ends for wear. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Bearing, Differential > Component Information > Testing and Inspection > Bearing Cups > Page 4747 Pinion Bearing: Testing and Inspection Differential Bearing Adjusters Test fit of bearing adjusters in their threads with bearing caps installed. Ensure that bearing caps are on sides that they were machined to fit. The faces of the adjusters that contact the bearing cups must be smooth and square. Examine threads in carrier if their fit is not proper and replace any adjuster with a damaged face or threads. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Bearing, Differential > Component Information > Testing and Inspection > Bearing Cups > Page 4748 Pinion Bearing: Testing and Inspection Pinion Retainer Inspect visually for damage. Ensure that pinion bearing cups are seated. Ensure that there are no chips or burrs on mounting flange. Clean all lubricant passages. If pinion bearing cups were removed, examine bores in retainer carefully. Any nicks or burrs in these bores must be removed to permit proper seating of cups. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Bearing, Differential > Component Information > Testing and Inspection > Page 4749 Pinion Bearing: Adjustments Fig. 4 Shim replacement for preload adjustment Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Bearing, Differential > Component Information > Testing and Inspection > Page 4750 Fig. 5 Final pinion depth check 1. Install preload shims and slinger, if equipped, onto the pinion. 2. Install bearing cone assembly using suitable tool. 3. Install end yoke, washer and new pinion nut. Torque nut to approximately 250 ft. lbs. on except model 30 axle or 200---220 ft. lbs. on model 30 axle. 4. Rotate pinion using a suitable torque wrench. Rotating torque should be 20---40 inch lbs. To increase preload, remove shims from drive pinion. To decrease preload, add shims to pinion, Fig. 4. 5. Install suitable gauge tube in housing, then the bearing caps and cap attaching bolts, Fig. 5. Torque cap attaching bolts to 80---90 ft. lbs. on except model 30 axle or 35---50 ft. lbs. on model 30 axle. 6. Insert proper final check gauge block on top of pinion face under the gauge tube, Fig. 5. Place thumb on gauge block to ensure block is level. 7. Insert feeler gauge or shims between gauge tube and final check gauge block until slight drag is felt. 8. The reading in step 7 should be .020 inch added to the drive pinion etching, which could be plus (+) or minus ( - ) with a tolerance of .002 inch. If the distance must be increased, remove shims from beneath the inner pinion bearing cup. If the distance must be decreased, add shims beneath the inner pinion bearing cup. 9. With drive pinion at the correct depth, remove the yoke, nut and washer using a suitable tool. 10. Apply suitable lubricant to oil seal, then install drive pinion oil seal using a suitable installer. Ensure seal spring is properly installed after seal installation. 11. Install yoke using suitable tool, then the washer and nut. Torque nut to approximately 250 ft. lbs. on except model 30 axle or 200---220 ft. lbs. on model 30 axle. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Bearing, Differential > Component Information > Service and Repair > Dana/Spicer, Rear Axle Pinion Bearing: Service and Repair Dana/Spicer, Rear Axle Pinion Bearing Cup Installation, DANA/SPICER, REAR AXLE 1. Place inner and outer bearing cups into carrier bore. 2. Install suitable inner bearing cup replacer tool on the inner bearing cup. 3. Install suitable outer bearing cup replacer tool on the outer bearing cup. 4. Install suitable threaded draw bar into the replacer tools, then tighten the draw bar to install cups into carrier bore. Pinion Bearing Preload & Final Depth Check, REAR AXLE Fig. 4 Shim replacement for preload adjustment Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Bearing, Differential > Component Information > Service and Repair > Dana/Spicer, Rear Axle > Page 4753 Fig. 5 Final pinion depth check 1. Install preload shims and slinger, if equipped, onto the pinion. 2. Install bearing cone assembly using suitable tool. 3. Install end yoke, washer and new pinion nut. Torque nut to approximately 250 ft. lbs. on except model 30 axle or 200---220 ft. lbs. on model 30 axle. 4. Rotate pinion using a suitable torque wrench. Rotating torque should be 20---40 inch lbs. To increase preload, remove shims from drive pinion. To decrease preload, add shims to pinion, Fig. 4. 5. Install suitable gauge tube in housing, then the bearing caps and cap attaching bolts, Fig. 5. Torque cap attaching bolts to 80---90 ft. lbs. on except model 30 axle or 35---50 ft. lbs. on model 30 axle. 6. Insert proper final check gauge block on top of pinion face under the gauge tube, Fig. 5. Place thumb on gauge block to ensure block is level. 7. Insert feeler gauge or shims between gauge tube and final check gauge block until slight drag is felt. 8. The reading in step 7 should be .020 inch added to the drive pinion etching, which could be plus (+) or minus ( - ) with a tolerance of .002 inch. If the distance must be increased, remove shims from beneath the inner pinion bearing cup. If the distance must be decreased, add shims beneath the inner pinion bearing cup. 9. With drive pinion at the correct depth, remove the yoke, nut and washer using a suitable tool. 10. Apply suitable lubricant to oil seal, then install drive pinion oil seal using a suitable installer. Ensure seal spring is properly installed after seal installation. 11. Install yoke using suitable tool, then the washer and nut. Torque nut to approximately 250 ft. lbs. on except model 30 axle or 200---220 ft. lbs. on model 30 axle. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Bearing, Differential > Component Information > Service and Repair > Dana/Spicer, Rear Axle > Page 4754 Pinion Bearing: Service and Repair Ford Removable Backlash & Differential Bearing Preload Adjustment 1. Remove adjusting nut locks and loosen differential bearing cap bolts, then torque cap bolts to approximately 20 ft. lbs. Left adjusting nut is on ring gear side of carrier and right adjusting nut is on pinion side. 2. Loosen right nut until it is away from cup and tighten left nut until ring gear is just forced into position with zero backlash, then rotate pinion several revolutions to ensure that no binding is evident. 3. Check right nut to ensure that it is still loose, then install dial indicator. 4. Tighten right nut until it just contacts bearing cup, then set dial indicator to zero and apply pressure to bearings by tightening right nut until indicator reads .008---.012 inch. 5. Turn pinion gear several times in each direction to seat bearings in cups and ensure that no binding is evident, then torque bearing caps to 70---80 ft. lbs. 6. Measure backlash on several teeth around ring gear. 7. If backlash varies by more than .004 inch between any two teeth, loosen one adjusting nut and tighten opposite nut an equal amount to move ring gear away from or toward pinion. Tightening left nut moves ring gear into pinion to decrease backlash while tightening right nut moves ring gear away. When moving adjusting nuts, final movement should always be made in a tightening direction. Assuming left nut had to be loosened one notch, loosen nut two notches, then tighten one notch. 8. Ensure that case spread remains within specifications as previously described. 9. Perform teeth pattern check as described under ``General Axle Service.'' If backlash is correct and gross pattern error results, recheck pinion shim selection. Drive Pinion & Bearing Retainer, FORD, REMOVABLE CARRIER, Fig. 7 Installing Pinion And Retainer Assembly Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Bearing, Differential > Component Information > Service and Repair > Dana/Spicer, Rear Axle > Page 4755 Fig. 8 Installing Companion Flange Fig. 9 Checking Pinion Bearing Preload A new ring gear and drive pinion should always be installed as a matched set. Ensure that identifying numbers on ring gear and head of drive pinion are identical. 1. Using suitable tool, install pinion rear bearing cone on pinion shaft, then position new spacer on pinion shaft. 2. Place bearing retainer on drive pinion shaft and install front bearing cone and roller, then, using tool T57L-4621-B or equivalent, press bearing cone and roller into position, being careful not to crush collapsible spacer. 3. Lubricate O-ring with suitable lubricant, install into groove in pinion retainer, and snap into place. Then lubricate front and rear pinion bearings. 4. Position selected shim on carrier housing and install pinion and retainer assembly, being careful not to pinch O-ring, Fig. 7. 5. Install pinion retainer attaching bolts, torquing to 30---40 ft. lbs., then install oil slinger, if equipped. 6. Using suitable tool, install new pinion oil seal in bearing retainer. 7. Install companion flange, Fig. 8. 8. Apply small amount of suitable lubricant to flange side of new pinion nut and start nut on drive pinion shaft. 9. Hold flange with suitable tool and tighten flange nut. 10. Check pinion bearing preload, Fig. 9. Correct preload is obtained when torque required to rotate pinion in retainer is 8---14 inch lbs. for original bearing or 16---29 inch lbs. for new bearing. If torque required to rotate pinion is less than specified, tighten pinion shaft nut a little at a time until proper preload is obtained. Do not over tighten nut. If excessive preload is obtained as a result of over tightening, replace collapsible bearing spacer. Do not back off pinion shaft nut to establish pinion bearing preload. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Bearing, Differential > Component Information > Service and Repair > Dana/Spicer, Rear Axle > Page 4756 Pinion Bearing Cups, Replace, FORD REMOVABLE CARRIER Do not remove drive pinion bearing cups from the retainer unless cups are worn or damaged. 1. Using suitable puller, remove bearing cups. 2. Using tool T71P-4616-A or equivalent, install new bearing cups. 3. Check seating of cups by attempting to insert a .0015 inch feeler gauge between cup and bottom of bore. Cone and roller assemblies should be replaced whenever cups are replaced. Selecting Correct Pinion Shim, FORD REMOVABLE CARRIER Fig. 5 Removable carrier 9 inch ring gear axle pinion depth tool gauge Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Bearing, Differential > Component Information > Service and Repair > Dana/Spicer, Rear Axle > Page 4757 Fig. 6 Using pinion depth gauge tool When the ring gear and drive pinion or pinion bearings are replaced, the correct pinion shim thickness must be determined using tool T79P-4020-A or equivalent. 1. Select proper rear pinion bearing aligning adapter and gauge disc and slide these adapters over screw or threaded shaft, Fig. 5. 2. Install gauge block on threaded shaft and tighten securely, Fig. 6 (1). 3. Place assembly and rear drive pinion bearing into pinion bearing retainer assembly, then install front pinion bearing and screw handle onto threaded shaft, tapered end into front pinion bearing, Fig. 6 (1) and (2). Flat end of handle has 3/8 inch hole cut in it so that an inch pound torque wrench may be used to obtain proper pinion bearing preload. 4. Install pinion bearing retainer assembly into carrier, less shim, torquing attaching bolts to 30---40 ft. lbs. 5. Rotate gauge block so that it rests against pilot boss, Fig. 6 (3). 6. Using feeler gauge, measure distance between gauge block and gauge tube, Fig. 6 (4). Insert blade directly along gauge block top to ensure a correct reading. Fit should be a slight drag-type feeling. 7. Select proper shim according to feeler gauge reading, Fig. 6. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Bearing, Differential > Component Information > Service and Repair > Dana/Spicer, Rear Axle > Page 4758 Pinion Bearing: Service and Repair Ford, Removable Carrier, Disassembly Fig. 3 Removing Pinion Shaft Nut Fig. 4 Removing Companion Flange 1. Remove drive pinion shaft nut, Fig. 3. 2. Remove companion flange from drive pinion shaft, Fig. 4. 3. Using suitable puller, remove pinion seal. 4. Remove the pinion, bearing, and retainer assembly from carrier housing. Extreme care must be taken not to damage mounting surfaces of retainer and carrier. 5. Place protective sleeve on pinion pilot bearing surface and press drive pinion shaft out of pinion retainer. 6. Using tool T71P-4621-B or equivalent, press pinion shaft out of pinion rear bearing cone. 7. Clean and inspect all parts as described in ``General Axle Service.'' Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Bearing, Differential > Component Information > Service and Repair > Dana/Spicer, Rear Axle > Page 4759 Pinion Bearing: Service and Repair Pinion Bearing Cup Installation 1. Place inner and outer bearing cups into carrier bore. 2. Install suitable inner bearing cup replacer tool on the inner bearing cup. 3. Install suitable outer bearing cup replacer tool on the outer bearing cup. 4. Install suitable threaded draw bar into the replacer tools, then tighten the draw bar to install cups into carrier bore. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Testing and Inspection Pinion Gear: Testing and Inspection Examine drive pinion and ring gear teeth for scoring or signs of excessive wear. Worn gears cannot be rebuilt to correct a noisy condition. Gear scoring and flaking are the result of excessive shock loading or the use of improper lubricant. Scored gears cannot be reused. Examine teeth and thrust surfaces of differential gears. Wear on hub of differential side gears may cause a chucking noise known as chuckle, when the vehicle is operated at low speeds. Wear of splines, thrust surfaces or thrust washers may contribute to excessive drive line backlash. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Adjustments > Depth Gauge Check Pinion Gear: Adjustments Depth Gauge Check If any of the gauge surfaces become nicked, the high spots should be removed using an oil stone. 1. Install a new rear pinion bearing over a suitable aligning adapter, then position into the pinion bearing retainer assembly. 2. Place front of pinion bearing into the bearing cup, then assemble the handle onto the screw and hand tighten. The square drive in the handle of the tool is to be used for obtaining the proper pinion bearing preload. Set preload to 20---40 inch lbs. 3. Center suitable gauge tube into the differential bearing bore, then install the differential bearing caps. 4. Using a feeler gauge tool or shims, select the thickest shim that will enter between the gauge tube and gauge block. Insert feeler gauge directly along the gauge block to ensure a correct reading. If the service pinion gear is marked with a plus (+) reading, this amount should be subtracted from the thickness dimension obtained in step 4. If the service pinion gear is marked with a minus ( - ) reading, this amount should be added to the thickness dimension obtained in step 4. 5. Remove inner pinion bearing cup and install the correct number of shims in the carrier bore. 6. Install bearing cup and oil slinger, if equipped, on the pinion, then press on bearing using a suitable tool. If a baffle or slinger is used, replace with a new one during assembly. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Adjustments > Depth Gauge Check > Page 4765 Pinion Gear: Adjustments Drive Pinion Depth of Mesh Setting Fig. 3 Shim setting chart Ring gears and pinions are supplied in matched sets only. Matched numbers on both the pinion and ring gear are etched for verification. On the face of each pinion there is etched either a plus or a minus number, or ``0,'' which indicates the best running position for each particular gear set. This dimension is controlled by shimming behind the inner pinion bearing cup. A pinion etched with a +3 would require .003 inch less shims that a pinion etched ``0.'' A pinion etched - 3 would require .003 inch more shims than a pinion etched ``0.'' If the etched figure is ``0'' the shim pack will remain the same. Refer to chart, Fig. 3. Shims are available in thicknesses of .003 inch, .005 inch, .010 inch and .030 inch. If old ring and pinion set is to be reused, measure the old shim pack and build a new shim pack to the same dimension. If a baffle is used in the axle assembly, it is considered a part of the shim pack. Measure each shim separately with a micrometer and add together to get the total shim pack thickness from the original build up. If a new gear set is being used, notice the (+) or ( - ) etching on both the new and old pinion and adjust thickness of new shim pack to compensate for the difference of these two figures. For example, if the old pinion reads +2 and the new pinion is - 2, add .004 inch shims to the original shim pack. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Adjustments > Depth Gauge Check > Page 4766 Pinion Gear: Adjustments Pinion Bearing Preload & Final Depth Check Fig. 4 Shim replacement for preload adjustment Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Adjustments > Depth Gauge Check > Page 4767 Fig. 5 Final pinion depth check 1. Install preload shims and slinger, if equipped, onto the pinion. 2. Install bearing cone assembly using suitable tool. 3. Install end yoke, washer and new pinion nut. Torque nut to approximately 250 ft. lbs. on except model 30 axle or 200---220 ft. lbs. on model 30 axle. 4. Rotate pinion using a suitable torque wrench. Rotating torque should be 20---40 inch lbs. To increase preload, remove shims from drive pinion. To decrease preload, add shims to pinion, Fig. 4. 5. Install suitable gauge tube in housing, then the bearing caps and cap attaching bolts, Fig. 5. Torque cap attaching bolts to 80---90 ft. lbs. on except model 30 axle or 35---50 ft. lbs. on model 30 axle. 6. Insert proper final check gauge block on top of pinion face under the gauge tube, Fig. 5. Place thumb on gauge block to ensure block is level. 7. Insert feeler gauge or shims between gauge tube and final check gauge block until slight drag is felt. 8. The reading in step 7 should be .020 inch added to the drive pinion etching, which could be plus (+) or minus ( - ) with a tolerance of .002 inch. If the distance must be increased, remove shims from beneath the inner pinion bearing cup. If the distance must be decreased, add shims beneath the inner pinion bearing cup. 9. With drive pinion at the correct depth, remove the yoke, nut and washer using a suitable tool. 10. Apply suitable lubricant to oil seal, then install drive pinion oil seal using a suitable installer. Ensure seal spring is properly installed after seal installation. 11. Install yoke using suitable tool, then the washer and nut. Torque nut to approximately 250 ft. lbs. on except model 30 axle or 200---220 ft. lbs. on model 30 axle. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Dana/Spicer, Rear Axle Pinion Gear: Service and Repair Dana/Spicer, Rear Axle Depth Gauge Check, Dana/Spicer, Rear Axle If any of the gauge surfaces become nicked, the high spots should be removed using an oil stone. 1. Install a new rear pinion bearing over a suitable aligning adapter, then position into the pinion bearing retainer assembly. 2. Place front of pinion bearing into the bearing cup, then assemble the handle onto the screw and hand tighten. The square drive in the handle of the tool is to be used for obtaining the proper pinion bearing preload. Set preload to 20---40 inch lbs. 3. Center suitable gauge tube into the differential bearing bore, then install the differential bearing caps. 4. Using a feeler gauge tool or shims, select the thickest shim that will enter between the gauge tube and gauge block. Insert feeler gauge directly along the gauge block to ensure a correct reading. If the service pinion gear is marked with a plus (+) reading, this amount should be subtracted from the thickness dimension obtained in step 4. If the service pinion gear is marked with a minus ( - ) reading, this amount should be added to the thickness dimension obtained in step 4. 5. Remove inner pinion bearing cup and install the correct number of shims in the carrier bore. 6. Install bearing cup and oil slinger, if equipped, on the pinion, then press on bearing using a suitable tool. If a baffle or slinger is used, replace with a new one during assembly. Drive Pinion Depth of Mesh Setting, Dana/Spicer, Rear Axle Fig. 3 Shim setting chart Ring gears and pinions are supplied in matched sets only. Matched numbers on both the pinion and ring gear are etched for verification. On the face of each pinion there is etched either a plus or a minus number, or ``0,'' which indicates the best running position for each particular gear set. This dimension is controlled by shimming behind the inner pinion bearing cup. A pinion etched with a +3 would require .003 inch less shims that a pinion etched ``0.'' A pinion etched - 3 would require .003 inch more shims than a pinion etched ``0.'' If the etched figure is ``0'' the shim pack will remain the same. Refer to chart, Fig. 3. Shims are available in thicknesses of .003 inch, .005 inch, .010 inch and .030 inch. If old ring and pinion set is to be reused, measure the old shim pack and build a new shim pack to the same dimension. If a baffle is used in the axle assembly, it is considered a part of the shim pack. Measure each shim separately with a micrometer and add together to get the total shim pack thickness from the original build up. If a new gear set is being used, notice the (+) or ( - ) etching on both the new and old pinion and adjust thickness of new shim pack to compensate for the difference of these two figures. For example, if the old pinion reads +2 and the new pinion is - 2, add .004 inch shims to the original shim pack. Pinion Bearing Preload & Final Depth Check, Rear Axle Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Dana/Spicer, Rear Axle > Page 4770 Fig. 4 Shim replacement for preload adjustment Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Dana/Spicer, Rear Axle > Page 4771 Fig. 5 Final pinion depth check 1. Install preload shims and slinger, if equipped, onto the pinion. 2. Install bearing cone assembly using suitable tool. 3. Install end yoke, washer and new pinion nut. Torque nut to approximately 250 ft. lbs. on except model 30 axle or 200---220 ft. lbs. on model 30 axle. 4. Rotate pinion using a suitable torque wrench. Rotating torque should be 20---40 inch lbs. To increase preload, remove shims from drive pinion. To decrease preload, add shims to pinion, Fig. 4. 5. Install suitable gauge tube in housing, then the bearing caps and cap attaching bolts, Fig. 5. Torque cap attaching bolts to 80---90 ft. lbs. on except model 30 axle or 35---50 ft. lbs. on model 30 axle. 6. Insert proper final check gauge block on top of pinion face under the gauge tube, Fig. 5. Place thumb on gauge block to ensure block is level. 7. Insert feeler gauge or shims between gauge tube and final check gauge block until slight drag is felt. 8. The reading in step 7 should be .020 inch added to the drive pinion etching, which could be plus (+) or minus ( - ) with a tolerance of .002 inch. If the distance must be increased, remove shims from beneath the inner pinion bearing cup. If the distance must be decreased, add shims beneath the inner pinion bearing cup. 9. With drive pinion at the correct depth, remove the yoke, nut and washer using a suitable tool. 10. Apply suitable lubricant to oil seal, then install drive pinion oil seal using a suitable installer. Ensure seal spring is properly installed after seal installation. 11. Install yoke using suitable tool, then the washer and nut. Torque nut to approximately 250 ft. lbs. on except model 30 axle or 200---220 ft. lbs. on model 30 axle. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Dana/Spicer, Rear Axle > Page 4772 Pinion Gear: Service and Repair Ford Drive Axle W/ Removable Carrier Backlash & Differential Bearing Preload Adjustment 1. Remove adjusting nut locks and loosen differential bearing cap bolts, then torque cap bolts to approximately 20 ft. lbs. Left adjusting nut is on ring gear side of carrier and right adjusting nut is on pinion side. 2. Loosen right nut until it is away from cup and tighten left nut until ring gear is just forced into position with zero backlash, then rotate pinion several revolutions to ensure that no binding is evident. 3. Check right nut to ensure that it is still loose, then install dial indicator. 4. Tighten right nut until it just contacts bearing cup, then set dial indicator to zero and apply pressure to bearings by tightening right nut until indicator reads .008---.012 inch. 5. Turn pinion gear several times in each direction to seat bearings in cups and ensure that no binding is evident, then torque bearing caps to 70---80 ft. lbs. 6. Measure backlash on several teeth around ring gear. 7. If backlash varies by more than .004 inch between any two teeth, loosen one adjusting nut and tighten opposite nut an equal amount to move ring gear away from or toward pinion. Tightening left nut moves ring gear into pinion to decrease backlash while tightening right nut moves ring gear away. When moving adjusting nuts, final movement should always be made in a tightening direction. Assuming left nut had to be loosened one notch, loosen nut two notches, then tighten one notch. 8. Ensure that case spread remains within specifications as previously described. 9. Perform teeth pattern check as described under ``General Axle Service.'' If backlash is correct and gross pattern error results, recheck pinion shim selection. Drive Pinion & Bearing Retainer, Disassembly Fig. 3 Removing Pinion Shaft Nut Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Dana/Spicer, Rear Axle > Page 4773 Fig. 4 Removing Companion Flange 1. Remove drive pinion shaft nut, Fig. 3. 2. Remove companion flange from drive pinion shaft, Fig. 4. 3. Using suitable puller, remove pinion seal. 4. Remove the pinion, bearing, and retainer assembly from carrier housing. Extreme care must be taken not to damage mounting surfaces of retainer and carrier. 5. Place protective sleeve on pinion pilot bearing surface and press drive pinion shaft out of pinion retainer. 6. Using tool T71P-4621-B or equivalent, press pinion shaft out of pinion rear bearing cone. 7. Clean and inspect all parts as described in ``General Axle Service.'' Drive Pinion & Bearing Retainer, Ford, Removable Carrier, Fig. 7 Installing Pinion And Retainer Assembly Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Dana/Spicer, Rear Axle > Page 4774 Fig. 8 Installing Companion Flange Fig. 9 Checking Pinion Bearing Preload A new ring gear and drive pinion should always be installed as a matched set. Ensure that identifying numbers on ring gear and head of drive pinion are identical. 1. Using suitable tool, install pinion rear bearing cone on pinion shaft, then position new spacer on pinion shaft. 2. Place bearing retainer on drive pinion shaft and install front bearing cone and roller, then, using tool T57L-4621-B or equivalent, press bearing cone and roller into position, being careful not to crush collapsible spacer. 3. Lubricate O-ring with suitable lubricant, install into groove in pinion retainer, and snap into place. Then lubricate front and rear pinion bearings. 4. Position selected shim on carrier housing and install pinion and retainer assembly, being careful not to pinch O-ring, Fig. 7. 5. Install pinion retainer attaching bolts, torquing to 30---40 ft. lbs., then install oil slinger, if equipped. 6. Using suitable tool, install new pinion oil seal in bearing retainer. 7. Install companion flange, Fig. 8. 8. Apply small amount of suitable lubricant to flange side of new pinion nut and start nut on drive pinion shaft. 9. Hold flange with suitable tool and tighten flange nut. 10. Check pinion bearing preload, Fig. 9. Correct preload is obtained when torque required to rotate pinion in retainer is 8---14 inch lbs. for original bearing or 16---29 inch lbs. for new bearing. If torque required to rotate pinion is less than specified, tighten pinion shaft nut a little at a time until proper preload is obtained. Do not over tighten nut. If excessive preload is obtained as a result of over tightening, replace collapsible bearing spacer. Do not back off pinion shaft nut to establish pinion bearing preload. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Dana/Spicer, Rear Axle > Page 4775 Selecting Correct Pinion Shim, Ford Removable Carrier Fig. 5 Removable carrier 9 inch ring gear axle pinion depth tool gauge Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Dana/Spicer, Rear Axle > Page 4776 Fig. 6 Using pinion depth gauge tool When the ring gear and drive pinion or pinion bearings are replaced, the correct pinion shim thickness must be determined using tool T79P-4020-A or equivalent. 1. Select proper rear pinion bearing aligning adapter and gauge disc and slide these adapters over screw or threaded shaft, Fig. 5. 2. Install gauge block on threaded shaft and tighten securely, Fig. 6 (1). 3. Place assembly and rear drive pinion bearing into pinion bearing retainer assembly, then install front pinion bearing and screw handle onto threaded shaft, tapered end into front pinion bearing, Fig. 6 (1) and (2). Flat end of handle has 3/8 inch hole cut in it so that an inch pound torque wrench may be used to obtain proper pinion bearing preload. 4. Install pinion bearing retainer assembly into carrier, less shim, torquing attaching bolts to 30---40 ft. lbs. 5. Rotate gauge block so that it rests against pilot boss, Fig. 6 (3). 6. Using feeler gauge, measure distance between gauge block and gauge tube, Fig. 6 (4). Insert blade directly along gauge block top to ensure a correct reading. Fit should be a slight drag-type feeling. 7. Select proper shim according to feeler gauge reading, Fig. 6. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component Information > Testing and Inspection > Gears Ring Gear: Testing and Inspection Gears Examine drive pinion and ring gear teeth for scoring or signs of excessive wear. Worn gears cannot be rebuilt to correct a noisy condition. Gear scoring and flaking are the result of excessive shock loading or the use of improper lubricant. Scored gears cannot be reused. Examine teeth and thrust surfaces of differential gears. Wear on hub of differential side gears may cause a chucking noise known as chuckle, when the vehicle is operated at low speeds. Wear of splines, thrust surfaces or thrust washers may contribute to excessive drive line backlash. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component Information > Testing and Inspection > Gears > Page 4781 Ring Gear: Testing and Inspection Runout 1987 models equipped with anti-lock brakes incorporate a multi-tooth exciter ring which is pressed on the differential case located behind the ring gear assembly. Do not remove exciter ring to measure ring gear runout. A space is provided between the exciter ring and ring gear to measure ring gear runout. If ring gear runout during disassembly exceeded specifications, the condition may be caused by a warped gear, or distorted or damaged case or foreign matter trapped between differential case halves or under ring gears. To determine cause of excessive runout, assemble differential case without ring gear, then check as described below. Install case in differential carrier without ring gear attached. Install bearing caps and adjuster nuts and tighten cap bolts to specifications. Tighten adjuster nuts to center differential side bearing. Mount a dial indicator and check runout of case flange and ring gear pilot. If runout at either point is excessive, install a new differential case. If runout is within specification, the ring gear is out of specification. When performing this check on a locking differential case the four compression springs within the case should be temporarily removed. This will prevent a false runout reading due to distortion caused by the springs forcing the case apart. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component Information > Adjustments > Assembly of Differential Into Housing Ring Gear: Adjustments Assembly of Differential Into Housing Ring Gear & Pinion Backlash 1. Position differential assembly, with pinion installed, into housing. Ensure master bearings are still assembled in case. 2. Install dial indicator on carrier housing in same location as when spreading case. 3. Force ring gear into mesh with pinion, then set dial indicator to ``0'' while maintaining force on differential case. 4. Force ring gear away from pinion gear and note dial reading. Repeat sequence until same indicator reading is obtained. This measurement indicates amount of shims needed between differential case and bearings on the ring gear side. 5. Remove dial indicator and differential case from carrier, then the master bearings from differential case. 6. Place shims determined in step 4 on ring gear hub of differential case. 7. Install bearing cone on ring gear side of differential case, then drive bearing into place. 8. To determine thickness of shims required on hub of drive pinion side of differential case, subtract thickness of shims installed in step 6 from total differential case endplay as measured in ``Differential Case Assembly'' procedure. To this figure, add .015 inch. 9. Place shims determined in step 8 on hub of drive pinion side of differential case. 10. Install bearing cone on hub of drive pinion side of differential case. 11. Position suitable step plate on ring gear side bearing to protect bearing. 12. Place bearing on drive pinion side hub and drive it into position. 13. Install spreader tool and dial indicator as previously described. Do not spread case more than .015 inch. 14. Assemble differential bearing cups to bearing cones, then install differential assembly into carrier. 15. Tap differential assembly into position in carrier using a soft-faced hammer, then remove spreader tool from case. 16. Install bearing caps in proper position, then torque cap screws to 80---90 ft. lbs. on except model 30 axle or 35---50 ft. lbs on model 30 axle. 17. Measure ring gear and pinion backlash at three equidistant points using a dial indicator. Backlash must measure .004---.009 inch on except model 30 axle or .005---.009 inch on model 30 axle and cannot vary more than .003 inch on except model 30 axle or .002 inch on model 30 axle between points checked. Backlash may be brought within specifications by switching shims from one side of differential case to the other. Move ring gear closer to pinion to correct high backlash, or further away from pinion to correct low backlash. 18. On except model 30 axle having a cover plate without a flat mounting surface, install cover plate, using a new gasket, and torque attaching bolts alternately and evenly to 30---40 ft. lbs. On model 30 axle, torque cover attaching bolts to 15---25 ft. lbs. 19. On units having a cover plate with a flat mounting surface, install cover as follows: a. Clean flat surface of cover plate and carrier mating surface. b. Apply suitable sealant to cover plate surface, ensuring bead of sealant is laid on inside of cover screw holes. c. Install two attaching bolts into cover at 2 o'clock and 8 o'clock positions. d. Position cover on carrier, then install remaining attaching bolts. e. Torque all attaching bolts alternately and evenly to 30---40 ft. lbs. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component Information > Adjustments > Assembly of Differential Into Housing > Page 4784 Ring Gear: Adjustments Backlash & Differential Bearing Preload Adjustment FORD REMOVABLE CARRIER 1. Remove adjusting nut locks and loosen differential bearing cap bolts, then torque cap bolts to approximately 20 ft. lbs. Left adjusting nut is on ring gear side of carrier and right adjusting nut is on pinion side. 2. Loosen right nut until it is away from cup and tighten left nut until ring gear is just forced into position with zero backlash, then rotate pinion several revolutions to ensure that no binding is evident. 3. Check right nut to ensure that it is still loose, then install dial indicator. 4. Tighten right nut until it just contacts bearing cup, then set dial indicator to zero and apply pressure to bearings by tightening right nut until indicator reads .008---.012 inch. 5. Turn pinion gear several times in each direction to seat bearings in cups and ensure that no binding is evident, then torque bearing caps to 70---80 ft. lbs. 6. Measure backlash on several teeth around ring gear. 7. If backlash varies by more than .004 inch between any two teeth, loosen one adjusting nut and tighten opposite nut an equal amount to move ring gear away from or toward pinion. Tightening left nut moves ring gear into pinion to decrease backlash while tightening right nut moves ring gear away. When moving adjusting nuts, final movement should always be made in a tightening direction. Assuming left nut had to be loosened one notch, loosen nut two notches, then tighten one notch. 8. Ensure that case spread remains within specifications as previously described. 9. Perform teeth pattern check as described under ``General Axle Service.'' If backlash is correct and gross pattern error results, recheck pinion shim selection. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Bearing > Component Information > Service and Repair > Dana/Spicer Integral Housing Type Axle Bearing: Service and Repair Dana/Spicer Integral Housing Type Full-Floating Axle 1. Set parking brake and loosen axle shaft bolts. 2. Raise and support rear of vehicle so that axle is parallel with floor. 3. Remove axle shaft bolts. 4. Remove axle shaft and discard gasket. 5. Pry out locking wedge with screwdriver. 6. Raise wheel until weight is removed from wheel bearing. 7. Remove wheel bearing adjustment nut. 8. Remove outer bearing cone and pull wheel assembly from axle. 9. Drive inner bearing cone and seal out of wheel hub with brass drift. 10. Inspect bearings and races and replace if worn or damaged. Drive races from wheel hub with brass drift. 11. Lubricate bearing cone and roller assemblies and place inner assemblies into wheel hub. Install new hub inner seal. 12. Wrap spindle threads with tape, then slide wheel assembly onto axle housing spindle and remove tape. 13. Install outer wheel bearing and start adjuster nut. Lower wheel to ground. 14. While rotating wheel, torque adjusting nut to 120-140 ft. lbs. Back off the nut to obtain 0.001---0.010 inch endplay (1/8-3/8 turn). If nut or locking wedge are damaged or do not allow for proper endplay they should be replaced. 15. Position locking wedge in key way slot, making sure it is not bottomed against the shoulder of adjusting nut. 16. Install axle shaft and new flange gasket, then install retaining bolts and torque locking bolts to 40---50 ft. lbs. 17. Adjust brakes. 18. Remove supports and lower vehicle. Semi-Floating Axle 1. Raise and support vehicle. 2. Remove wheel and brake drum. 3. Remove cover plate and discard gasket. 4. Remove differential pinion shaft lock screw and the shaft. 5. Remove C-clip from button end of shaft by pushing inward on other end. 6. Pull shaft from axle tube. Do not rotate differential side gears. 7. Remove and discard oil seal from axle tube. 8. Pull bearing from axle tube. 9. Lubricate new bearing and install in axle tube. 10. Lubricate and install new oil seal. 11. Insert shaft into axle tube, making sure splines engage side gears, then install C-clip and pull shaft outward until the clip locks. 12. Install pinion mate shaft, aligning lock pin holes, and pinion gear side washers. 13. Install new lock screw and torque to 8 ft. lbs. on 1980---81 models, or 20---25 ft. lbs. on 1982---87 models. 14. Install cover plate and gasket. Torque bolts to 30---40 ft. lbs. 15. Install wheel and drum assembly. 16. Remove supports and lower vehicle. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Bearing > Component Information > Service and Repair > Dana/Spicer Integral Housing Type > Page 4790 Axle Bearing: Service and Repair Ford Integral Carrier Type Axle 1. Remove axle shaft as outlined in ``Axle Shaft, Replace''. 2. Insert tool T83T-1226-A for models with 8.8 inch ring gear, or tool T85T-1225-AH for models with 10.25 inch ring gear, and tool T50T-100-A into axle bore so tangs on tool engage bearing outer race. Remove bearing and seal as an assembly. 3. Install new bearing using tool T83T-1225-B on models with 8.8 inch ring gear, or tool T80T-4000-W on models with 10.25 inch ring gear, and new seal using tool T83T-1175-A on models with 8.8 inch ring gear, or tool T80T-4000-Y on models with 10.25 inch ring gear. Pack lips of seal with C1AZ-19590-B or equivalent. 4. Reinstall axle. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Bearing > Component Information > Service and Repair > Dana/Spicer Integral Housing Type > Page 4791 Axle Bearing: Service and Repair Ford Removable Carrier Type Removal, Units w/Ball Bearing 1. Remove wheel assembly. 2. Remove brake drum from flange. 3. Working through hole provided in axle shaft flange, remove nuts that secure wheel bearing retainer. 4. Pull axle shaft out of housing. If bearing is a tight fit in axle housing, use a slide hammer type puller. 5. Remove brake backing plate and secure to frame rail. 6. If the axle shaft bearing is to be replaced, loosen the inner retainer by nicking it deeply with a chisel in several places. The bearing will then slide off easily. 7. Press bearing from axle shaft. 8. Inspect machined surface of axle shaft and housing for rough spots that would affect sealing action of the oil seal. Carefully remove any burrs or rough spots. Installation 1. Press new bearing on shaft until it seats firmly against shoulder on shaft. 2. Press inner bearing retainer on shaft until it seats firmly against bearing. 3. If oil seal is to be replaced, use a hook-type tool to pull it out of housing. Wipe a small amount of oil resistant sealer on outer edge of seal before it is installed. Removal, Units W/Roller Bearing 1. Remove wheel assembly. 2. Remove brake drum from flange. 3. Working through hole provided in axle flange, remove nuts securing wheel bearing retainer. 4. Pull axle shaft carefully from housing to prevent damage to outer seal rubber. Use a slide hammer type puller to remove tapered bearing cup from housing. Remove brake backing plate and secure to frame rail. 5. If the axle shaft bearing or seal is to be replaced, split the inner bearing retainer. 6. Press bearing from axle shaft. 7. Inspect machined surface of axle shaft and housing for rough spots that would affect sealing action of the oil seal. Carefully remove any burrs or rough spots. 8. Install outer retainer plate on axle shaft. Press lubricated seal and bearing onto shaft until firmly seated. Oil seal for rear drum brake equipped vehicles is different than that used on vehicles with rear disc brakes. Seals used with drum brakes have a gray metal colored outer rim, while seals used with disc brakes have a black or orange color. 9. Press new bearing retainer onto shaft until seated. Installation 1. On 1980---84 models, place a new gasket on each side of brake carrier plate, and slide axle shaft into housing. On models with roller bearing, ensure outer seal is fully seated on bearing. 2. Start splines into differential side gear and push shaft in until bearing bottoms in housing. 3. Torque bearing retainer nuts to 20---40 ft. lbs. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Dana/Spicer Integral Housing Type Axle Shaft: Service and Repair Dana/Spicer Integral Housing Type Full-Floating Axle 1. Set parking brake and loosen axle shaft bolts. 2. Raise and support rear of vehicle so that axle is parallel with floor. 3. Remove axle shaft bolts. 4. Remove axle shaft and discard gasket. 5. Pry out locking wedge with screwdriver. 6. Raise wheel until weight is removed from wheel bearing. 7. Remove wheel bearing adjustment nut. 8. Remove outer bearing cone and pull wheel assembly from axle. 9. Drive inner bearing cone and seal out of wheel hub with brass drift. 10. Inspect bearings and races and replace if worn or damaged. Drive races from wheel hub with brass drift. 11. Lubricate bearing cone and roller assemblies and place inner assemblies into wheel hub. Install new hub inner seal. 12. Wrap spindle threads with tape, then slide wheel assembly onto axle housing spindle and remove tape. 13. Install outer wheel bearing and start adjuster nut. Lower wheel to ground. 14. While rotating wheel, torque adjusting nut to 120-140 ft. lbs. Back off the nut to obtain 0.001---0.010 inch endplay (1/8-3/8 turn). If nut or locking wedge are damaged or do not allow for proper endplay they should be replaced. 15. Position locking wedge in key way slot, making sure it is not bottomed against the shoulder of adjusting nut. 16. Install axle shaft and new flange gasket, then install retaining bolts and torque locking bolts to 40---50 ft. lbs. 17. Adjust brakes. 18. Remove supports and lower vehicle. Semi-Floating Axle 1. Raise and support vehicle. 2. Remove wheel and brake drum. 3. Remove cover plate and discard gasket. 4. Remove differential pinion shaft lock screw and the shaft. 5. Remove C-clip from button end of shaft by pushing inward on other end. 6. Pull shaft from axle tube. Do not rotate differential side gears. 7. Remove and discard oil seal from axle tube. 8. Pull bearing from axle tube. 9. Lubricate new bearing and install in axle tube. 10. Lubricate and install new oil seal. 11. Insert shaft into axle tube, making sure splines engage side gears, then install C-clip and pull shaft outward until the clip locks. 12. Install pinion mate shaft, aligning lock pin holes, and pinion gear side washers. 13. Install new lock screw and torque to 8 ft. lbs. on 1980---81 models, or 20---25 ft. lbs. on 1982---87 models. 14. Install cover plate and gasket. Torque bolts to 30---40 ft. lbs. 15. Install wheel and drum assembly. 16. Remove supports and lower vehicle. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Dana/Spicer Integral Housing Type > Page 4797 Axle Shaft: Service and Repair Ford Integral Carrier Type Axle 1. Raise and support vehicle, then remove rear wheel and brake drum. 2. Loosen rear housing cover screws and allow lubricant to drain, then remove cover. 3. Remove differential pinion shaft lock bolt and differential pinion shaft. 4. Move flanged end of axle shaft inward and remove C-lock from end of shaft. 5. Remove axle shaft from housing by pulling outward. 6. Reverse procedure to install. Apply Loctite EOAZ-19554-B to pinion shaft lock bolt threads, then torque lock bolt to 15-30 ft. lbs. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Dana/Spicer Integral Housing Type > Page 4798 Axle Shaft: Service and Repair Ford Removable Carrier Type Removal, Units w/Ball Bearing 1. Remove wheel assembly. 2. Remove brake drum from flange. 3. Working through hole provided in axle shaft flange, remove nuts that secure wheel bearing retainer. 4. Pull axle shaft out of housing. If bearing is a tight fit in axle housing, use a slide hammer type puller. 5. Remove brake backing plate and secure to frame rail. 6. If the axle shaft bearing is to be replaced, loosen the inner retainer by nicking it deeply with a chisel in several places. The bearing will then slide off easily. 7. Press bearing from axle shaft. 8. Inspect machined surface of axle shaft and housing for rough spots that would affect sealing action of the oil seal. Carefully remove any burrs or rough spots. Installation 1. Press new bearing on shaft until it seats firmly against shoulder on shaft. 2. Press inner bearing retainer on shaft until it seats firmly against bearing. 3. If oil seal is to be replaced, use a hook-type tool to pull it out of housing. Wipe a small amount of oil resistant sealer on outer edge of seal before it is installed. Removal, Units W/Roller Bearing 1. Remove wheel assembly. 2. Remove brake drum from flange. 3. Working through hole provided in axle flange, remove nuts securing wheel bearing retainer. 4. Pull axle shaft carefully from housing to prevent damage to outer seal rubber. Use a slide hammer type puller to remove tapered bearing cup from housing. Remove brake backing plate and secure to frame rail. 5. If the axle shaft bearing or seal is to be replaced, split the inner bearing retainer. 6. Press bearing from axle shaft. 7. Inspect machined surface of axle shaft and housing for rough spots that would affect sealing action of the oil seal. Carefully remove any burrs or rough spots. 8. Install outer retainer plate on axle shaft. Press lubricated seal and bearing onto shaft until firmly seated. Oil seal for rear drum brake equipped vehicles is different than that used on vehicles with rear disc brakes. Seals used with drum brakes have a gray metal colored outer rim, while seals used with disc brakes have a black or orange color. 9. Press new bearing retainer onto shaft until seated. Installation 1. On 1980---84 models, place a new gasket on each side of brake carrier plate, and slide axle shaft into housing. On models with roller bearing, ensure outer seal is fully seated on bearing. 2. Start splines into differential side gear and push shaft in until bearing bottoms in housing. 3. Torque bearing retainer nuts to 20---40 ft. lbs. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Technical Service Bulletins > Customer Interest for Seals and Gaskets: > 88912042788 > Apr > 88 > Full Float Hub Seal - Lubricant Leak Seals and Gaskets: Customer Interest Full Float Hub Seal - Lubricant Leak Article No. 88-9-12 AXLE - REAR - FORD 10.25" FULL FLOAT DESIGN - HUB SEAL LEAKS LEAKS - LUBRICANT FROM HUB SEAL FORD 10.25" FULL FLOAT DESIGN REAR AXLE LIGHT TRUCK: 1985-88 F-250/350 ISSUE: Lubricant leaking from the rear axle on F-250 and F-350 trucks, with Ford 10.25" full float axles may be caused by the hub seal. The leaking condition could affect trucks with single or dual rear wheels. ACTION: To correct this, install a new design hub seal with improved sealing qualities. The new hub seal is "green" in color to assist in part identification. Refer to the appropriate Light Truck Shop Manual, Volume A, Section 15-09 and the following service procedure for removal and installation instructions. FIGURE 12 1. Position hub seal with the "Ford" logo facing up, Figure 12. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Technical Service Bulletins > Customer Interest for Seals and Gaskets: > 88912042788 > Apr > 88 > Full Float Hub Seal - Lubricant Leak > Page 4807 FIGURE 13 2. Install hub seal on hub seal installer tool (T85T-1175-AH), Figure 13. FIGURE 14 3. Insert tool with seal squarely into hub, Figure 14. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Technical Service Bulletins > Customer Interest for Seals and Gaskets: > 88912042788 > Apr > 88 > Full Float Hub Seal - Lubricant Leak > Page 4808 FIGURE 15 4. Hold tool straight and strike handle until hub seal is fully seated, Figure 15. CAUTION: Install new seal if seal is damaged during or after installation. FIGURE 16 NOTE: UNITIZED WHEEL SEALS ARE STANDARD ITEMS ON FULL FLOAT REAR AXLES. THE UNITIZED WHEEL SEAL COMBINES THE FUNCTION OF A WEAR SLEEVE AND SEAL IN ONE SELF-CONTAINED UNIT WITH THE SEAL AND SLEEVE SURFACE INSIDE. THE UNITIZED DESIGN PROVIDES MAXIMUM PROTECTION FOR THE SEALING SURFACE DURING INSTALLATION AND OPERATION, FIGURE 16. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Technical Service Bulletins > Customer Interest for Seals and Gaskets: > 88912042788 > Apr > 88 > Full Float Hub Seal - Lubricant Leak > Page 4809 PART NUMBER PART NAME CLASS E7HZ-1175-A Hub Seal B OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Eligible Under Powertrain Warranty Coverage OPERATION: 880912A - Install one hub seal TIME: 0.7 Hr. OPERATION: 880912B - Install both hub seals 1.2 Hrs. DLR. CODING: Basic Part No. 1177 Condition Code: 48 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Technical Service Bulletins > Customer Interest for Seals and Gaskets: > 851917 > Sep > 85 > Front Drive Axle - Spindle Seal Premature Wear Technical Service Bulletin # 851917 Date: 850926 Front Drive Axle - Spindle Seal Premature Wear Article No. 85-19-17 AXLE - FRONT DRIVE - SPINDLE SEAL IMPROVEMENT LIGHT TRUCK 1982-86 F150/250 (4x4), BRONCO Operation on vehicles in off-road, severe environments may result in the one-piece design spindle seal and the spindle needle bearing seal allowing water and contaminants to get into the spindle needle bearings. This causes premature seal and bearing wear. The following service action is suggested for installation of the previous style sealing system ("V" ring/"V" block seals and spacer/thrustwasher). This is similar to the sealing system on the model 501FS used on F350 4x4's. Removal 1. Raise the front of the vehicle and install safety stands. 2. Remove the lug nuts and remove the front wheel and tire assembly. 3. Remove the caliper as described in Section 12-24, Disc Brakes - Light and Heavy Duty - Sliding Caliper of the 1986 Light Truck Shop Manual. Securely wire the caliper to the frame. CAUTION: After removal, the caliper must be wired to the frame or otherwise supported to prevent suspending the caliper by the flexible hose. If securing the caliper is not practical, disconnect and plug the hose to the caliper. Upon caliper installation, bleed the brake system as described in Section 12- 01, General Hydraulic Brake Service in the 1985 Light Truck Shop Manual. Figure 12 - DANA MODEL 44IFS FRONT DRIVING AXLE 4. Remove the six Allen-head capscrews retaining the manual locking hub cap to the hub body and remove the cap. 5. Remove the snap ring that retains the axle shaft in the hub body assembly. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Technical Service Bulletins > Customer Interest for Seals and Gaskets: > 851917 > Sep > 85 > Front Drive Axle - Spindle Seal Premature Wear > Page 4814 6. Remove the lock ring seated in the groove of the wheel hub. 7. Remove the body assembly from the hub. If the body is difficult to remove, install two capscrews and pull the body assembly out of the hub. 8. Remove the outer locknut from the spindle with a Spanner Locknut Wrench, T83T-1197-B. 9. Remove the lockwasher from the spindle. 10. Remove the inner locknut from the spindle using a Spanner Locknut Wrench, T83T-1197-B. 11. Remove the hub and rotor assembly and outer bearing from the spindle. 12. Remove the nuts retaining the spindle to the knuckle. Lightly tap the spindle with a rawhide hammer to remove it from the knuckle, 13. Remove the splash shield from the steering knuckle. FIGURE 13 14. Remove slip yoke boot clamps on the R.H. axle shaft assembly. Pull the axle shaft out of the steering knuckle. Refer to Figure 13. FIGURE 14 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Technical Service Bulletins > Customer Interest for Seals and Gaskets: > 851917 > Sep > 85 > Front Drive Axle - Spindle Seal Premature Wear > Page 4815 15. Remove the inner oil seal assembly from the axle shaft. Refer to Figure 14. Figure 15 - REMOVAL - SPINDLE BEARING AND SEAL Figure 20 - SPINDLE CHECKING AREAS FOR RUST/SCORING/PITTING 16. Remove the seal and needle bearing from the spindle as shown in Figure 15. Inspect the sealing surfaces of the spindle for severely corroded, pitted, worn or galled sealing surfaces. Replace spindle if damaged. Refer to Figure 20. 17. Inspect the outer shaft (3B387) of the axle shaft assembly for corroded, pitted, worn or galled surfaces in the inner oil seal and/or needle bearing areas. If damage to this area is evident, replace the outer shaft (3B387). Repair axle shaft as follows: Refer to Section 15-60 of the 1985 Light Truck Shop Manual. a. Remove the snap rings that retain the bearings in the yokes of the axle shaft. b. Position U-Joint Tool, T74P-4635-C, onto the axle shaft and press the bearing out of the yoke. If the bearing cannot be pressed completely out of the yoke, remove it with a vise grip or channel lock pliers. Mark the yoke and the shaft so that they will be reassembled in the same relative position. c. Reposition the tool to press on the spider in order to remove the bearing from the opposite side of the flange. d. Remove the yoke from the spider of axle shaft. e. Remove the bearings and spider from the other end of the axle shaft in the same manner. Assembly (Refer to Section 15-60/Light Truck Shop Manual) a. Start a new bearing into the axle shaft yoke. b. Position the spider in the axle shaft and press the bearing 6 mm (1/4") below the axle shaft surface using U-Joint Tool, T74P-4635-C. c. Remove the tool and install a new snap ring. d. Start a new bearing on the opposite side of the axle shaft. e. Install the U-Joint Tool, T74P-4635-C, and press the bearing until the snap ring of the opposite bearing contacts the axle shaft. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Technical Service Bulletins > Customer Interest for Seals and Gaskets: > 851917 > Sep > 85 > Front Drive Axle - Spindle Seal Premature Wear > Page 4816 f. Remove the tool and install a new snap ring. g. Install the yoke on the spider in position marked during disassembly. h. Install two new bearings and snap rings in the yoke and in the same manner as the axle shaft. i. Check the U-Joint for freedom of movement. If a binding condition results, tap the ears of the axle shaft sharply to relieve the binding. DO NOT INSTALL AN AXLE SHAFT IF THE U-JOINT SHOWS SIGNS OF BINDING. Installation Figure 16 - SPINDLE BEARING INSTALLATION 1. Position a new needle bearing (3123) in the spindle bore of the spindle (3107). The writing on the bearing must face the rear of the spindle. Drive the bearing into the spindle with the Spindle Bearing Replacer, T80T-4000-R, and Driver Handle, T80T-400-W. Pack the bearing with Long Life Lubricant (C1AZ-19590-B) ESA-M1C75-B. Install the seal (1175) in the bore against the bearing with the open end of the "V" facing the rear of the spindle. Refer to Figure 16. Figure 17 - SLINGER/SEAL/PLASTIC SPACER INSTALLATION Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Technical Service Bulletins > Customer Interest for Seals and Gaskets: > 851917 > Sep > 85 > Front Drive Axle - Spindle Seal Premature Wear > Page 4817 Figure 18 - "V" SEAL TO SLINGER INSTALLATION Figure 19 - APPLY GREASE TO SEAL LIP 2. Press a new slinger on the axle shaft with an appropriate piece of press stock. Refer to Figures 17, 18 and 19. Figure 19 - APPLY GREASE TO SEAL LIP 3. Install the rubber V-seal on the slinger and axle shaft. The lip of the seal should face towards the spindle. Refer to Figure 19. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Technical Service Bulletins > Customer Interest for Seals and Gaskets: > 851917 > Sep > 85 > Front Drive Axle - Spindle Seal Premature Wear > Page 4818 Figure 18 - "V" SEAL TO SLINGER INSTALLATION 4. Install the plastic spacer (3299) on the axle shaft. The chamferred side of the spacer should be inboard against the axle shaft. Refer to Figure 18. Figure 20 - SPINDLE CHECKING AREAS FOR RUST/SCORING/PITTING 5. Pack the thrust face of the seal in the spindle bore and the V-seal on the axle shaft with Long Life Lubricant (C1AZ-19590-B) ESA-M1C75-B or equivalent. Refer to Figure 20. 6. Carefully guide the axle shaft through the knuckle and into the axle housing. Guide the R.H. axle shaft into the slip yoke. Install a new slip yoke boot clamp on R.H. side. Make sure the L.H. axle shaft splines are engaged in the differential side gear splines. 7. Install the splash shield on the steering knuckle. 8. Pack the caged needle bearing and seal area of the spindle with Long Life Lubricant (C1AZ-19590-B) ESA-M1C75-B or equivalent. 9. Place the spindle on the steering knuckle. Install and tighten the retaining nuts to 20-30 ft.lbs. torque. 10. Install the hub and rotor assembly on the spindle. 11. Install the inner locknut on the spindle and seat the bearing by tightening the locknut to 68 N-m (50 ft.lbs.) with Spanner Locknut Wrench, D85T- 1197-A. 12. While rotating the hub and rotor, back off the locknut 135-150 degrees. 13. Install the lockwasher so the key is positioned in the spindle groove. Rotate the inner locknut so the pin is aligned into the nearest lockwasher hole. 14. Install the outer locknut and retighten to 203 N-m (150 ft.lbs.) using Spanner Locknut Wrench, T83T-1197-B. NOTE: The final spindle end play should be 0.000-0.015 mm (0.000-0.006 inch). 15. Install the manual locking hub body assembly into the hub and rotor as outlined under Manual Locking Hub Removal/Installation. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Technical Service Bulletins > Customer Interest for Seals and Gaskets: > 851917 > Sep > 85 > Front Drive Axle - Spindle Seal Premature Wear > Page 4819 16. Install the lock ring in the hub groove to retain the body in the hub. 17. Install the snap ring on the end of the axle shaft to retain the shaft to the body. PART NUMBER PART NAME CLASS D3TZ-3C132-A Slinger B D6TZ-1175-A Seal A D6TZ-1175-C Seal A D6TZ-3299-A Spacer AM C6TZ-3123-A Needle Bearing A OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION: SP3076A85L TIME: 0.9 Hr. - Left hand side seals OPERATION: SP3076A85R TIME: 0.9 Hr. - Right hand side seals OPERATION: SP3076A85T TIME: 1.7 Hrs. - Both side seals OPERATION: SP3220A85L TIME: 0.3 Hr. - Extra time to replace left outer shaft OPERATION: SP3220A85R TIME: 0.3 Hr. - Extra time to replace right outer shaft OPERATION: SP3220A85T TIME: 0.5 Hr. - Extra time to replace both outer shafts DLR. CODING: Basic Part No. 1175 - Code: 48 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > 88912042788 > Apr > 88 > Full Float Hub Seal - Lubricant Leak Seals and Gaskets: All Technical Service Bulletins Full Float Hub Seal - Lubricant Leak Article No. 88-9-12 AXLE - REAR - FORD 10.25" FULL FLOAT DESIGN - HUB SEAL LEAKS LEAKS - LUBRICANT FROM HUB SEAL FORD 10.25" FULL FLOAT DESIGN REAR AXLE LIGHT TRUCK: 1985-88 F-250/350 ISSUE: Lubricant leaking from the rear axle on F-250 and F-350 trucks, with Ford 10.25" full float axles may be caused by the hub seal. The leaking condition could affect trucks with single or dual rear wheels. ACTION: To correct this, install a new design hub seal with improved sealing qualities. The new hub seal is "green" in color to assist in part identification. Refer to the appropriate Light Truck Shop Manual, Volume A, Section 15-09 and the following service procedure for removal and installation instructions. FIGURE 12 1. Position hub seal with the "Ford" logo facing up, Figure 12. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > 88912042788 > Apr > 88 > Full Float Hub Seal - Lubricant Leak > Page 4825 FIGURE 13 2. Install hub seal on hub seal installer tool (T85T-1175-AH), Figure 13. FIGURE 14 3. Insert tool with seal squarely into hub, Figure 14. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > 88912042788 > Apr > 88 > Full Float Hub Seal - Lubricant Leak > Page 4826 FIGURE 15 4. Hold tool straight and strike handle until hub seal is fully seated, Figure 15. CAUTION: Install new seal if seal is damaged during or after installation. FIGURE 16 NOTE: UNITIZED WHEEL SEALS ARE STANDARD ITEMS ON FULL FLOAT REAR AXLES. THE UNITIZED WHEEL SEAL COMBINES THE FUNCTION OF A WEAR SLEEVE AND SEAL IN ONE SELF-CONTAINED UNIT WITH THE SEAL AND SLEEVE SURFACE INSIDE. THE UNITIZED DESIGN PROVIDES MAXIMUM PROTECTION FOR THE SEALING SURFACE DURING INSTALLATION AND OPERATION, FIGURE 16. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > 88912042788 > Apr > 88 > Full Float Hub Seal - Lubricant Leak > Page 4827 PART NUMBER PART NAME CLASS E7HZ-1175-A Hub Seal B OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Eligible Under Powertrain Warranty Coverage OPERATION: 880912A - Install one hub seal TIME: 0.7 Hr. OPERATION: 880912B - Install both hub seals 1.2 Hrs. DLR. CODING: Basic Part No. 1177 Condition Code: 48 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > 851917 > Sep > 85 > Front Drive Axle - Spindle Seal Premature Wear Technical Service Bulletin # 851917 Date: 850926 Front Drive Axle - Spindle Seal Premature Wear Article No. 85-19-17 AXLE - FRONT DRIVE - SPINDLE SEAL IMPROVEMENT LIGHT TRUCK 1982-86 F150/250 (4x4), BRONCO Operation on vehicles in off-road, severe environments may result in the one-piece design spindle seal and the spindle needle bearing seal allowing water and contaminants to get into the spindle needle bearings. This causes premature seal and bearing wear. The following service action is suggested for installation of the previous style sealing system ("V" ring/"V" block seals and spacer/thrustwasher). This is similar to the sealing system on the model 501FS used on F350 4x4's. Removal 1. Raise the front of the vehicle and install safety stands. 2. Remove the lug nuts and remove the front wheel and tire assembly. 3. Remove the caliper as described in Section 12-24, Disc Brakes - Light and Heavy Duty - Sliding Caliper of the 1986 Light Truck Shop Manual. Securely wire the caliper to the frame. CAUTION: After removal, the caliper must be wired to the frame or otherwise supported to prevent suspending the caliper by the flexible hose. If securing the caliper is not practical, disconnect and plug the hose to the caliper. Upon caliper installation, bleed the brake system as described in Section 12- 01, General Hydraulic Brake Service in the 1985 Light Truck Shop Manual. Figure 12 - DANA MODEL 44IFS FRONT DRIVING AXLE 4. Remove the six Allen-head capscrews retaining the manual locking hub cap to the hub body and remove the cap. 5. Remove the snap ring that retains the axle shaft in the hub body assembly. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > 851917 > Sep > 85 > Front Drive Axle - Spindle Seal Premature Wear > Page 4832 6. Remove the lock ring seated in the groove of the wheel hub. 7. Remove the body assembly from the hub. If the body is difficult to remove, install two capscrews and pull the body assembly out of the hub. 8. Remove the outer locknut from the spindle with a Spanner Locknut Wrench, T83T-1197-B. 9. Remove the lockwasher from the spindle. 10. Remove the inner locknut from the spindle using a Spanner Locknut Wrench, T83T-1197-B. 11. Remove the hub and rotor assembly and outer bearing from the spindle. 12. Remove the nuts retaining the spindle to the knuckle. Lightly tap the spindle with a rawhide hammer to remove it from the knuckle, 13. Remove the splash shield from the steering knuckle. FIGURE 13 14. Remove slip yoke boot clamps on the R.H. axle shaft assembly. Pull the axle shaft out of the steering knuckle. Refer to Figure 13. FIGURE 14 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > 851917 > Sep > 85 > Front Drive Axle - Spindle Seal Premature Wear > Page 4833 15. Remove the inner oil seal assembly from the axle shaft. Refer to Figure 14. Figure 15 - REMOVAL - SPINDLE BEARING AND SEAL Figure 20 - SPINDLE CHECKING AREAS FOR RUST/SCORING/PITTING 16. Remove the seal and needle bearing from the spindle as shown in Figure 15. Inspect the sealing surfaces of the spindle for severely corroded, pitted, worn or galled sealing surfaces. Replace spindle if damaged. Refer to Figure 20. 17. Inspect the outer shaft (3B387) of the axle shaft assembly for corroded, pitted, worn or galled surfaces in the inner oil seal and/or needle bearing areas. If damage to this area is evident, replace the outer shaft (3B387). Repair axle shaft as follows: Refer to Section 15-60 of the 1985 Light Truck Shop Manual. a. Remove the snap rings that retain the bearings in the yokes of the axle shaft. b. Position U-Joint Tool, T74P-4635-C, onto the axle shaft and press the bearing out of the yoke. If the bearing cannot be pressed completely out of the yoke, remove it with a vise grip or channel lock pliers. Mark the yoke and the shaft so that they will be reassembled in the same relative position. c. Reposition the tool to press on the spider in order to remove the bearing from the opposite side of the flange. d. Remove the yoke from the spider of axle shaft. e. Remove the bearings and spider from the other end of the axle shaft in the same manner. Assembly (Refer to Section 15-60/Light Truck Shop Manual) a. Start a new bearing into the axle shaft yoke. b. Position the spider in the axle shaft and press the bearing 6 mm (1/4") below the axle shaft surface using U-Joint Tool, T74P-4635-C. c. Remove the tool and install a new snap ring. d. Start a new bearing on the opposite side of the axle shaft. e. Install the U-Joint Tool, T74P-4635-C, and press the bearing until the snap ring of the opposite bearing contacts the axle shaft. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > 851917 > Sep > 85 > Front Drive Axle - Spindle Seal Premature Wear > Page 4834 f. Remove the tool and install a new snap ring. g. Install the yoke on the spider in position marked during disassembly. h. Install two new bearings and snap rings in the yoke and in the same manner as the axle shaft. i. Check the U-Joint for freedom of movement. If a binding condition results, tap the ears of the axle shaft sharply to relieve the binding. DO NOT INSTALL AN AXLE SHAFT IF THE U-JOINT SHOWS SIGNS OF BINDING. Installation Figure 16 - SPINDLE BEARING INSTALLATION 1. Position a new needle bearing (3123) in the spindle bore of the spindle (3107). The writing on the bearing must face the rear of the spindle. Drive the bearing into the spindle with the Spindle Bearing Replacer, T80T-4000-R, and Driver Handle, T80T-400-W. Pack the bearing with Long Life Lubricant (C1AZ-19590-B) ESA-M1C75-B. Install the seal (1175) in the bore against the bearing with the open end of the "V" facing the rear of the spindle. Refer to Figure 16. Figure 17 - SLINGER/SEAL/PLASTIC SPACER INSTALLATION Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > 851917 > Sep > 85 > Front Drive Axle - Spindle Seal Premature Wear > Page 4835 Figure 18 - "V" SEAL TO SLINGER INSTALLATION Figure 19 - APPLY GREASE TO SEAL LIP 2. Press a new slinger on the axle shaft with an appropriate piece of press stock. Refer to Figures 17, 18 and 19. Figure 19 - APPLY GREASE TO SEAL LIP 3. Install the rubber V-seal on the slinger and axle shaft. The lip of the seal should face towards the spindle. Refer to Figure 19. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > 851917 > Sep > 85 > Front Drive Axle - Spindle Seal Premature Wear > Page 4836 Figure 18 - "V" SEAL TO SLINGER INSTALLATION 4. Install the plastic spacer (3299) on the axle shaft. The chamferred side of the spacer should be inboard against the axle shaft. Refer to Figure 18. Figure 20 - SPINDLE CHECKING AREAS FOR RUST/SCORING/PITTING 5. Pack the thrust face of the seal in the spindle bore and the V-seal on the axle shaft with Long Life Lubricant (C1AZ-19590-B) ESA-M1C75-B or equivalent. Refer to Figure 20. 6. Carefully guide the axle shaft through the knuckle and into the axle housing. Guide the R.H. axle shaft into the slip yoke. Install a new slip yoke boot clamp on R.H. side. Make sure the L.H. axle shaft splines are engaged in the differential side gear splines. 7. Install the splash shield on the steering knuckle. 8. Pack the caged needle bearing and seal area of the spindle with Long Life Lubricant (C1AZ-19590-B) ESA-M1C75-B or equivalent. 9. Place the spindle on the steering knuckle. Install and tighten the retaining nuts to 20-30 ft.lbs. torque. 10. Install the hub and rotor assembly on the spindle. 11. Install the inner locknut on the spindle and seat the bearing by tightening the locknut to 68 N-m (50 ft.lbs.) with Spanner Locknut Wrench, D85T- 1197-A. 12. While rotating the hub and rotor, back off the locknut 135-150 degrees. 13. Install the lockwasher so the key is positioned in the spindle groove. Rotate the inner locknut so the pin is aligned into the nearest lockwasher hole. 14. Install the outer locknut and retighten to 203 N-m (150 ft.lbs.) using Spanner Locknut Wrench, T83T-1197-B. NOTE: The final spindle end play should be 0.000-0.015 mm (0.000-0.006 inch). 15. Install the manual locking hub body assembly into the hub and rotor as outlined under Manual Locking Hub Removal/Installation. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > 851917 > Sep > 85 > Front Drive Axle - Spindle Seal Premature Wear > Page 4837 16. Install the lock ring in the hub groove to retain the body in the hub. 17. Install the snap ring on the end of the axle shaft to retain the shaft to the body. PART NUMBER PART NAME CLASS D3TZ-3C132-A Slinger B D6TZ-1175-A Seal A D6TZ-1175-C Seal A D6TZ-3299-A Spacer AM C6TZ-3123-A Needle Bearing A OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION: SP3076A85L TIME: 0.9 Hr. - Left hand side seals OPERATION: SP3076A85R TIME: 0.9 Hr. - Right hand side seals OPERATION: SP3076A85T TIME: 1.7 Hrs. - Both side seals OPERATION: SP3220A85L TIME: 0.3 Hr. - Extra time to replace left outer shaft OPERATION: SP3220A85R TIME: 0.3 Hr. - Extra time to replace right outer shaft OPERATION: SP3220A85T TIME: 0.5 Hr. - Extra time to replace both outer shafts DLR. CODING: Basic Part No. 1175 - Code: 48 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > Page 4838 Seals and Gaskets: By Symptom Technical Service Bulletin # 88912042788 Date: 880401 Full Float Hub Seal - Lubricant Leak Article No. 88-9-12 AXLE - REAR - FORD 10.25" FULL FLOAT DESIGN - HUB SEAL LEAKS LEAKS - LUBRICANT FROM HUB SEAL FORD 10.25" FULL FLOAT DESIGN REAR AXLE LIGHT TRUCK: 1985-88 F-250/350 ISSUE: Lubricant leaking from the rear axle on F-250 and F-350 trucks, with Ford 10.25" full float axles may be caused by the hub seal. The leaking condition could affect trucks with single or dual rear wheels. ACTION: To correct this, install a new design hub seal with improved sealing qualities. The new hub seal is "green" in color to assist in part identification. Refer to the appropriate Light Truck Shop Manual, Volume A, Section 15-09 and the following service procedure for removal and installation instructions. FIGURE 12 1. Position hub seal with the "Ford" logo facing up, Figure 12. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > Page 4839 FIGURE 13 2. Install hub seal on hub seal installer tool (T85T-1175-AH), Figure 13. FIGURE 14 3. Insert tool with seal squarely into hub, Figure 14. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > Page 4840 FIGURE 15 4. Hold tool straight and strike handle until hub seal is fully seated, Figure 15. CAUTION: Install new seal if seal is damaged during or after installation. FIGURE 16 NOTE: UNITIZED WHEEL SEALS ARE STANDARD ITEMS ON FULL FLOAT REAR AXLES. THE UNITIZED WHEEL SEAL COMBINES THE FUNCTION OF A WEAR SLEEVE AND SEAL IN ONE SELF-CONTAINED UNIT WITH THE SEAL AND SLEEVE SURFACE INSIDE. THE UNITIZED DESIGN PROVIDES MAXIMUM PROTECTION FOR THE SEALING SURFACE DURING INSTALLATION AND OPERATION, FIGURE 16. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > Page 4841 PART NUMBER PART NAME CLASS E7HZ-1175-A Hub Seal B OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Eligible Under Powertrain Warranty Coverage OPERATION: 880912A - Install one hub seal TIME: 0.7 Hr. OPERATION: 880912B - Install both hub seals 1.2 Hrs. DLR. CODING: Basic Part No. 1177 Condition Code: 48 Technical Service Bulletin # 851917 Date: 850926 Front Drive Axle - Spindle Seal Premature Wear Article No. 85-19-17 AXLE - FRONT DRIVE - SPINDLE SEAL IMPROVEMENT LIGHT TRUCK 1982-86 F150/250 (4x4), BRONCO Operation on vehicles in off-road, severe environments may result in the one-piece design spindle seal and the spindle needle bearing seal allowing water and contaminants to get into the spindle needle bearings. This causes premature seal and bearing wear. The following service action is suggested for installation of the previous style sealing system ("V" ring/"V" block seals and spacer/thrustwasher). This is similar to the sealing system on the model 501FS used on F350 4x4's. Removal 1. Raise the front of the vehicle and install safety stands. 2. Remove the lug nuts and remove the front wheel and tire assembly. 3. Remove the caliper as described in Section 12-24, Disc Brakes - Light and Heavy Duty - Sliding Caliper of the 1986 Light Truck Shop Manual. Securely wire the caliper to the frame. CAUTION: After removal, the caliper must be wired to the frame or otherwise supported to prevent suspending the caliper by the flexible hose. If securing the caliper is not practical, disconnect and plug the hose to the caliper. Upon caliper installation, bleed the brake system as described in Section 12- 01, General Hydraulic Brake Service in the 1985 Light Truck Shop Manual. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > Page 4842 Figure 12 - DANA MODEL 44IFS FRONT DRIVING AXLE 4. Remove the six Allen-head capscrews retaining the manual locking hub cap to the hub body and remove the cap. 5. Remove the snap ring that retains the axle shaft in the hub body assembly. 6. Remove the lock ring seated in the groove of the wheel hub. 7. Remove the body assembly from the hub. If the body is difficult to remove, install two capscrews and pull the body assembly out of the hub. 8. Remove the outer locknut from the spindle with a Spanner Locknut Wrench, T83T-1197-B. 9. Remove the lockwasher from the spindle. 10. Remove the inner locknut from the spindle using a Spanner Locknut Wrench, T83T-1197-B. 11. Remove the hub and rotor assembly and outer bearing from the spindle. 12. Remove the nuts retaining the spindle to the knuckle. Lightly tap the spindle with a rawhide hammer to remove it from the knuckle, 13. Remove the splash shield from the steering knuckle. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > Page 4843 FIGURE 13 14. Remove slip yoke boot clamps on the R.H. axle shaft assembly. Pull the axle shaft out of the steering knuckle. Refer to Figure 13. FIGURE 14 15. Remove the inner oil seal assembly from the axle shaft. Refer to Figure 14. Figure 15 - REMOVAL - SPINDLE BEARING AND SEAL Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > Page 4844 Figure 20 - SPINDLE CHECKING AREAS FOR RUST/SCORING/PITTING 16. Remove the seal and needle bearing from the spindle as shown in Figure 15. Inspect the sealing surfaces of the spindle for severely corroded, pitted, worn or galled sealing surfaces. Replace spindle if damaged. Refer to Figure 20. 17. Inspect the outer shaft (3B387) of the axle shaft assembly for corroded, pitted, worn or galled surfaces in the inner oil seal and/or needle bearing areas. If damage to this area is evident, replace the outer shaft (3B387). Repair axle shaft as follows: Refer to Section 15-60 of the 1985 Light Truck Shop Manual. a. Remove the snap rings that retain the bearings in the yokes of the axle shaft. b. Position U-Joint Tool, T74P-4635-C, onto the axle shaft and press the bearing out of the yoke. If the bearing cannot be pressed completely out of the yoke, remove it with a vise grip or channel lock pliers. Mark the yoke and the shaft so that they will be reassembled in the same relative position. c. Reposition the tool to press on the spider in order to remove the bearing from the opposite side of the flange. d. Remove the yoke from the spider of axle shaft. e. Remove the bearings and spider from the other end of the axle shaft in the same manner. Assembly (Refer to Section 15-60/Light Truck Shop Manual) a. Start a new bearing into the axle shaft yoke. b. Position the spider in the axle shaft and press the bearing 6 mm (1/4") below the axle shaft surface using U-Joint Tool, T74P-4635-C. c. Remove the tool and install a new snap ring. d. Start a new bearing on the opposite side of the axle shaft. e. Install the U-Joint Tool, T74P-4635-C, and press the bearing until the snap ring of the opposite bearing contacts the axle shaft. f. Remove the tool and install a new snap ring. g. Install the yoke on the spider in position marked during disassembly. h. Install two new bearings and snap rings in the yoke and in the same manner as the axle shaft. i. Check the U-Joint for freedom of movement. If a binding condition results, tap the ears of the axle shaft sharply to relieve the binding. DO NOT INSTALL AN AXLE SHAFT IF THE U-JOINT SHOWS SIGNS OF BINDING. Installation Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > Page 4845 Figure 16 - SPINDLE BEARING INSTALLATION 1. Position a new needle bearing (3123) in the spindle bore of the spindle (3107). The writing on the bearing must face the rear of the spindle. Drive the bearing into the spindle with the Spindle Bearing Replacer, T80T-4000-R, and Driver Handle, T80T-400-W. Pack the bearing with Long Life Lubricant (C1AZ-19590-B) ESA-M1C75-B. Install the seal (1175) in the bore against the bearing with the open end of the "V" facing the rear of the spindle. Refer to Figure 16. Figure 17 - SLINGER/SEAL/PLASTIC SPACER INSTALLATION Figure 18 - "V" SEAL TO SLINGER INSTALLATION Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > Page 4846 Figure 19 - APPLY GREASE TO SEAL LIP 2. Press a new slinger on the axle shaft with an appropriate piece of press stock. Refer to Figures 17, 18 and 19. Figure 19 - APPLY GREASE TO SEAL LIP 3. Install the rubber V-seal on the slinger and axle shaft. The lip of the seal should face towards the spindle. Refer to Figure 19. Figure 18 - "V" SEAL TO SLINGER INSTALLATION 4. Install the plastic spacer (3299) on the axle shaft. The chamferred side of the spacer should be inboard against the axle shaft. Refer to Figure 18. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > Page 4847 Figure 20 - SPINDLE CHECKING AREAS FOR RUST/SCORING/PITTING 5. Pack the thrust face of the seal in the spindle bore and the V-seal on the axle shaft with Long Life Lubricant (C1AZ-19590-B) ESA-M1C75-B or equivalent. Refer to Figure 20. 6. Carefully guide the axle shaft through the knuckle and into the axle housing. Guide the R.H. axle shaft into the slip yoke. Install a new slip yoke boot clamp on R.H. side. Make sure the L.H. axle shaft splines are engaged in the differential side gear splines. 7. Install the splash shield on the steering knuckle. 8. Pack the caged needle bearing and seal area of the spindle with Long Life Lubricant (C1AZ-19590-B) ESA-M1C75-B or equivalent. 9. Place the spindle on the steering knuckle. Install and tighten the retaining nuts to 20-30 ft.lbs. torque. 10. Install the hub and rotor assembly on the spindle. 11. Install the inner locknut on the spindle and seat the bearing by tightening the locknut to 68 N-m (50 ft.lbs.) with Spanner Locknut Wrench, D85T- 1197-A. 12. While rotating the hub and rotor, back off the locknut 135-150 degrees. 13. Install the lockwasher so the key is positioned in the spindle groove. Rotate the inner locknut so the pin is aligned into the nearest lockwasher hole. 14. Install the outer locknut and retighten to 203 N-m (150 ft.lbs.) using Spanner Locknut Wrench, T83T-1197-B. NOTE: The final spindle end play should be 0.000-0.015 mm (0.000-0.006 inch). 15. Install the manual locking hub body assembly into the hub and rotor as outlined under Manual Locking Hub Removal/Installation. 16. Install the lock ring in the hub groove to retain the body in the hub. 17. Install the snap ring on the end of the axle shaft to retain the shaft to the body. PART NUMBER PART NAME CLASS D3TZ-3C132-A Slinger B D6TZ-1175-A Seal A D6TZ-1175-C Seal A D6TZ-3299-A Spacer AM C6TZ-3123-A Needle Bearing A OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION: SP3076A85L TIME: 0.9 Hr. - Left hand side seals OPERATION: SP3076A85R TIME: 0.9 Hr. - Right hand side seals Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > Page 4848 OPERATION: SP3076A85T TIME: 1.7 Hrs. - Both side seals OPERATION: SP3220A85L TIME: 0.3 Hr. - Extra time to replace left outer shaft OPERATION: SP3220A85R TIME: 0.3 Hr. - Extra time to replace right outer shaft OPERATION: SP3220A85T TIME: 0.5 Hr. - Extra time to replace both outer shafts DLR. CODING: Basic Part No. 1175 - Code: 48 Technical Service Bulletin # 88912042788 Date: 880401 Full Float Hub Seal - Lubricant Leak Article No. 88-9-12 AXLE - REAR - FORD 10.25" FULL FLOAT DESIGN - HUB SEAL LEAKS LEAKS - LUBRICANT FROM HUB SEAL FORD 10.25" FULL FLOAT DESIGN REAR AXLE LIGHT TRUCK: 1985-88 F-250/350 ISSUE: Lubricant leaking from the rear axle on F-250 and F-350 trucks, with Ford 10.25" full float axles may be caused by the hub seal. The leaking condition could affect trucks with single or dual rear wheels. ACTION: To correct this, install a new design hub seal with improved sealing qualities. The new hub seal is "green" in color to assist in part identification. Refer to the appropriate Light Truck Shop Manual, Volume A, Section 15-09 and the following service procedure for removal and installation instructions. FIGURE 12 1. Position hub seal with the "Ford" logo facing up, Figure 12. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > Page 4849 FIGURE 13 2. Install hub seal on hub seal installer tool (T85T-1175-AH), Figure 13. FIGURE 14 3. Insert tool with seal squarely into hub, Figure 14. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > Page 4850 FIGURE 15 4. Hold tool straight and strike handle until hub seal is fully seated, Figure 15. CAUTION: Install new seal if seal is damaged during or after installation. FIGURE 16 NOTE: UNITIZED WHEEL SEALS ARE STANDARD ITEMS ON FULL FLOAT REAR AXLES. THE UNITIZED WHEEL SEAL COMBINES THE FUNCTION OF A WEAR SLEEVE AND SEAL IN ONE SELF-CONTAINED UNIT WITH THE SEAL AND SLEEVE SURFACE INSIDE. THE UNITIZED DESIGN PROVIDES MAXIMUM PROTECTION FOR THE SEALING SURFACE DURING INSTALLATION AND OPERATION, FIGURE 16. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > Page 4851 PART NUMBER PART NAME CLASS E7HZ-1175-A Hub Seal B OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Eligible Under Powertrain Warranty Coverage OPERATION: 880912A - Install one hub seal TIME: 0.7 Hr. OPERATION: 880912B - Install both hub seals 1.2 Hrs. DLR. CODING: Basic Part No. 1177 Condition Code: 48 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Technical Service Bulletins > Page 4852 Seals and Gaskets: Service and Repair Removal, Units w/Ball Bearing 1. Remove wheel assembly. 2. Remove brake drum from flange. 3. Working through hole provided in axle shaft flange, remove nuts that secure wheel bearing retainer. 4. Pull axle shaft out of housing. If bearing is a tight fit in axle housing, use a slide hammer type puller. 5. Remove brake backing plate and secure to frame rail. 6. If the axle shaft bearing is to be replaced, loosen the inner retainer by nicking it deeply with a chisel in several places. The bearing will then slide off easily. 7. Press bearing from axle shaft. 8. Inspect machined surface of axle shaft and housing for rough spots that would affect sealing action of the oil seal. Carefully remove any burrs or rough spots. Installation 1. Press new bearing on shaft until it seats firmly against shoulder on shaft. 2. Press inner bearing retainer on shaft until it seats firmly against bearing. 3. If oil seal is to be replaced, use a hook-type tool to pull it out of housing. Wipe a small amount of oil resistant sealer on outer edge of seal before it is installed. Removal, Units W/Roller Bearing 1. Remove wheel assembly. 2. Remove brake drum from flange. 3. Working through hole provided in axle flange, remove nuts securing wheel bearing retainer. 4. Pull axle shaft carefully from housing to prevent damage to outer seal rubber. Use a slide hammer type puller to remove tapered bearing cup from housing. Remove brake backing plate and secure to frame rail. 5. If the axle shaft bearing or seal is to be replaced, split the inner bearing retainer. 6. Press bearing from axle shaft. 7. Inspect machined surface of axle shaft and housing for rough spots that would affect sealing action of the oil seal. Carefully remove any burrs or rough spots. 8. Install outer retainer plate on axle shaft. Press lubricated seal and bearing onto shaft until firmly seated. Oil seal for rear drum brake equipped vehicles is different than that used on vehicles with rear disc brakes. Seals used with drum brakes have a gray metal colored outer rim, while seals used with disc brakes have a black or orange color. 9. Press new bearing retainer onto shaft until seated. Installation 1. On 1980---84 models, place a new gasket on each side of brake carrier plate, and slide axle shaft into housing. On models with roller bearing, ensure outer seal is fully seated on bearing. 2. Start splines into differential side gear and push shaft in until bearing bottoms in housing. 3. Torque bearing retainer nuts to 20---40 ft. lbs. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Specifications Wheel Bearing: Specifications Wheel Adjusting Nut [1] ....................................................................................................................... ........................................... 30-33 Nm (22-25 ft lbs) Bearing End Play .............................................................................................................................................................. 0.025-0.254mm (0.001-0.010 in) [1] Back off the adjusting nut 1/8 turn and install the retainer and new cotter pin without additional movement of the adjusting nut. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Specifications > Page 4856 Wheel Bearing: Adjustments 1. Raise the vehicle until the tire clears the floor and install safety stands. 2. Remove the wheel cover. 3. Remove the grease cap from the hub. Wipe the excess grease from the end of the spindle. Remove the cotter pin and locknut. 4. Loosen the adjusting nut three turns. Attempt to obtain running clearance between the rotor brake surface and the disc pads by rocking the wheel, hub and rotor assembly in and out several times to push the pads away from the rotor. If running clearance cannot be maintained throughout bearing adjustment in Steps 5 and 6, the caliper must be removed. NOTE: Do not pry on the phenolic caliper piston. 5. Tighten the wheel adjusting nut to 30-33 Nm (22-25 ft lbs) while rotating the disc brake rotor in the opposite direction. 6. Back off the adjusting nut 1/8 turn and install the retainer and new cotter pin without additional movement of the adjusting nut. Bearing end play should be 0.025-0.254mm (0.001-0.010 in). Bend the ends of the cotter pin around the castellated flange of the locknut. 7. Check front wheel rotation. If the wheel rotates properly, reinstall the grease cap and wheel cover. If rotation is noisy or rough, remove and inspect the bearings. Service as required. WARNING: Before driving the vehicle, pump the brake pedal several times to restore normal brake pedal travel. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Specifications > Page 4857 Wheel Bearing: Service and Repair Wheel bearing lubricant is a lithium-base grease. Sodium-base grease is not compatible with lithium-base grease and should not be intermixed. Therefore, do not lubricate front and/or rear wheel bearings without first identifying the type of original wheel bearing lubricant. Usage of incompatible bearing lubricants may result in premature lubricant breakdown. REMOVAL Front Hub And Rotor Assembly 1. Raise the vehicle until the tire clears the floor and remove the wheel and tire assembly. 2. Remove the brake caliper and secure to the underbody to prevent damage to the brake hose. It is not necessary to disconnect the hose from the caliper. Do not let the caliper hang with its weight on the brake hose or the hose may become stretched, twisted or ruptured. See: Brakes and Traction Control/Disc Brake System/Brake Caliper/Service and Repair 3. Remove the grease cap, cotter pin, retainer adjusting nut and washer. 4. Remove the outer bearing cone and roller. 5. Pull the hub and rotor off the spindle and remove and discard the grease seal. 6. Remove the inner bearing cone and roller from the hub. Remove all traces of old lubricant from bearings, hub and axle spindle. 7. Inspect the cups for scratches, pits or cracks. If the cups are worn or damaged, remove them with a drift. Clean the inner and outer bearing cones and rollers with solvent and dry thoroughly. CAUTION: Do not spin the bearings dry with compressed air. 8. Inspect the cones and rollers for cracks, nicks, brinelling, or seized rollers. Inspect the grease retainer and replace it if it is cracked, nicked, dented or worn. 9. Cover the spindle with a clean cloth. A water dampened cloth or water based solution should be used to remove and dust or loose dirt from the brake assembly. Remove the cloth from the spindle carefully to prevent dirt from falling on the spindle. NOTE: Do not use compressed air. INSTALLATION Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Specifications > Page 4858 Installing Bearing Cups (Typical) 1. If inner or outer bearing cups were removed, install replacement inner and outer bearing cups in the hub with the appropriate bearing cup replacer tool. Be sure to seat the cups properly in the hub. The cups will be properly seated when they are fully bottomed. Replace grease retainers. Polish grease retainer journal on spindle with 400 grit sandpaper. Clean with clean cloth. 2. Pack the inside of the hub with lithium-base grease or equivalent. Fill the hub until the grease is flush with the inside diameters of both bearing cups. Pack the bearing cones and rollers with wheel bearing grease. Use a bearing packer for this operation. If a packer is not available, work as much lubricant as possible between the rollers and cages. Lubricate the cone surfaces with grease. Installing Grease Seal (Typical) 3. Place the inner bearing cone and roller in the inner cup and install the new grease seal. Be sure that the seal is fully seated. 4. Install the hub and rotor on the wheel spindle. Keep the hub centered on the spindle to prevent damage to the grease retainer or the spindle threads. 5. Install the outer bearing cone and roller and the flat washer on the spindle, then install the adjusting nut, and adjust the wheel bearing. 6. Install the retainer, new cotter pin, and grease cap. 7. Install the caliper. 8. Install the wheel and tire assembly. 9. Lower vehicle and torque the lug nuts to specification. Re-install the wheel cover or hub cap. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Specifications > Page 4859 WARNING: Before driving the vehicle, pump the brake pedal several times to restore normal brake pedal travel. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub > Axle Nut > Component Information > Technical Service Bulletins > Front Drive Axle - Retaining Nut Revision Axle Nut: Technical Service Bulletins Front Drive Axle - Retaining Nut Revision Article No. 85-21-13 AXLE - FRONT DRIVE (DANA 441FSHD, 501FS, 60F MONOBEAM) - NEW WHEEL BEARING LOCKNUTS LIGHT TRUCK 1985-86 F-250 HD/350 (4x4) Front axle hub and rotor assembly bearing adjusting and retaining nuts and lockwashers have been revised. Removal and installation procedures are the same as outlined in Section 11-12 of the 1985-86 Light Truck Shop Manual except the Front Wheel Bearing Adjusting Spanner, tool number D78T-1197-B (6-prong) is used with the old design adjusting nut (Dana part number 33732) and tool number D85T-1197-A (4- prong) is required for the new nuts (Dana part number 621029). OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Seal > Component Information > Technical Service Bulletins > Customer Interest for Wheel Seal: > 9167 > Mar > 91 > Rear Axle Hub Seal Lubricant Leaks Wheel Seal: Customer Interest Rear Axle Hub Seal - Lubricant Leaks Article No. 91-6-7 03/18/91 ^ AXLE - NEW HUB SEAL AND HUB SEAL REPLACER TOOL - VEHICLES WITH 10.25 INCH RING GEAR, FULL - FLOATING REAR AXLES ^ LEAKS - AXLE LUBE - 10.25 INCH RING GEAR, FULL - FLOATING REAR AXLES LIGHT TRUCK: 1985-91 F-250, F-350 ISSUE: A new hub seal and a hub seal replacer tool are now available for service. The new hub seal is designed to improve sealing when properly installed using the new hub seal replacer tool. ACTION: Install a new hub seal (FOTZ-1177-A) with the new hub seal replacer tool (T91T-1175-A). Refer to the following inspection list and service procedure for details. NOTE: DO NOT USE THE OLD HUB SEAL REPLACER TOOL (T85T-1175-AH). IT IS NOT DESIGNED TO INSTALL THE NEW SEAL. THE NEW HUB SEAL REPLACER TOOL IS AVAILABLE IN THE 1991 DEALER ESSENTIAL SERVICE TOOL KIT AND IS THE ONLY TOOL APPROVED TO INSTALL THE NEW SEAL. INSPECTION PRIOR TO SEAL INSTALLATION Prior to seal installation, make sure that the following items are checked and servicing action taken where indicated. ^ Inspect the outer diameter of the hub seal to be sure that it is dry and free of oil and grease. ^ Check the hub bore to be sure it is free of grease, dirt and debris. ^ Remove any nicks or burrs from the hub bore. ^ Inspect the inner and outer bearing for damage and replace as required. ^ Pack each hub bearing cone and roller with a bearing packing tool using XG-1-C grease. ^ Make sure that no residual grease from freshly greased bearings gets into the hub bore. ^ Prior to installing the hub assembly, clean the spindle thoroughly and inspect the seal and bearing journals for nicks and/or scratches. Remove nicks or scratches using crocus cloth or similar material. ^ Wipe spindle clean and lightly oil with clean axle lube or engine oil. Figure 1 REMOVAL & INSTALLATION PROCEDURE 1. Install the hub in a soft jawed vice. 2. Remove the hub seal as shown in Figure 1. CAUTION: CARE MUST BE TAKEN NOT TO DAMAGE THE HUB SEAL BORE WITH THE SEAL REMOVAL TOOL. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Seal > Component Information > Technical Service Bulletins > Customer Interest for Wheel Seal: > 9167 > Mar > 91 > Rear Axle Hub Seal Lubricant Leaks > Page 4873 Figure 2 3. Thoroughly clean and inspect the hub bore, Figure 2. CAUTION: MAKE SURE THE HUB BORE IS FREE OF DIRT, GREASE, BURRS OR NICKS. NOTE: HUB BEARINGS MUST BE PRELUBED WITH GREASE PRIOR TO INSTALLATION. USE XG-1-C GREASE OR EQUIVALENT. 4. Pack each bearing cone and roller assembly with a bearing packing tool. Figure 3 5. Install the seal in the hub with the Ford logo facing up, Figure 3. CAUTION: HUB SEAL MUST BE FREE OF DIRT OR GREASE. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Seal > Component Information > Technical Service Bulletins > Customer Interest for Wheel Seal: > 9167 > Mar > 91 > Rear Axle Hub Seal Lubricant Leaks > Page 4874 Figure 4 6. Install the hub oil seal on the hub seal installer tool, T91T-1175-A, Figure 4. Figure 5 7. Insert the tool with the seal squarely into the hub, Figure 5. Figure 6 8. Hold the tool straight. Strike the handle until the hub seal is fully seated (until tool strikes hub), Figure 6. CAUTION: INSTALL NEW SEAL IF SEAL IS MISALIGNED DURING OR AFTER INSTALLATION. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Seal > Component Information > Technical Service Bulletins > Customer Interest for Wheel Seal: > 9167 > Mar > 91 > Rear Axle Hub Seal Lubricant Leaks > Page 4875 It is extremely important that the 1991 F-Series Shop Manual procedures be followed when installing the hub assembly. CAUTION: THE SPECIFIED TORQUING AND BACKING OFF OF THE HUB NUT IS CRITICAL IN ORDER TO PERFORM THE REPAIR CORRECTLY. NOTE: ALWAYS TURN THE HUB WHILE TIGHTENING THE HUB NUT. ONCE THE SPECIFIED TORQUE 55-65 LB.FT., (75-88 N-m) IS ACHIEVED, RATCHETING BACK ON THE HUB NUT VARIES DEPENDING ON WHETHER THE HUB BEARINGS ARE NEW OR USED. BACK OFF 5 CLICKS FOR NEW BEARING AND 8 CLICKS FOR USED BEARINGS. Make sure hub nut wrench tool (T85T-4252-AH) is used as shown in the Shop Manual procedure. Consult The 1991 F-Series Light Truck Shop Manual, Section 05-02B, for service procedures and torque specifications. PART NUMBER PART NAME CLASS FOTZ-1177-A Hub Seal B XG-1-C Grease (14 oz. cartridge, Pkg. V 60) OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 509000 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Seal > Component Information > Technical Service Bulletins > Customer Interest for Wheel Seal: > 862223 > Nov > 86 > Axle - Rear Axle Hub Seals Leak Wheel Seal: Customer Interest Axle - Rear Axle Hub Seals Leak Article No. 86-22-23 AXLE (10.25") - REAR - HUB SEALS LEAK - VENT PLUGGED LIGHT TRUCK 1985-86 F-250/350 A plugged rear axle vent may cause water to be sucked in through the seals and grease to be pushed out. This happens when pressures rise and fall inside the axle during various driving conditions and temperatures. The purpose of the vent is to relieve those pressures. If the vent is plugged with mud or other foreign materials, the axle cannot "breathe". To eliminate this concern, perform the following procedure: Figure 17 1. Remove the vent from the axle (Figure 17). 2. Place the vent in a vise so as not to damage the threads. 3. Drill out the vent using a 3/16 inch drill bit. Clean all shavings from vent. 4. Install vent. 5. Make sure entire vent hose is clear of dirt and mud, etc. 6. Install hose. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION: SP4022A86 TIME: 0.5 Hr. DLR. CODING: Basic Part No. 4022 - Code: 55 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Seal > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Seal: > 9167 > Mar > 91 > Rear Axle Hub Seal - Lubricant Leaks Wheel Seal: All Technical Service Bulletins Rear Axle Hub Seal - Lubricant Leaks Article No. 91-6-7 03/18/91 ^ AXLE - NEW HUB SEAL AND HUB SEAL REPLACER TOOL - VEHICLES WITH 10.25 INCH RING GEAR, FULL - FLOATING REAR AXLES ^ LEAKS - AXLE LUBE - 10.25 INCH RING GEAR, FULL - FLOATING REAR AXLES LIGHT TRUCK: 1985-91 F-250, F-350 ISSUE: A new hub seal and a hub seal replacer tool are now available for service. The new hub seal is designed to improve sealing when properly installed using the new hub seal replacer tool. ACTION: Install a new hub seal (FOTZ-1177-A) with the new hub seal replacer tool (T91T-1175-A). Refer to the following inspection list and service procedure for details. NOTE: DO NOT USE THE OLD HUB SEAL REPLACER TOOL (T85T-1175-AH). IT IS NOT DESIGNED TO INSTALL THE NEW SEAL. THE NEW HUB SEAL REPLACER TOOL IS AVAILABLE IN THE 1991 DEALER ESSENTIAL SERVICE TOOL KIT AND IS THE ONLY TOOL APPROVED TO INSTALL THE NEW SEAL. INSPECTION PRIOR TO SEAL INSTALLATION Prior to seal installation, make sure that the following items are checked and servicing action taken where indicated. ^ Inspect the outer diameter of the hub seal to be sure that it is dry and free of oil and grease. ^ Check the hub bore to be sure it is free of grease, dirt and debris. ^ Remove any nicks or burrs from the hub bore. ^ Inspect the inner and outer bearing for damage and replace as required. ^ Pack each hub bearing cone and roller with a bearing packing tool using XG-1-C grease. ^ Make sure that no residual grease from freshly greased bearings gets into the hub bore. ^ Prior to installing the hub assembly, clean the spindle thoroughly and inspect the seal and bearing journals for nicks and/or scratches. Remove nicks or scratches using crocus cloth or similar material. ^ Wipe spindle clean and lightly oil with clean axle lube or engine oil. Figure 1 REMOVAL & INSTALLATION PROCEDURE 1. Install the hub in a soft jawed vice. 2. Remove the hub seal as shown in Figure 1. CAUTION: CARE MUST BE TAKEN NOT TO DAMAGE THE HUB SEAL BORE WITH THE SEAL REMOVAL TOOL. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Seal > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Seal: > 9167 > Mar > 91 > Rear Axle Hub Seal - Lubricant Leaks > Page 4885 Figure 2 3. Thoroughly clean and inspect the hub bore, Figure 2. CAUTION: MAKE SURE THE HUB BORE IS FREE OF DIRT, GREASE, BURRS OR NICKS. NOTE: HUB BEARINGS MUST BE PRELUBED WITH GREASE PRIOR TO INSTALLATION. USE XG-1-C GREASE OR EQUIVALENT. 4. Pack each bearing cone and roller assembly with a bearing packing tool. Figure 3 5. Install the seal in the hub with the Ford logo facing up, Figure 3. CAUTION: HUB SEAL MUST BE FREE OF DIRT OR GREASE. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Seal > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Seal: > 9167 > Mar > 91 > Rear Axle Hub Seal - Lubricant Leaks > Page 4886 Figure 4 6. Install the hub oil seal on the hub seal installer tool, T91T-1175-A, Figure 4. Figure 5 7. Insert the tool with the seal squarely into the hub, Figure 5. Figure 6 8. Hold the tool straight. Strike the handle until the hub seal is fully seated (until tool strikes hub), Figure 6. CAUTION: INSTALL NEW SEAL IF SEAL IS MISALIGNED DURING OR AFTER INSTALLATION. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Seal > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Seal: > 9167 > Mar > 91 > Rear Axle Hub Seal - Lubricant Leaks > Page 4887 It is extremely important that the 1991 F-Series Shop Manual procedures be followed when installing the hub assembly. CAUTION: THE SPECIFIED TORQUING AND BACKING OFF OF THE HUB NUT IS CRITICAL IN ORDER TO PERFORM THE REPAIR CORRECTLY. NOTE: ALWAYS TURN THE HUB WHILE TIGHTENING THE HUB NUT. ONCE THE SPECIFIED TORQUE 55-65 LB.FT., (75-88 N-m) IS ACHIEVED, RATCHETING BACK ON THE HUB NUT VARIES DEPENDING ON WHETHER THE HUB BEARINGS ARE NEW OR USED. BACK OFF 5 CLICKS FOR NEW BEARING AND 8 CLICKS FOR USED BEARINGS. Make sure hub nut wrench tool (T85T-4252-AH) is used as shown in the Shop Manual procedure. Consult The 1991 F-Series Light Truck Shop Manual, Section 05-02B, for service procedures and torque specifications. PART NUMBER PART NAME CLASS FOTZ-1177-A Hub Seal B XG-1-C Grease (14 oz. cartridge, Pkg. V 60) OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 509000 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Seal > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Seal: > 862223 > Nov > 86 > Axle Rear Axle Hub Seals Leak Wheel Seal: All Technical Service Bulletins Axle - Rear Axle Hub Seals Leak Article No. 86-22-23 AXLE (10.25") - REAR - HUB SEALS LEAK - VENT PLUGGED LIGHT TRUCK 1985-86 F-250/350 A plugged rear axle vent may cause water to be sucked in through the seals and grease to be pushed out. This happens when pressures rise and fall inside the axle during various driving conditions and temperatures. The purpose of the vent is to relieve those pressures. If the vent is plugged with mud or other foreign materials, the axle cannot "breathe". To eliminate this concern, perform the following procedure: Figure 17 1. Remove the vent from the axle (Figure 17). 2. Place the vent in a vise so as not to damage the threads. 3. Drill out the vent using a 3/16 inch drill bit. Clean all shavings from vent. 4. Install vent. 5. Make sure entire vent hose is clear of dirt and mud, etc. 6. Install hose. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION: SP4022A86 TIME: 0.5 Hr. DLR. CODING: Basic Part No. 4022 - Code: 55 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Propeller Shaft <--> [Drive/Propeller Shaft] > Component Information > Technical Service Bulletins > Customer Interest for Propeller Shaft: > 872218 > Nov > 87 > Driveline - Clunk/Grunt Noise On Start Up Propeller Shaft: Customer Interest Driveline - Clunk/Grunt Noise On Start Up Article No. 87-22-18 ^ DRIVELINE - "CLUNK" OR "GRUNT" NOISE FROM DRIVELINE DURING STARTING AND STOPPING ^ NOISE - "CLUNK" OR "GRUNT" FROM DRIVELINE DURING STARTING AND STOPPING LIGHT TRUCK: 1978-87 E-250/350 1981-87 F-150/350, E-150 1983-87 RANGER 1986-87 AEROSTAR This article is being republished in its entirety to clarify the slip yoke application chart. ISSUE: A "clunk" or "grunt" noise from the vehicle driveline during start-up and stopping drive modes may be caused by engine torque preventing the slip yoke from sliding smoothly on the transmission output shaft splines. During the same drive modes, rear suspension wrap-up overcomes slip yoke-to-output shaft friction causing sudden slip yoke/driveshaft movement, which results in a "clunk" or "grunt" noise. The affected vehicles are 1978-87 E-250/350 with a C6 transmission; 1981-87 F-150/350 (4x2) with a C6, NPG 435, AOD, TOD, or T18 transmission; 1981-87 E-150 with a C6 or AOD transmission; 1985-86 F- 150/250 (4x4); 1983-87 Ranger (4x2) and 1986-87 Aerostar. ACTION: To correct this, install a new design slip yoke with nickel-plated splines to allow for smooth slip yoke movement. Refer to the appropriate Shop Manual, Section 15-60 for slip yoke removal and installation procedures. Also, refer to the slip yoke application chart below for the correct service part number. PART NUMBER PART NAME CLASS E6TZ-4841-D Slip Yoke C E6TZ-4841-E Slip Yoke C E6TZ-4841-F Slip Yoke C E4TZ-4841-G Slip Yoke B E1TZ-4841-D Slip Yoke B D5UZ-4841-C Slip Yoke B OTHER APPLICABLE ARTICLES: Supersedes 86-21-14, 87-17-11 WARRANTY STATUS: Eligible Under Powertrain Coverage OPERATION: SP872218A TIME: 0.6 Hr. DLR. CODING: Basic Part No. 4841 - Code: 41 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Propeller Shaft <--> [Drive/Propeller Shaft] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Propeller Shaft: > 872218 > Nov > 87 > Driveline - Clunk/Grunt Noise On Start Up Propeller Shaft: All Technical Service Bulletins Driveline - Clunk/Grunt Noise On Start Up Article No. 87-22-18 ^ DRIVELINE - "CLUNK" OR "GRUNT" NOISE FROM DRIVELINE DURING STARTING AND STOPPING ^ NOISE - "CLUNK" OR "GRUNT" FROM DRIVELINE DURING STARTING AND STOPPING LIGHT TRUCK: 1978-87 E-250/350 1981-87 F-150/350, E-150 1983-87 RANGER 1986-87 AEROSTAR This article is being republished in its entirety to clarify the slip yoke application chart. ISSUE: A "clunk" or "grunt" noise from the vehicle driveline during start-up and stopping drive modes may be caused by engine torque preventing the slip yoke from sliding smoothly on the transmission output shaft splines. During the same drive modes, rear suspension wrap-up overcomes slip yoke-to-output shaft friction causing sudden slip yoke/driveshaft movement, which results in a "clunk" or "grunt" noise. The affected vehicles are 1978-87 E-250/350 with a C6 transmission; 1981-87 F-150/350 (4x2) with a C6, NPG 435, AOD, TOD, or T18 transmission; 1981-87 E-150 with a C6 or AOD transmission; 1985-86 F- 150/250 (4x4); 1983-87 Ranger (4x2) and 1986-87 Aerostar. ACTION: To correct this, install a new design slip yoke with nickel-plated splines to allow for smooth slip yoke movement. Refer to the appropriate Shop Manual, Section 15-60 for slip yoke removal and installation procedures. Also, refer to the slip yoke application chart below for the correct service part number. PART NUMBER PART NAME CLASS E6TZ-4841-D Slip Yoke C E6TZ-4841-E Slip Yoke C E6TZ-4841-F Slip Yoke C E4TZ-4841-G Slip Yoke B E1TZ-4841-D Slip Yoke B D5UZ-4841-C Slip Yoke B OTHER APPLICABLE ARTICLES: Supersedes 86-21-14, 87-17-11 WARRANTY STATUS: Eligible Under Powertrain Coverage OPERATION: SP872218A TIME: 0.6 Hr. DLR. CODING: Basic Part No. 4841 - Code: 41 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Slip Yoke > Component Information > Technical Service Bulletins > Customer Interest for Slip Yoke: > 872218 > Nov > 87 > Driveline Clunk/Grunt Noise On Start Up Slip Yoke: Customer Interest Driveline - Clunk/Grunt Noise On Start Up Article No. 87-22-18 ^ DRIVELINE - "CLUNK" OR "GRUNT" NOISE FROM DRIVELINE DURING STARTING AND STOPPING ^ NOISE - "CLUNK" OR "GRUNT" FROM DRIVELINE DURING STARTING AND STOPPING LIGHT TRUCK: 1978-87 E-250/350 1981-87 F-150/350, E-150 1983-87 RANGER 1986-87 AEROSTAR This article is being republished in its entirety to clarify the slip yoke application chart. ISSUE: A "clunk" or "grunt" noise from the vehicle driveline during start-up and stopping drive modes may be caused by engine torque preventing the slip yoke from sliding smoothly on the transmission output shaft splines. During the same drive modes, rear suspension wrap-up overcomes slip yoke-to-output shaft friction causing sudden slip yoke/driveshaft movement, which results in a "clunk" or "grunt" noise. The affected vehicles are 1978-87 E-250/350 with a C6 transmission; 1981-87 F-150/350 (4x2) with a C6, NPG 435, AOD, TOD, or T18 transmission; 1981-87 E-150 with a C6 or AOD transmission; 1985-86 F- 150/250 (4x4); 1983-87 Ranger (4x2) and 1986-87 Aerostar. ACTION: To correct this, install a new design slip yoke with nickel-plated splines to allow for smooth slip yoke movement. Refer to the appropriate Shop Manual, Section 15-60 for slip yoke removal and installation procedures. Also, refer to the slip yoke application chart below for the correct service part number. PART NUMBER PART NAME CLASS E6TZ-4841-D Slip Yoke C E6TZ-4841-E Slip Yoke C E6TZ-4841-F Slip Yoke C E4TZ-4841-G Slip Yoke B E1TZ-4841-D Slip Yoke B D5UZ-4841-C Slip Yoke B OTHER APPLICABLE ARTICLES: Supersedes 86-21-14, 87-17-11 WARRANTY STATUS: Eligible Under Powertrain Coverage OPERATION: SP872218A TIME: 0.6 Hr. DLR. CODING: Basic Part No. 4841 - Code: 41 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Slip Yoke > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Slip Yoke: > 872218 > Nov > 87 > Driveline - Clunk/Grunt Noise On Start Up Slip Yoke: All Technical Service Bulletins Driveline - Clunk/Grunt Noise On Start Up Article No. 87-22-18 ^ DRIVELINE - "CLUNK" OR "GRUNT" NOISE FROM DRIVELINE DURING STARTING AND STOPPING ^ NOISE - "CLUNK" OR "GRUNT" FROM DRIVELINE DURING STARTING AND STOPPING LIGHT TRUCK: 1978-87 E-250/350 1981-87 F-150/350, E-150 1983-87 RANGER 1986-87 AEROSTAR This article is being republished in its entirety to clarify the slip yoke application chart. ISSUE: A "clunk" or "grunt" noise from the vehicle driveline during start-up and stopping drive modes may be caused by engine torque preventing the slip yoke from sliding smoothly on the transmission output shaft splines. During the same drive modes, rear suspension wrap-up overcomes slip yoke-to-output shaft friction causing sudden slip yoke/driveshaft movement, which results in a "clunk" or "grunt" noise. The affected vehicles are 1978-87 E-250/350 with a C6 transmission; 1981-87 F-150/350 (4x2) with a C6, NPG 435, AOD, TOD, or T18 transmission; 1981-87 E-150 with a C6 or AOD transmission; 1985-86 F- 150/250 (4x4); 1983-87 Ranger (4x2) and 1986-87 Aerostar. ACTION: To correct this, install a new design slip yoke with nickel-plated splines to allow for smooth slip yoke movement. Refer to the appropriate Shop Manual, Section 15-60 for slip yoke removal and installation procedures. Also, refer to the slip yoke application chart below for the correct service part number. PART NUMBER PART NAME CLASS E6TZ-4841-D Slip Yoke C E6TZ-4841-E Slip Yoke C E6TZ-4841-F Slip Yoke C E4TZ-4841-G Slip Yoke B E1TZ-4841-D Slip Yoke B D5UZ-4841-C Slip Yoke B OTHER APPLICABLE ARTICLES: Supersedes 86-21-14, 87-17-11 WARRANTY STATUS: Eligible Under Powertrain Coverage OPERATION: SP872218A TIME: 0.6 Hr. DLR. CODING: Basic Part No. 4841 - Code: 41 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Description and Operation Universal Joint: Description and Operation Fig. 3 Cross & roller type universal joints Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Description and Operation > Page 4922 Fig. 4 Cross & roller type universal joints & propeller shaft Figs. 3 and 4 illustrate typical examples of universal joints of this type. They all operate on the same principle and similar service and replacement procedures may be applied to all. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Servicing Using Universal Joint Replacement Tool Universal Joint: Service and Repair Servicing Using Universal Joint Replacement Tool Fig. 7 Removing bearing caps using tool & adapter Fig. 8 Removing bearing cap by holding cap in vise & striking center yoke with hammer Disassembly 1. Place driveshaft in a vise using care to avoid damaging it. 2. Remove bearing retaining snap rings. Some universal joints use injected nylon retainers in place of snap rings. During servicing, the snap rings supplied with the replacement universal joint assembly must be used. 3. Position tool on shaft and press bearing out of yoke, Fig. 7. If bearing cannot be pressed all the way out, remove it using vise grips or channel lock pliers or position driveshaft as shown and strike center yoke with hammer, Fig. 8. Mark yoke and shaft to make sure they will be reassembled in their same relative positions. 4. Reposition tool so that it presses on the spider in order to press other bearing from opposite side of flange. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Servicing Using Universal Joint Replacement Tool > Page 4925 5. If used, remove flange from spider. Assembly 1. Start new bearing into yoke, then position spider into yoke and press bearing until it is 1/4 inch below surface. 2. Remove tool and install a new snap ring. 3. Start new bearing in opposite side of yoke, then install tool and press on bearing until opposite bearing contacts snap ring. 4. Remove tool and install remaining snap ring. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Servicing Using Universal Joint Replacement Tool > Page 4926 Universal Joint: Service and Repair Servicing Without Universal Joint Replacement Tool Fig. 5 Removing bearings from yoke using a small socket as a driver & large socket as a receiver Disassembly 1. Remove snap rings (or retainer plates) that retain bearings in yoke and drive shaft. 2. Place U-joint in a vise. 3. Select a wrench socket with an outside diameter slightly smaller than the U-joint bearings. Select another wrench socket with an inside diameter slightly larger than the U-joint bearings. 4. Place the sockets at opposite bearings in the yoke so that the smaller socket becomes a bearing pusher and the larger socket becomes a bearing receiver when the vise jaws come together, Fig. 5. Close vise jaws until both bearings are free of yoke and remove bearings from the cross or spider. 5. If bearings will not come all the way out, close vise until bearing in receiver socket protrudes from yoke as much as possible without using excessive force. Then remove from vise and place that portion of bearing which protrudes from yoke between vise jaws. Tighten vise to hold bearing and drive yoke off with a soft hammer. 6. To remove opposite bearing from yoke, replace in vise with pusher socket on exposed cross journal with receiver socket over bearing cup. Then tighten vise jaws to press bearing back through yoke into receiving socket. 7. Remove yoke from drive shaft and again place protruding portion of bearing between vise jaws. Then tighten vise to hold bearing while driving yoke off bearing with soft hammer. 8. Turn spider or cross 1/4 turn and use the same procedure to press bearings out of drive shaft. Fig. 6 Installing bearings into driveshaft yoke Assembly 1. If old parts are to be reassembled, pack bearing cups with universal joint grease. Do not fill cups completely or use excessive amounts as Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Servicing Using Universal Joint Replacement Tool > Page 4927 over-lubrication may damage seals during reassembly. Use new seals. 2. If new parts are being installed, check new bearings for adequate grease before assembling. 3. With the pusher (smaller) socket, press one bearing part way into drive shaft. Position spider into the partially installed bearing. Place second bearing into drive shaft. Fasten drive shaft in vise so that bearings are in contact with faces of vise jaws, Fig. 6. Some spiders are provided with locating lugs which must face toward drive shaft when installed. 4. Press bearings all the way into position and install snap rings or retainer plates. 5. Install bearings in yoke in same manner. When installation is completed, check U-joint for binding or roughness. If free movement is impeded, correct the condition before installation in vehicle. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Flywheel > Component Information > Specifications Flywheel: Specifications Flywheel To Crankshaft Bolts 75-85 ft.lb Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Locations Four Wheel Drive Indicator Lamp: Locations LH Quarter Panel Area (F150-350) On Transfer Case Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions Four Wheel Drive Indicator Lamp: Diagram Information and Instructions Symbol Identification Wire Color Code Identification Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 4938 NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 4939 Fig. 25 Four Wheel Drive Indicator Lamp Wiring Circuit Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Counter Gear, M/T > Component Information > Service and Repair Counter Gear: Service and Repair DISASSEMBLE Disassembled View Of Warner T-19B & T-19D 4-speed Manual Transmission 1. Remove dummy shaft and bearing rollers from countershaft gear. 2. Remove bearing spacers and center spacer from gear. ASSEMBLE 1. Slide long bearing spacer into countershaft gear bore, then insert well greased dummy shaft into spacer. 2. Install one bearing spacer, then 22 pilot rollers in gear bore, While holding gear in a vertical position. 3. Install second spacer, then the remaining 22 rollers and spacer. 4. Apply suitable grease to face of large thrust washer, then hold washer against face of countershaft gear and invert assembly. Install rollers, spacers and thrust washer in opposite end of gear. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Countershaft, M/T > Component Information > Technical Service Bulletins > Customer Interest: > 87535 > Mar > 87 > M/T - T19 Leaks Fluid Countershaft: Customer Interest M/T - T19 Leaks Fluid Article No. TRANSMISSION - T19 - LEAKS FLUID 87-5-35 LIGHT TRUCK 1983-86 F-250/350 ISSUE: Fluid leaks at the rear of the main case at the countershaft bore, reverse idler shaft bore and the keeper plate bolt hole may be caused by lack of sealing. ACTION: To correct this, install a new design countershaft (C5TZ-7111-B) and reverse idler shaft (C5TZ-7140-A) fitted with O-rings in the machined grooves of the shafts. The leak at the keeper plate bolt hole may be corrected by applying sealer around the keeper bolt threads. Refer to the Light Truck Shop Manual, Section 16- 24 for removal and installation procedures. NOTE: T19 transmissions built after 09/15/86 use the new design countershaft and reverse idler shaft. PART NUMBER PART NAME CLASS C5TZ-7111-B Countershaft B C5TZ-7140-A Reverse Idler Shaft C OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual OPERATION: SP870535A TIME: 3.4 Hrs. - 4x2 4.3 Hrs. - 4x4 OPERATION: SP870535S1 - Extra time if equipped with coupling shaft TIME: 0.2 Hr. OPERATION: SP870535S2 - Extra time if equipped with full floor carpet TIME: 0.5 Hr. OPERATION: SP870535S3 - Extra time if equipped with skid plate TIME: 0.2 Hr. OPERATION: SP870535S4 - Extra time if equipped with PTO TIME: 0.5 Hr. DLR. CODING: Basic Part No. 7003 - Code: 77 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Countershaft, M/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 87535 > Mar > 87 > M/T - T19 Leaks Fluid Countershaft: All Technical Service Bulletins M/T - T19 Leaks Fluid Article No. TRANSMISSION - T19 - LEAKS FLUID 87-5-35 LIGHT TRUCK 1983-86 F-250/350 ISSUE: Fluid leaks at the rear of the main case at the countershaft bore, reverse idler shaft bore and the keeper plate bolt hole may be caused by lack of sealing. ACTION: To correct this, install a new design countershaft (C5TZ-7111-B) and reverse idler shaft (C5TZ-7140-A) fitted with O-rings in the machined grooves of the shafts. The leak at the keeper plate bolt hole may be corrected by applying sealer around the keeper bolt threads. Refer to the Light Truck Shop Manual, Section 16- 24 for removal and installation procedures. NOTE: T19 transmissions built after 09/15/86 use the new design countershaft and reverse idler shaft. PART NUMBER PART NAME CLASS C5TZ-7111-B Countershaft B C5TZ-7140-A Reverse Idler Shaft C OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual OPERATION: SP870535A TIME: 3.4 Hrs. - 4x2 4.3 Hrs. - 4x4 OPERATION: SP870535S1 - Extra time if equipped with coupling shaft TIME: 0.2 Hr. OPERATION: SP870535S2 - Extra time if equipped with full floor carpet TIME: 0.5 Hr. OPERATION: SP870535S3 - Extra time if equipped with skid plate TIME: 0.2 Hr. OPERATION: SP870535S4 - Extra time if equipped with PTO TIME: 0.5 Hr. DLR. CODING: Basic Part No. 7003 - Code: 77 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Countershaft, M/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Countershaft: > 932410 > Nov > 93 > Instrument Cluster Warning Lights - Dimly Lit Ignition Switch: All Technical Service Bulletins Instrument Cluster Warning Lights - Dimly Lit Article No. 93-24-10 11/24/93 ^ LAMP - MALFUNCTION OF FOUR PIN LOW OIL LEVEL RELAY - VEHICLES BUILT AFTER 8/1/92 OR 1983-1993 VEHICLES THAT HAVE HAD SERVICE REPLACEMENT IGNITION SWITCHES AFTER 8/1/92 ^ LAMPS - INSTRUMENT CLUSTER WARNING LIGHTS DIMLY LIT - VEHICLES BUILT AFTER 8/1/92 OR 1983-1993 VEHICLES THAT HAVE HAD SERVICE REPLACEMENT IGNITION SWITCHES AFTER 8/1/92 FORD: 1983 FAIRMONT 1983-89 CROWN VICTORIA, ESCORT 1983-93 MUSTANG, THUNDERBIRD 1983-94 PROBE 1984-86 LTD 1984-94 TEMPO LINCOLN-MERCURY: 1983 LN7, ZEPHYR 1983-87 CONTINENTAL, LYNX 1983-89 GRAND MARQUIS, TOWN CAR 1983-93 COUGAR 1984-86 CAPRI, MARQUIS 1984-94 TOPAZ LIGHT TRUCK: 1983-91 BRONCO 1983-93 ECONOLINE, F-150-350 SERIES, RANGER 1986-91 AEROSTAR 1991-93 EXPLORER ISSUE: The instrument cluster warning light(s) may be dimly lit or there may be a malfunction of the four pin low oil relay on vehicles so equipped. This could be due to the ignition switch. ACTION: If the vehicle displays the subject symptoms and meets the following conditions, replace the ignition switch. Refer to the appropriate Car or Light Truck Service Manual (Section 13-04 for 1983-1990 Cars, Section 11-04 for 1991-1993 Cars and Section 13-05 for 1983-1990 Light Trucks, Section 11-05 for 1991-1993 Light Trucks) for removal and installation procedures. Refer to the Parts Block in this article for correct parts usage. CONDITIONS ^ The vehicle has 14401 wiring attached to the P2 terminal of the ignition switch. Refer to the wiring schematic and/or Electrical And Vacuum Troubleshooting Manual (EVTM) for the concern vehicle. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Countershaft, M/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Countershaft: > 932410 > Nov > 93 > Instrument Cluster Warning Lights - Dimly Lit > Page 4962 ^ The vehicle is equipped with one of the ignition switches identified in the Ignition Switch Part Number Chart. NOTE: THE SERVICE PART NUMBERS FOR THE REPLACEMENT IGNITION SWITCHES WILL HAVE THE SAME PART NUMBERS AS THOSE REPLACED. THE NEW SWITCH HAS BEEN IMPROVED TO CORRECT THE SUBJECT ISSUE. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of The Bumper To Bumper For 1992/93 Models, Basic Warranty Coverage For All Other Models Except Lincolns. Major Component Warranty Coverage For Lincolns OPERATION DESCRIPTION TIME 932410A Replace Ignition Switch - 0.5 Hr. All Light and Compact Trucks DEALER CODING BASIC PART NO. CONDITION CODE 11572 X1 OASIS CODES: 201000, 201100, 206000 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Countershaft, M/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Countershaft: > 932410 > Nov > 93 > Instrument Cluster Warning Lights - Dimly Lit > Page 4968 ^ The vehicle is equipped with one of the ignition switches identified in the Ignition Switch Part Number Chart. NOTE: THE SERVICE PART NUMBERS FOR THE REPLACEMENT IGNITION SWITCHES WILL HAVE THE SAME PART NUMBERS AS THOSE REPLACED. THE NEW SWITCH HAS BEEN IMPROVED TO CORRECT THE SUBJECT ISSUE. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of The Bumper To Bumper For 1992/93 Models, Basic Warranty Coverage For All Other Models Except Lincolns. Major Component Warranty Coverage For Lincolns OPERATION DESCRIPTION TIME 932410A Replace Ignition Switch - 0.5 Hr. All Light and Compact Trucks DEALER CODING BASIC PART NO. CONDITION CODE 11572 X1 OASIS CODES: 201000, 201100, 206000 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Technical Service Bulletins > Drivetrain - Lubricant Usage Fluid - M/T: Technical Service Bulletins Drivetrain - Lubricant Usage Article No. 89-8-16 ^ DRIVETRAIN - LUBRICATION USAGE ^ TRANSMISSION - MANUAL - LUBRICATION USAGE LIGHT TRUCK: 1980-89 BRONCO, ECONOLINE, F-150, F-250, F-350 1983-89 RANGER 1984-89 BRONCO II 1986-89 AEROSTAR ISSUE: A quick reference manual transmission fluid usage chart and a quick reference drivetrain lubrication usage chart for light trucks has been put together to assist technicians in the event service is required. FIGURE 1 FIGURE 2 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Technical Service Bulletins > Drivetrain - Lubricant Usage > Page 4973 ACTION: Refer to the transmission fluid application chart in Figure 1 for the correct fluid usage. Refer to the drivetrain lubrication application chart in Figure 2 for the correct lubricant usage. PART NUMBER PART NAME CLASS D8DZ-19C547-A Standard Transmission BG Lubricant - 5 gallons C1AZ-19590-BA Long Life Lubricant B (molybdenum disulfide) - 14.5 ounces DOAZ-19584-AA Multi-Purpose Grease - 4 ounce B tube D7AZ-19584-AA Multi-Purpose Grease - 15 B ounce aerosol can XT-2-QDX Transmission Fluid (Mercon) - V quart can (pkg. of 12) C6AZ-19580-E Gear Oil (Dana axle) - 1 gallon AG C8AZ-19B546-A Additive Friction Modifier - 4 AM ounce bottle D7AZ-19590-A Disc Brake Caliper Slide AM Grease - 4 ounce tube E8TZ-19590-A Grease - 14.5 ounces B E1TZ-19590-A Automatic Hublock Grease - 5 B ounce tube E5RY-19C547-A Merkur Synthetic Manual B Transmission Fluid OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 5970 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Technical Service Bulletins > Drivetrain - Lubricant Usage > Page 4974 Fluid - M/T: Technical Service Bulletins A/T, M/T - New `Mercon' Transmission Fluid TRANSMISSION - AUTOMATIC/MANUAL - Article No. NEW FLUID AND USAGE CHART 87-18-14 FORD: 1986 And Prior LTD 1988 And Prior ESCORT, TEMPO, MUSTANG, TAURUS, THUNDERBIRD, FORD LINCOLN-MERCURY: 1986 And Prior CAPRI, MARQUIS 1987 And Prior LYNX 1988 And Prior TOPAZ, SABLE, COUGAR, MERCURY, MARK VII, CONTINENTAL, LINCOLN TOWN CAR MERKUR: 1985-88 XR4Ti 1988 SCORPIO LIGHT TRUCK: 1988 And Prior E SERIES, F SERIES, BRONCO, RANGER, BRONCO II, AEROSTAR ISSUE: A new Transmission Fluid, MERCON (Ford Specification "MERCON") (XT-2- QDX, Quart), (XT-2-DDX, 55 Gallon Drum) is available for service. Use of the Motorcraft "MERCON" transmission fluid, where specified, will improve cold weather shift effort and synchronized operation. ACTION: The chart on page 44 of this TSB gives transmission fluid applications for automatic transmissions and certain manual transmissions for Ford, Lincoln-Mercury, and Merkur vehicles. NOTE: The use of MERCON is NOT RECOMMENDED for power steering systems. The manual transmission lubricant for the 1985 Merkur XR4Ti is a semi-synthetic oil. When adding oil to the transmission, use only E5RY-19C547-A (Ford Specification ESD-M2C175-A) or equivalent. PART NUMBER PART NAME CLASS XT-2-QDX MERCON - Quart V Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Technical Service Bulletins > Drivetrain - Lubricant Usage > Page 4975 XT-2-DDX MERCON - 55 Gallon V Drum E5RY-19C547-A Semi-Synthetic Oil B OTHER APPLICABLE ARTICLES: 82-9-9 Supersedes 85-1-15, 85-6-7 WARRANTY STATUS: "INFORMATION ONLY" Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Technical Service Bulletins > Page 4976 Fluid - M/T: Specifications See TSB 06-14-4 1987 5-speed Mercon(R) V Automatic Transmission Fluid All others 80W EP CAPACITY, Refill: 3-speed 3.5 pt (US) 4-speed ex. OD 7.0 pt (US) W/OD 4.5 pt (US) 5-speed 7.4 pt (US) Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Gear, M/T > Synchronizer Hub, M/T > Component Information > Service and Repair Synchronizer Hub: Service and Repair DISASSEMBLE 1. Scribe alignment marks on synchronizer hub and sleeve for assembly reference. Disassembled View Of Ford Overdrive (Top Mounted Shifter) 4-Speed Manual Transmission (Part 1 Of 2) Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Gear, M/T > Synchronizer Hub, M/T > Component Information > Service and Repair > Page 4981 Disassembled View Of Ford Overdrive (Top Mounted Shifter) 4-Speed Manual Transmission (Part 2 Of 2) 2. Push synchronizer hubs from sleeves. 3. Remove inserts and insert springs from hubs. ASSEMBLE 1. Position hubs in sleeves, ensuring scribe marks are properly aligned. 2. Install inserts and insert springs, ensuring tab is located in a common insert rotating in opposite directions. Do not stagger springs. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Gear, M/T > Synchronizer Ring, M/T > Component Information > Service and Repair > TOD (4-Speed Overdrive) Top Mounted Shifter Synchronizer Ring: Service and Repair TOD (4-Speed Overdrive) Top Mounted Shifter DISASSEMBLE 1. Scribe alignment marks on synchronizer hub and sleeve for assembly reference. Disassembled View Of Ford Overdrive (Top Mounted Shifter) 4-Speed Manual Transmission (Part 1 Of 2) Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Gear, M/T > Synchronizer Ring, M/T > Component Information > Service and Repair > TOD (4-Speed Overdrive) Top Mounted Shifter > Page 4986 Disassembled View Of Ford Overdrive (Top Mounted Shifter) 4-Speed Manual Transmission (Part 2 Of 2) 2. Push synchronizer hubs from sleeves. 3. Remove inserts and insert springs from hubs. ASSEMBLE 1. Position hubs in sleeves, ensuring scribe marks are properly aligned. 2. Install inserts and insert springs, ensuring tab is located in a common insert rotating in opposite directions. Do not stagger springs. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Gear, M/T > Synchronizer Ring, M/T > Component Information > Service and Repair > TOD (4-Speed Overdrive) Top Mounted Shifter > Page 4987 Synchronizer Ring: Service and Repair Warner T-18 / T-19 (4-Speed) DISASSEMBLE Disassembled View Of Warner T-19B & T-19D 4-speed Manual Transmission 1. Remove spring from each side of synchronizer assembly. 2. Remove 3 inserts from assembly, then slide hub out of sleeve. ASSEMBLE NOTE: The following procedure applies to the 1st-2nd synchronizer assembly. Assembly of the 3rd-4th synchronizer is identical except that the two grooves on the chamfered portion of the clutch sleeve can be assembled in either direction on the hub. 1. Install 1st-2nd clutch hub into sleeve, ensuring hub counterbore is on same side as sleeve chamfer. 2. Position 3 inserts into hub slots. 3. Hook end of spring under an insert, then position spring around hub and under each insert. 4. Invert assembly and hook end of second spring over opposite end of insert used for hooking first spring. 5. Position spring around hub and under each insert, in opposite direction of first spring. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Input Shaft, M/T > Component Information > Service and Repair Input Shaft: Service and Repair DISASSEMBLE Disassembled View Of Warner T-19B & T-19D 4-speed Manual Transmission 1. Remove thrust spacer and pilot bearing rollers from gear bore. 2. Remove input shaft bearing using a suitable puller. ASSEMBLE 1. Press bearing and oil baffle onto input shaft and against gear. 2. Apply suitable grease to gear bore and position 17 pilot rollers in bore. 3. Install thrust spacer in bore and hold in position with grease. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Output Shaft, M/T > Component Information > Service and Repair > Output Shaft Output Shaft: Service and Repair Output Shaft DISASSEMBLE Disassembled View Of Warner T-19B & T-19D 4-speed Manual Transmission 1. Remove snap ring, 3rd-4th synchronizer assembly, blocking ring and 3rd gear from output shaft. 2. Remove reverse gear from shaft using an arbor press or suitable puller. 3. Remove 1st gear snap ring, 1st gear and blocker ring from shaft. 4. Remove 1st-2nd synchronizer snap ring and the synchronizer assembly. 5. Remove 2nd gear snap ring, blocking ring and 2nd gear. ASSEMBLE 1. Position output shaft vertically with front of shaft downward and slide 2nd gear onto shaft with gear cone toward rear. 2. Install snap ring on output shaft at rear of 2nd gear. 3. Position blocking ring in 1st-2nd synchronizer assembly next to side of hub with counterbore. Ensure ring slots align with insert. 4. Install 1st-2nd synchronizer assembly on shaft while holding blocking ring in place, and secure assembly with snap ring. 5. Install second blocking ring into synchronizer assembly, ensuring ring slots are aligned with inserts. 6. Install 1st gear and snap ring on shaft, ensuring coned portion of gear faces 1st-2nd synchronizer assembly. 7. Install output shaft in a suitable press, then press reverse gear and rear bearing cone onto shaft. 8. Remove output shaft from press and install 3rd gear with cone toward front. 9. Position blocking ring in 3rd-4th synchronizer assembly on side with larger diameter hub. Ensure ring slots align with inserts. 10. Slide 3rd-4th synchronizer assembly onto shaft while holding blocking ring in position, then install thrust bearing against race. 11. Apply suitable grease to face of blocking ring, then install ring on shaft and into 3rd-4th synchronizer assembly. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Output Shaft, M/T > Component Information > Service and Repair > Output Shaft > Page 4995 Output Shaft: Service and Repair Output Shaft & Geartrain DISASSEMBLE Disassembled View Of Ford Overdrive (Top Mounted Shifter) 4-Speed Manual Transmission (Part 1 Of 2) Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Output Shaft, M/T > Component Information > Service and Repair > Output Shaft > Page 4996 Disassembled View Of Ford Overdrive (Top Mounted Shifter) 4-Speed Manual Transmission (Part 2 Of 2) 1. Remove snap ring from front of output shaft. 2. Remove 3rd-4th synchronizer assembly and overdrive gear from shaft. 3. Remove snap ring, 2nd gear thrust washer, 2nd gear and blocking ring from shaft. 4. Remove snap ring, then press 1st-2nd synchronizer assembly off shaft. ASSEMBLE 1. Apply suitable lubricant to 1st gear journal, then press 1st-2nd synchronizer assembly onto front of output shaft, ensuring shift fork groove is facing toward rear of shaft. 2. Install 1st speed gear and blocking ring on rear of shaft. 3. Install snap ring in front of 1st-2nd synchronizer assembly. 4. Position blocking ring on 2nd gear, then apply suitable lubricant to 2nd gear journal on shaft. 5. Install 2nd speed gear and blocking ring on front of shaft, ensuring inserts in synchronizer engage notches in blocking ring. 6. Install 2nd gear thrust washer and snap ring, then apply suitable lubricant to overdrive gear journal on shaft. 7. Install overdrive gear on shaft with coned synchronizer surface facing forward. 8. Install blocking ring on overdrive gear, then slide 3rd-4th synchronizer assembly onto shaft. Ensure synchronizer inserts engage notches in blocking ring and small thrust surface faces forward. 9. Install snap ring on front of shaft. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Reverse Idler Gear > Component Information > Technical Service Bulletins > Customer Interest for Reverse Idler Gear: > 87535 > Mar > 87 > M/T - T19 Leaks Fluid Reverse Idler Gear: Customer Interest M/T - T19 Leaks Fluid Article No. TRANSMISSION - T19 - LEAKS FLUID 87-5-35 LIGHT TRUCK 1983-86 F-250/350 ISSUE: Fluid leaks at the rear of the main case at the countershaft bore, reverse idler shaft bore and the keeper plate bolt hole may be caused by lack of sealing. ACTION: To correct this, install a new design countershaft (C5TZ-7111-B) and reverse idler shaft (C5TZ-7140-A) fitted with O-rings in the machined grooves of the shafts. The leak at the keeper plate bolt hole may be corrected by applying sealer around the keeper bolt threads. Refer to the Light Truck Shop Manual, Section 16- 24 for removal and installation procedures. NOTE: T19 transmissions built after 09/15/86 use the new design countershaft and reverse idler shaft. PART NUMBER PART NAME CLASS C5TZ-7111-B Countershaft B C5TZ-7140-A Reverse Idler Shaft C OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual OPERATION: SP870535A TIME: 3.4 Hrs. - 4x2 4.3 Hrs. - 4x4 OPERATION: SP870535S1 - Extra time if equipped with coupling shaft TIME: 0.2 Hr. OPERATION: SP870535S2 - Extra time if equipped with full floor carpet TIME: 0.5 Hr. OPERATION: SP870535S3 - Extra time if equipped with skid plate TIME: 0.2 Hr. OPERATION: SP870535S4 - Extra time if equipped with PTO TIME: 0.5 Hr. DLR. CODING: Basic Part No. 7003 - Code: 77 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Reverse Idler Gear > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Reverse Idler Gear: > 87535 > Mar > 87 > M/T - T19 Leaks Fluid Reverse Idler Gear: All Technical Service Bulletins M/T - T19 Leaks Fluid Article No. TRANSMISSION - T19 - LEAKS FLUID 87-5-35 LIGHT TRUCK 1983-86 F-250/350 ISSUE: Fluid leaks at the rear of the main case at the countershaft bore, reverse idler shaft bore and the keeper plate bolt hole may be caused by lack of sealing. ACTION: To correct this, install a new design countershaft (C5TZ-7111-B) and reverse idler shaft (C5TZ-7140-A) fitted with O-rings in the machined grooves of the shafts. The leak at the keeper plate bolt hole may be corrected by applying sealer around the keeper bolt threads. Refer to the Light Truck Shop Manual, Section 16- 24 for removal and installation procedures. NOTE: T19 transmissions built after 09/15/86 use the new design countershaft and reverse idler shaft. PART NUMBER PART NAME CLASS C5TZ-7111-B Countershaft B C5TZ-7140-A Reverse Idler Shaft C OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual OPERATION: SP870535A TIME: 3.4 Hrs. - 4x2 4.3 Hrs. - 4x4 OPERATION: SP870535S1 - Extra time if equipped with coupling shaft TIME: 0.2 Hr. OPERATION: SP870535S2 - Extra time if equipped with full floor carpet TIME: 0.5 Hr. OPERATION: SP870535S3 - Extra time if equipped with skid plate TIME: 0.2 Hr. OPERATION: SP870535S4 - Extra time if equipped with PTO TIME: 0.5 Hr. DLR. CODING: Basic Part No. 7003 - Code: 77 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Reverse Idler Gear > Component Information > Technical Service Bulletins > Page 5010 Reverse Idler Gear: Service and Repair DISASSEMBLE Disassembled View Of Warner T-19B & T-19D 4-speed Manual Transmission 1. Remove snap ring, idler gear bearing rollers and thrust washer from reverse idler gear. 2. Remove bearing spacer, bushing and remaining snap ring from gear. ASSEMBLE 1. Install snap ring on one end of gear, then position gear vertically with snap ring at bottom. 2. Install thrust washer into gear on top of snap ring. 3. Apply suitable grease to outside of bushing, then install bushing on top of washer. 4. Install 37 rollers between bushing and gear bore. Install spacer on top of rollers, then insert remaining 37 rollers. 5. Install remaining thrust washer and snap ring. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shifter M/T > Component Information > Technical Service Bulletins > M/T - Shift Lever Return Request Shifter M/T: Technical Service Bulletins M/T - Shift Lever Return Request Number: 92586 To: All Ford and Lincoln-Mercury Dealers Subject: Request for Return of Shift Lever Assy (Manual Tranamission) E6TZ-7210-D Because the subject part may not meet Ford's high quality requirements, it should be withdrawn from all inventories. All unused E6TZ-7210-D should be returned to your facing PDC within 30 days from the date of this letter. Use the least expensive mode of transportation for your return. The subject part is obsolete and replaced by E6TZ-7210-F, which is available for ordering immediately. You are requested to complete a separate FPS-340 form in accordance with the instructions on the front of the form. Annotate "Returned Per FPSD Instructions Purge No. PN 1027" in the Customer's Detail Explanation Section and use Reason Code J (Unsatisfactory Service stock). You will receive full credit in your parts statement for the price of each unused part returned, plus the prepaid transportation cost. In order to receive credit, all parts must be received at the Parts Distribution Center within 30 days from the date of this letter. Material other than E6TZ-7210-D received on this return will be sent back to you freight collect. Any questions should be referred to your Zone Manager or facing PDC Manager. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shifter M/T > Component Information > Technical Service Bulletins > M/T - Shift Lever Return Request > Page 5015 Shifter M/T: Technical Service Bulletins M/T - T19 Reverse Shifter Pivot Arm Screw - New Tool Article No. 86-20-16 TRANSMISSION - T19 - REVERSE SHIFTER PIVOT ARM SCREW - NEW TOOL LIGHT TRUCK 1986-87 F-250/350 The reverse shifter arm pivot screw has been redesigned so that it cannot be removed when attempting to check fluid level. The pivot now requires a tamper-proof torx driver bit for removal. The special tool number is T82L-12270-AT50 and was originally released to service the tamper-proof distributor hold-down screw on the 3.8L engine. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shifter M/T > Component Information > Technical Service Bulletins > M/T - Shift Lever Return Request > Page 5016 Shifter M/T: Technical Service Bulletins M/T - T18/19 Shift Tower/Shift Gate Revision Article No. 85-20-15 WARNER TRANSMISSION - T18/19 - SHIFT TOWER/SHIFT GATE REVISION TRANSMISSIONS BUILT AFTER NOVEMBER 20, 1984 LIGHT TRUCK 1985-86 F150-350 Figure 9 - Shift Tower/Shift Gate A new transmission gear shift housing (7222) and a new "spring-loaded" design 1st/2nd gear shift gate assembly (7279) became effective on transmissions built after November 20, 1984. The revisions in the shift gate are designed to retain the shift lever in the 3rd/4th gear shift mode and make transmission shifting into all gears smoother. See Figure 9. Because of a required casting change to the gear shift housing, to accomodate the new spring-loaded shift gate, interchangeability between the old and new design gear shift housing is affected. The old design gear shift housing can only be used with the old design 1st/2nd gear shift gate on transmissions built before November 2O, 1984.The new design gear shift housing (7222) can be used with either the old design or new design spring-loaded lst/2nd gear shift gate (7222) and can be used on transmissions built both before and after November 20, 1984. PART NUMBER PART NAME CLASS E5TZ-7222-A T18: Gear Shift Housing R - New D3TZ-7222-B T18: Gear Shift Housing R - Old E5TZ-7279-A 1-2 Shift Gate - New R C8TZ-7279-A 1-2 Shift Gate - Old RM E5TZ-7222-B T19: Gear Shift Housing C - New C9TZ-7222-A T19: Gear Shift Housing C Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shifter M/T > Component Information > Technical Service Bulletins > M/T - Shift Lever Return Request > Page 5017 - Old E5TZ-7279-B 1-2 Shift Gate - New C C8TZ-7279-B 1-2 Shift Gate - Old C OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Linkage <--> [Shift Linkage, M/T] > Component Information > Technical Service Bulletins > M/T - T19 Reverse Shifter Pivot Arm Screw New Tool Transmission Linkage: Technical Service Bulletins M/T - T19 Reverse Shifter Pivot Arm Screw New Tool Article No. 86-20-16 TRANSMISSION - T19 - REVERSE SHIFTER PIVOT ARM SCREW - NEW TOOL LIGHT TRUCK 1986-87 F-250/350 The reverse shifter arm pivot screw has been redesigned so that it cannot be removed when attempting to check fluid level. The pivot now requires a tamper-proof torx driver bit for removal. The special tool number is T82L-12270-AT50 and was originally released to service the tamper-proof distributor hold-down screw on the 3.8L engine. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Linkage <--> [Shift Linkage, M/T] > Component Information > Technical Service Bulletins > M/T - T19 Reverse Shifter Pivot Arm Screw New Tool > Page 5022 Transmission Linkage: Technical Service Bulletins M/T - T18/19 Shift Tower/Shift Gate Revision Article No. 85-20-15 WARNER TRANSMISSION - T18/19 - SHIFT TOWER/SHIFT GATE REVISION TRANSMISSIONS BUILT AFTER NOVEMBER 20, 1984 LIGHT TRUCK 1985-86 F150-350 Figure 9 - Shift Tower/Shift Gate A new transmission gear shift housing (7222) and a new "spring-loaded" design 1st/2nd gear shift gate assembly (7279) became effective on transmissions built after November 20, 1984. The revisions in the shift gate are designed to retain the shift lever in the 3rd/4th gear shift mode and make transmission shifting into all gears smoother. See Figure 9. Because of a required casting change to the gear shift housing, to accomodate the new spring-loaded shift gate, interchangeability between the old and new design gear shift housing is affected. The old design gear shift housing can only be used with the old design 1st/2nd gear shift gate on transmissions built before November 2O, 1984.The new design gear shift housing (7222) can be used with either the old design or new design spring-loaded lst/2nd gear shift gate (7222) and can be used on transmissions built both before and after November 20, 1984. PART NUMBER PART NAME CLASS E5TZ-7222-A T18: Gear Shift Housing R - New D3TZ-7222-B T18: Gear Shift Housing R - Old E5TZ-7279-A 1-2 Shift Gate - New R C8TZ-7279-A 1-2 Shift Gate - Old RM E5TZ-7222-B T19: Gear Shift Housing C - New C9TZ-7222-A T19: Gear Shift Housing C Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Linkage <--> [Shift Linkage, M/T] > Component Information > Technical Service Bulletins > M/T - T19 Reverse Shifter Pivot Arm Screw New Tool > Page 5023 - Old E5TZ-7279-B 1-2 Shift Gate - New C C8TZ-7279-B 1-2 Shift Gate - Old C OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Fluid - Transfer Case > Component Information > Technical Service Bulletins > Drivetrain - Lubricant Usage Fluid - Transfer Case: Technical Service Bulletins Drivetrain - Lubricant Usage Article No. 89-8-16 ^ DRIVETRAIN - LUBRICATION USAGE ^ TRANSMISSION - MANUAL - LUBRICATION USAGE LIGHT TRUCK: 1980-89 BRONCO, ECONOLINE, F-150, F-250, F-350 1983-89 RANGER 1984-89 BRONCO II 1986-89 AEROSTAR ISSUE: A quick reference manual transmission fluid usage chart and a quick reference drivetrain lubrication usage chart for light trucks has been put together to assist technicians in the event service is required. FIGURE 1 FIGURE 2 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Fluid - Transfer Case > Component Information > Technical Service Bulletins > Drivetrain - Lubricant Usage > Page 5029 ACTION: Refer to the transmission fluid application chart in Figure 1 for the correct fluid usage. Refer to the drivetrain lubrication application chart in Figure 2 for the correct lubricant usage. PART NUMBER PART NAME CLASS D8DZ-19C547-A Standard Transmission BG Lubricant - 5 gallons C1AZ-19590-BA Long Life Lubricant B (molybdenum disulfide) - 14.5 ounces DOAZ-19584-AA Multi-Purpose Grease - 4 ounce B tube D7AZ-19584-AA Multi-Purpose Grease - 15 B ounce aerosol can XT-2-QDX Transmission Fluid (Mercon) - V quart can (pkg. of 12) C6AZ-19580-E Gear Oil (Dana axle) - 1 gallon AG C8AZ-19B546-A Additive Friction Modifier - 4 AM ounce bottle D7AZ-19590-A Disc Brake Caliper Slide AM Grease - 4 ounce tube E8TZ-19590-A Grease - 14.5 ounces B E1TZ-19590-A Automatic Hublock Grease - 5 B ounce tube E5RY-19C547-A Merkur Synthetic Manual B Transmission Fluid OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 5970 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Locations Four Wheel Drive Indicator Lamp: Locations LH Quarter Panel Area (F150-350) On Transfer Case Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions Four Wheel Drive Indicator Lamp: Diagram Information and Instructions Symbol Identification Wire Color Code Identification Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 5035 NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 5036 Fig. 25 Four Wheel Drive Indicator Lamp Wiring Circuit Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Locations Four Wheel Drive Indicator Lamp: Locations LH Quarter Panel Area (F150-350) On Transfer Case Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions Four Wheel Drive Indicator Lamp: Diagram Information and Instructions Symbol Identification Wire Color Code Identification Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 5043 NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 5044 Fig. 25 Four Wheel Drive Indicator Lamp Wiring Circuit Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Locations Four Wheel Drive Indicator Lamp: Locations LH Quarter Panel Area (F150-350) On Transfer Case Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions Four Wheel Drive Indicator Lamp: Diagram Information and Instructions Symbol Identification Wire Color Code Identification Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 5053 NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 5054 Fig. 25 Four Wheel Drive Indicator Lamp Wiring Circuit Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Manual Bleeding Brake Bleeding: Service and Repair Manual Bleeding NOTE: Bleed primary and secondary hydraulic brake systems separately, bleeding longest line first on each system. Do not allow reservoir to run dry during bleeding operation. Never reuse fluid that has been drained from hydraulic system. 1. Loosen master cylinder to hydraulic line nuts and wrap shop cloths around tubing below fitting to absorb escaping brake fluid. 2. Depress brake pedal slowly by hand to floor of cab, forcing air trapped in master cylinder out at fitting. 3. Hold pedal down and tighten fittings, then release brake pedal. NOTE: Releasing brake pedal before fittings are tightened will allow air to enter the master cylinder. 4. Repeat steps 1 through 3 until air ceases to escape at fittings and brake pedal is firm. 5. Bleed rear brakes as follows: RR, LR, RF, LF WARNING: Do not bleed the brakes with the drums removed. The wheel-cylinders will over-extend and eject the pistons. a. Pump pedal several times, then hold pedal down firmly. WARNING: Do not Full Stroke the brake pedal, this may damage the master cylinder. Place a 2 inch block of wood under the brake pedal to prevent Full Stroking. b. With pedal firmly depressed, open bleeder screw on one rear brake until pedal fades to floor, then close bleeder valve. NOTE: Do not release the brake pedal until the bleeder valve is fully shut. c. Repeat procedure until a continuous flow of brake fluid is released from bleeder valve. d. Repeat steps 5a through 5c on other rear brake. 6. Bleed front brakes using same procedure as for rear brakes. 7. Fill master cylinder reservoirs to 1/4 inch from top of reservoirs. 9. Check brake operation and ensure pedal is firm, road test vehicle. For additional information see Bleeding Notes. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Manual Bleeding > Page 5060 Brake Bleeding: Service and Repair Master Cylinder Bleeding 1. Support the master cylinder body in a vise, and fill both fluid reservoirs with heavy duty DOT 3 brake fluid. 2. Install plugs in the front and rear brake outlet ports. Bleed the rear brake outlet system first. 3. Loosen the plug in the rear brake outlet port. Depress the primary piston slowly to force the air out of the master cylinder. Tighten plug while piston is depressed or air will enter the master cylinder. 4. Repeat this procedure until air ceases to exit at the outlet port. 5. Repeat steps 3 and 4 for the front brake outlet port with the rear brake outlet plugged. 6. Tighten the plugs and try to depress the piston. Depressing the piston should be harder after all air is expelled. 7. Install the cover and diaphragm assembly making sure the cover retainer is tightened securely. Remove the plugs. For additional information see Bench Bleeding. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Manual Bleeding > Page 5061 Brake Bleeding: Service and Repair Pressure Bleeding Be sure the bleeder tank contains enough of the specified brake fluid to complete the bleeding operation. Charge the tank with approximately 69-206 kPa (10-30 psi). Never exceed 345 kPa (50 psi). Never use brake fluid that has been drained from the hydraulic system. Bleed the longest lines first 1. Clean all dirt from the master cylinder reservoir cap. 2. Remove the master cylinder reservoir cap and fill the master cylinder reservoir with the specified brake fluid. Install the pressure bleeder adapter tool on the master cylinder, and attach the bleeder tank hose to the fitting on the adapter. NOTE: Master cylinder pressure bleeder adapter tools are available from the manufacturers of pressure bleeding equipment. Follow the manufacturer's instructions when installing the adapter. 3. Place a 3/8 inch box wrench on the bleeder fitting on the right rear brake wheel cylinder. Attach a bleeder tube snugly to the bleeder fitting. 4. Open the valve on the bleeder tank and admit pressurized brake fluid to the master cylinder reservoir. 5. Submerge the free end of the tube in a container partially filled with clean brake fluid, and loosen the bleeder fitting. 6. When air bubbles no longer appear in the fluid at the submerged end of the bleeder tube, close the bleeder fitting and remove the tube. 7. Repeat Steps 3 through 6 at the opposite wheel cylinder. On front brakes, bleed the right front caliper first. 8. When the bleeding operation is completed, close the bleeder tank valve and remove the tank hose from the adapter fitting. 9. Remove the pressure bleeder adapter tool. Fill the master cylinder reservoirs with the specified brake fluid to within 3 mm (1/8 in) from the top of the filler neck. Install the master cylinder cover. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions Brake Warning Indicator: Diagram Information and Instructions Symbol Identification Wire Color Code Identification Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 5066 NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 5067 Fig. 51 Warning Indicator Wiring Circuit. Models W/Gasoline Engine Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Technical Service Bulletins > Customer Interest for Brake Caliper: > 88137 > Jun > 88 > Brake Caliper - Rattling Noise Brake Caliper: Customer Interest Brake Caliper - Rattling Noise BRAKE - CALIPER "RATTLING" NOISE - VEHICLES BUILT BEFORE 3/01/88 BRAKE - CALIPER PINS - SERVICE REMOVAL TOOL NOISE - "RATTLE" FROM BRAKE CALIPER - VEHICLES BUILT BEFORE 3/01 /88 Article No. 88-13-7 LIGHT TRUCK: 1983-88 RANGER 1984-88 BRONCO II 1986-88 AEROSTAR, BRONCO, E SERIES, F SERIES 1988 F-SUPER DUTY ISSUE: A "rattling" noise may be heard coming from the front disc brake calipers. The caliper pins may eventually take a set under certain load conditions allowing the disc brake caliper to "rattle". The "rattling" noise is more likely to develop on units that are driven off-road or operated on rough roads. ACTION: To correct this, install new design caliper pins. A new caliper pin removal tool can be made to aid in removal of the pins. Refer to the caliper pin application chart on this page for the correct service part number. FIGURE 8 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Technical Service Bulletins > Customer Interest for Brake Caliper: > 88137 > Jun > 88 > Brake Caliper - Rattling Noise > Page 5077 FIGURE 9 FIGURE 10 FIGURE 11 The caliper pin removal tool is recommended for use on all the above listed vehicles, including 1988 Super Duty, Figures 8 through 11. This caliper pin tool can be made from a 1/2 inch diameter rod 7 inches long. Simply grind or cut a "V" notch in one (1) end. The "V" notch is used to compress the pin retention tabs while the tool is also used to drive the pin out of the caliper slide groove. This tool replaces a pair of pliers and screwdriver as outlined in the Shop Manual service procedure. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Technical Service Bulletins > Customer Interest for Brake Caliper: > 88137 > Jun > 88 > Brake Caliper - Rattling Noise > Page 5078 The idea for this tool was submitted for the Best Idea Contest by Joseph L. Kaiser, Bauer Ford Inc., Brookville, Indiana. See "Service Life", Winter 1987 issue for featured article. CALIPER PIN APPLICATION CHART Part Number Part Name Vehicle Usage E8TZ-2C150-A Caliper Pin Super Duty E8TZ-2C150-B Caliper Pin Ranger, Bronco II, Aerostar, Bronco, E Series, F Series PART NUMBER PART NAME CLASS E8TZ-2C150-A Caliper Pin B E8TZ-2C150-B Caliper Pin B OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION: 881307A - Both sides TIME: 0.5 Hr. DLR. CODING: Basic Part No. 2C150 Condition Code: 33 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Caliper: > 88137 > Jun > 88 > Brake Caliper - Rattling Noise Brake Caliper: All Technical Service Bulletins Brake Caliper - Rattling Noise BRAKE - CALIPER "RATTLING" NOISE - VEHICLES BUILT BEFORE 3/01/88 BRAKE - CALIPER PINS - SERVICE REMOVAL TOOL NOISE - "RATTLE" FROM BRAKE CALIPER - VEHICLES BUILT BEFORE 3/01 /88 Article No. 88-13-7 LIGHT TRUCK: 1983-88 RANGER 1984-88 BRONCO II 1986-88 AEROSTAR, BRONCO, E SERIES, F SERIES 1988 F-SUPER DUTY ISSUE: A "rattling" noise may be heard coming from the front disc brake calipers. The caliper pins may eventually take a set under certain load conditions allowing the disc brake caliper to "rattle". The "rattling" noise is more likely to develop on units that are driven off-road or operated on rough roads. ACTION: To correct this, install new design caliper pins. A new caliper pin removal tool can be made to aid in removal of the pins. Refer to the caliper pin application chart on this page for the correct service part number. FIGURE 8 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Caliper: > 88137 > Jun > 88 > Brake Caliper - Rattling Noise > Page 5084 FIGURE 9 FIGURE 10 FIGURE 11 The caliper pin removal tool is recommended for use on all the above listed vehicles, including 1988 Super Duty, Figures 8 through 11. This caliper pin tool can be made from a 1/2 inch diameter rod 7 inches long. Simply grind or cut a "V" notch in one (1) end. The "V" notch is used to compress the pin retention tabs while the tool is also used to drive the pin out of the caliper slide groove. This tool replaces a pair of pliers and screwdriver as outlined in the Shop Manual service procedure. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Caliper: > 88137 > Jun > 88 > Brake Caliper - Rattling Noise > Page 5085 The idea for this tool was submitted for the Best Idea Contest by Joseph L. Kaiser, Bauer Ford Inc., Brookville, Indiana. See "Service Life", Winter 1987 issue for featured article. CALIPER PIN APPLICATION CHART Part Number Part Name Vehicle Usage E8TZ-2C150-A Caliper Pin Super Duty E8TZ-2C150-B Caliper Pin Ranger, Bronco II, Aerostar, Bronco, E Series, F Series PART NUMBER PART NAME CLASS E8TZ-2C150-A Caliper Pin B E8TZ-2C150-B Caliper Pin B OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION: 881307A - Both sides TIME: 0.5 Hr. DLR. CODING: Basic Part No. 2C150 Condition Code: 33 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Technical Service Bulletins > Page 5086 Brake Caliper: Description and Operation Fig. 3 Exploded view of disc brake caliper assembly These models use the LD (Light Duty) pin rail sliding caliper type system, in which the single piston caliper slides on two pins attaching the caliper to the spindle assembly. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Inspection Brake Caliper: Service and Repair Inspection For additional information see Installation Notes. See: Fundamentals and Basics Installing Anti-Rattle Clip 1. Place a new anti-rattle clip on the lower end of the inner pad. Be sure the tabs on the clip are positioned properly and the clip is fully seated. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Inspection > Page 5089 Anti-Rattle Clip Position 2. Position the inner pad and anti-rattle clip in the pad abutment with the anti-rattle clip tab against the pad abutment and the loop-type spring away from the rotor. Compress the anti-rattle clip and slide the upper end of the pad in position. 3. Install the outer pad. Crimp or bend outer pad tabs to prevent pads from rattling in caliper. 4. Install caliper on the spindle. Make sure the mounting surfaces are free of dirt and lubricate the caliper grooves with disc brake caliper grease. Caliper Pin Installation 5. Position pin with the pin retention tabs oriented adjacent to the spindle groove. NOTE: Do not use the bolt and nut with the new pin. 6. Tap the pin on the outboard end with a hammer. Continue tapping the pin inward until the retention tabs on the sides of the pin contact the spindle face. Repeat procedure for the lower pin. Correct Caliper Pin Installation CAUTION: During the installation procedure do not allow the tabs of the caliper pin to be tapped too far into the spindle groove. If this happens Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Inspection > Page 5090 it will be necessary to tap the other end of the caliper pin until the tabs snap into place. The tabs on each end of the caliper pin must be free to catch on the spindle flanks. 7. If removed, install the brake hose to the caliper and perform brake bleeding procedures. Caliper Inlet Block 8. Install the wheel and tire assembly. 9. Lower the vehicle, check the brake fluid level and fill as necessary. Check brakes for proper operation. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Inspection > Page 5091 Brake Caliper: Service and Repair Rebuild NOTE: Do not use a screwdriver or any similar tool to pry piston into or out of the bore to prevent chipping or scuffing damage to the phenolic piston. DISASSEMBLY Disc Brake Caliper Disassembled 1. Remove the caliper assembly from the vehicle. Remove outer brake shoe to avoid damage to lining material. Substitute shoe with a piece of wood of similar size and shape, or use a worn out shoe and lining assembly. Place a cloth over the piston before applying air pressure to prevent damage to the piston. 2. Apply air pressure to the fluid port in the caliper with a rubber-tipped nozzle to remove the piston. If the piston is seized and cannot be forced from the caliper, tap lightly around the piston while applying air pressure. NOTE: Use care because the piston can develop considerable force from pressure build-up. 3. Remove the dust boot from the caliper assembly. 4. Remove the rubber piston seal from the cylinder and discard it. NOTE: Do not remove the steel ring from the piston. CLEANING and INSPECTION Clean all metal parts with isopropyl alcohol. Clean out and dry the grooves and passageways with compressed air. Make sure that caliper bore and component parts are thoroughly clean. Use a wire brush to remove any rust or corrosion from the machined surfaces of the caliper housing. NOTE: Do not use a wire brush in the cylinder bore. Check the cylinder bore and piston for damage or excessive wear. Replace the piston if it is pitted, scored or worn. Do not replace phenolic pistons for cosmetic surface irregularities or small chips between the piston groove and pad face. Use a wire brush to clean corrosion from the boot groove and the machined surfaces of the spindle assembly. Replace the anti-rattle clip, piston seal and dust boot with new components. ASSEMBLY 1. Apply a film of clean brake fluid to the new caliper piston seal, and install it in the cylinder bore. Be sure the seal does not become twisted but is firmly seated in the groove. 2. Install a new dust boot by setting the flange squarely in the outer groove of the caliper bore. 3. Coat the piston with brake fluid, and install the piston in the cylinder bore. Spread the dust boot over the piston as it is installed. Seat the dust boot in the piston groove, behind the pressed-on steel ring. 4. Install the caliper over the rotor. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Inspection > Page 5092 Brake Caliper: Service and Repair Removal 1. To avoid overflow when the caliper piston is compressed into the caliper piston bore, remove a portion of brake fluid from master cylinder disc brake reservoir. Properly dispose the removed fluid. 2. Raise and support vehicle. Remove wheel and tire assembly. Bottoming Caliper Piston 3. Install an eight inch C-clamp on caliper. Tighten clamp to bottom caliper piston in cylinder bore. Remove the clamp. NOTE: Do not use screwdriver or other edged tool to pry piston from rotor. 4. Clean excess dirt from area around pin tabs. 5. Tap upper caliper pin towards inboard side until pin tabs touch the spindle face. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Inspection > Page 5093 6. Insert a screwdriver into the slot provided behind the pin tabs on the inboard side of the pin. Compressing Pin Tabs 7. Use needle nose pliers to compress the outboard end of the pin while prying at the same time with the screwdriver, until tabs slip into the spindle groove. 8. Place one end of a punch (approximately 7/16 inch diameter) against the end of the caliper pin and drive the caliper pin out of the caliper slide groove. 9. Repeat removal procedure for lower pin. 10. Remove the caliper from the rotor. If the caliper is to be removed for service, remove the brake hose from the caliper. If the caliper is not going to be removed, secure it to the vehicle to avoid damage to the brake hose. Caliper Inlet Block 11. Remove the outer brake pad. Remove the anti-rattle clips and the inner brake pad. For additional information see Removal Notes. See: Fundamentals and Basics Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Fundamentals and Basics > Removal Notes Brake Caliper: Fundamentals and Basics Removal Notes When Removing the Caliper, Remember... - Prior to removing the calipers, remove/siphon brake fluid from master-cylinder until the reservoir is only 1/3 full. - Brake fluid will remove paint and damage electrical connections. Use a drip pan and fender covers to protect the vehicle's finish and electrical system. - Always replace all brake linings on an axle. Never replace only one wheel. Unequal lining thickness between wheels on the same axle will result in a strong steering pull when the brakes are applied. - Work on one side at a time. If you forget how to reassemble the parts you can always use the other side as a model. - When forcing the piston back into the caliper, open the bleeder valve first. Corrosion and other deposits accumulate inside of the caliper. If the bleeder valve is not opened when the piston is forced back into the caliper, these deposits will be forced back through the brake lines and into the master-cylinder. When pushing the pistons back into the caliper with the bleeder screw open, a stream of brake fluid will be expelled from the bleeder screw for 2-3 feet. Use a drip pan and be careful not to "shoot" brake fluid onto the vehicle's finish. A cleaner method is to use a piece of clear plastic hose and a glass or plastic jar to catch the expelled fluid. - Upon removal, Do Not allow the calipers to hang by the flexible brake hoses. The brake hoses can be damaged easily by this practice. These hoses are double walled, damage to the interior pressure hose will not be visible. - Do not depress the brake pedal with either caliper removed from the rotor. The caliper pistons will be inadvertently expelled from the caliper. If this occurs rebuild or replace the caliper, do not attempt to insert the piston back into the caliper. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Fundamentals and Basics > Removal Notes > Page 5096 Brake Caliper: Fundamentals and Basics Installation Notes WHEN INSTALLING CALIPERS AND PADS, REMEMBER... - Clean and lubricate caliper slide joint/pins with high temperature silicone grease: Unlike drum brakes, disc brakes do not utilize a spring to withdraw the pads/linings when the brake pedal is released. Disc brakes rely on the elasticity of the piston seals, and the unrestricted movement of the caliper slide assemblies to release the brakes. If the slide joints/pins are not cleaned and lubricated properly the disc brake linings will drag upon the release of the brake pedal. This will result in overheated brakes and premature brake wear. Disc Brake Mechanical Force Diagram NOTE: Floating calipers require free and unrestricted movement on the caliper mounting. Floating or sliding calipers have pistons only on one side of the rotor. The first part of the piston's travel forces the inner pad against the rotor, then further travel forces the movable part of the caliper to pull the outer pad against the rotor. High temperature silicone lubricant must be used. Low temperature grease can melt and contaminate the pads and rotors, or can bake into a very hard substance which binds the slides. Petroleum based grease can cause the slide boots to soften and swell. Work on one side at a time. If you forget how to reassemble the parts you can always use the other side as a model. Anti-squeal Coating - Apply an anti-squeal coating to the back side of the pads/linings. This coatings acts as an insulator to dampen high frequency vibrations that are generated during normal braking. These compounds are highly effective in preventing brake squeal. - Many professional repair shops recommend always rebuilding or replacing the calipers when replacing the brake linings, because: When the pistons are forced back into the calipers, the piston seals are dragged across any corrosion or abrasives that may be deposited on the inside of the caliper. Damage to the seals may not be initially evident. As the new brake linings begin to wear, the piston is gradually withdrawn from the caliper. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Fundamentals and Basics > Removal Notes > Page 5097 This results in the piston seals again being dragged across the layer of corrosion and deposits. Calipers which are not rebuilt or replaced have a higher probability of sticking or leaking. - Check to ensure the bleeder screw is not frozen prior to reinstalling caliper. Freeing a stuck bleeder screw is much easier with the caliper removed from the vehicle. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Technical Service Bulletins > Customer Interest: > 892516 > Dec > 89 > Front Brakes - Premature Lining Wear/Hard Pedal Brake Pad: Customer Interest Front Brakes - Premature Lining Wear/Hard Pedal Article No. 89-25-16 ^ BRAKES - FRONT - PREMATURE LINING WEAR ^ BRAKES - REAR HEIGHT SENSING PROPORTIONING VALVE - INOPERATIVE DUE TO SUSPENSION MODIFICATION LIGHT TRUCK: 1985-86 F-250, F-350 1985-89 E-250, E-350 ISSUE: High brake pedal efforts or increased front brake lining wear may be caused by aftermarket suspension modifications. The modified suspension may affect the performance of the height sensing proportioning valve. Figure 2 Figure 3 ACTION: Inspect the truck to determine if the suspension has been modified. Compare the rear suspension (springs) to the suspension specifications Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Technical Service Bulletins > Customer Interest: > 892516 > Dec > 89 > Front Brakes - Premature Lining Wear/Hard Pedal > Page 5106 shown in the Light Truck Facts Book and the spring codes listed on the vehicle certification label, Figure 2 and 3. If the suspension has been modified or will be modified, use the following procedure. If the suspension has not been modified, replace the height sensing proportioning valve as outlined in TSB 88-12-20. Figure 1 1. Remove the nut from the valve shaft and remove the leading arm of the linkage assembly, Figure 1. Save the nut. 2. Remove the two (2) nuts from the differential housing bolts and remove the linkage bracket, Figure 1. 3. Return the linkage to the customer. Figure 4 4. Rotate the valve shaft one (1) full turn in either direction. Position the shaft with the flat at the bottom and parallel with the ground, Figure 3. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Technical Service Bulletins > Customer Interest: > 892516 > Dec > 89 > Front Brakes - Premature Lining Wear/Hard Pedal > Page 5107 Figure 5 5. Rotate the valve shaft counter-clockwise 90~ so that the flat of the shaft is vertical, Figure 5. Figure 6 6. Place the valve shaft positioner, (E9TZ-2W125-A) over the valve shaft as shown in Figure 6. Make sure the shaft flat fits into the "D"-slot of the positioner and that the shroud is fully seated over the valve casting. 7. Re-install the nut saved in Step 1 on the valve shaft. Hold the shaft positioner and tighten the nut to a torque of 8-10 lb.ft. (11-14 N-m). 8. Install an "Authorized Modification" decal on the brake booster listing the modification as follows: "HSPV REAR BRAKE OPERATION MODIFIED". Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Technical Service Bulletins > Customer Interest: > 892516 > Dec > 89 > Front Brakes - Premature Lining Wear/Hard Pedal > Page 5108 Obtain an Authorized Modifications Decal and list the date, dealer number, and summary of alterations performed. Select a prominent place adjacent to the Vehicle Emission Control Information Decal suitable for installing the Authorized Modifications Decal. Clean the area, install the decal, and cover it with a clear plastic decal shield. PART NUMBER PART NAME CLASS E9TZ-2W125-A Valve Shaft Positioner C OTHER APPLICABLE ARTICLES: 88-12-20 WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION DESCRIPTION TIME 892516A Modify Height Sensing 0.6 Hr. Valve DEALER CODING BASIC PART NO. CONDITION CODE 2B547 53 OASIS CODES: 3050, 3051 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Technical Service Bulletins > Customer Interest: > 86813 > Apr > 86 > Front Disc Brakes - Squealing Noise Brake Pad: Customer Interest Front Disc Brakes - Squealing Noise Article No. 86-8-13 BRAKES - FRONT DISC - SQUEAL LIGHT TRUCK 1980-86 E100/350, F100/350, BRONCO If the subject vehicles are experiencing a brake squeal concern, they should be serviced by installing insulator pads. Information in TSB 85-3-10 should not be used, this new service action supersedes the previous article with updated information. The following procedures and precautions should be observed when servicing front brake squeal concerns. ^ Remove the caliper and clean the sliding surfaces with a wire brush. Apply a light coating of ESAM1C172-A(D7AZ-19590-A) lubricant to both surfaces. Be careful not to get lube on rotors or linings. Wipe any excess lube off after assembly. Visually inspect rotors for any obvious damage or scoring. ^ Check the front wheel bearing end play adjustment. Adjust the front wheel bearings using the procedures included in the Light Truck Shop Manual, Sections 11-10 and 11-12. NOTE: The disc brake caliper and pads must be removed from the spindle prior to adjusting the front wheel bearings. ^ Clean lining and rotor surfaces. Remove any uneven glaze buildup on lining and rotor braking surfaces by sanding with medium to fine sandpaper or emery cloth. Uniform rotor sanding can be accomplished by holding the paper against the rotor braking surface while manually turning the rotor. ^ Remove any loose insulator material from the pad backing plates with sandpaper or an appropriate solvent. This procedure applies only to the following models: 1980-86 E100/150, F100/150, Bronco, F250 4x2 under 6900 lbs. GVW (single piston calipers). ^ Install the service insulator (E1TZ-2B321-A) to the backing plate of the OUTBOARD pad and lining assembly (both L.H. and R.H. brake). Bond the insulator to the back side of the brake pad assembly with ESA-M1C140-A1 (D7AZ-19554-C) adhesive. Apply adhesive to the light color side of each insulator. Assure that insulator is centered on backing plate and that directions for applying adhesive are followed. This procedure is for 1980-86 F250 4x2 over 6900 lbs. GVW, F250 4x4, F350, E250/350 (dual piston calipers). ^ Install the service insulator (E1TZ-2B321-B) to the back side of the INBOARD pad and lining assembly (both L.H. and R.H. brake). Bond the insulator to the backing plate and lining assembly using the previously listed procedure. ^ Install the service shim (E6TZ-2B321-A) to the back side of the outboard pad and lining assembly (both L.H. and R.H. brake) by clipping the shim over the straight edge of the backing plate. Be sure the shim is fully seated and centered on the straight edge of the backing plate. NOTE: For dual piston caliper application only. ^ Reinstall caliper to the spindle assembly. NOTE: DO NOT replace linings unless required for wear or additional concerns (Shop Manual, Section 12-24). PART NUMBER PART NAME CLASS E1TZ-2B321-A Insulator BM E1TZ-2B321-B Insulator BM E6TZ-2B321-A Shim B D7AZ-19590-A Lubricant A D7AZ-19554-C Adhesive AM OTHER APPLICABLE ARTICLES: Supersedes 85-3-10 WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION: SP2321A86A - 1980-85 TIME: 1.1 Hrs. OPERATION: SP2321A86B - 1986 TIME: 1.0 Hr. DLR. CODING: Basic Part No. 2001 - Code: 56 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Pad: > 90226 > Oct > 90 > Brakes - Intermittent Brake Squeal Brake Pad: All Technical Service Bulletins Brakes - Intermittent Brake Squeal Article No. 90-22-6 ^ BRAKES - OCCASIONAL OR INTERMITTENT "SQUEAL" ^ NOISE - BRAKES - OCCASIONAL OR INTERMITTENT SQUEAL" FORD: 1985-86 LTD 1985-88 EXP 1985-91 CROWN VICTORIA, ESCORT, MUSTANG, TEMPO, THUNDERBIRD 1986-91 TAURUS LINCOLN-MERCURY: 1985-86 CAPRI, MARQUIS 1985-87 LYNX 1985-91 CONTINENTAL, COUGAR, GRAND MARQUIS, MARK VII, TOPAZ, TOWN CAR 1986-91 SABLE 1987-91 TRACER 1991 CAPRI MERKUR: 1985-89 XR4TI LIGHT TRUCK: 1985-90 BRONCO II 1985-91 BRONCO, ECONOLINE, F-150-350 SERIES, RANGER 1986-91 AEROSTAR 1988-91 F SUPER DUTY 1991 EXPLORER This TSB article is being republished in its entirety to expand the model and model year coverage. ISSUE: Occasional or intermittent brake squeal may be cause by the brake friction material generating noise and heat in order to dissipate energy. This occasional or intermittent squeal may be a normal condition and requires no corrective action. ACTION: If a customer is concerned about occasional or intermittent brake squeal, it should be explained that brake friction materials inherently generate noise and heat in order to dissipate energy. As a result, an occasional squeal condition may be normal, and could be affected by cold, heat, wetness, snow, salt, mud etc. NOTE: THIS OCCASIONAL OR INTERMITTENT SQUEAL IS NOT A FUNCTIONAL PROBLEM AND DOES NOT INDICATE ANY LOSS OF BRAKE EFFECTIVENESS. OTHER APPLICABLE ARTICLES: None SUPERSEDES: 87-16-7 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 301000, 702000, 702100 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Pad: > 892516 > Dec > 89 > Front Brakes Premature Lining Wear/Hard Pedal Brake Pad: All Technical Service Bulletins Front Brakes - Premature Lining Wear/Hard Pedal Article No. 89-25-16 ^ BRAKES - FRONT - PREMATURE LINING WEAR ^ BRAKES - REAR HEIGHT SENSING PROPORTIONING VALVE - INOPERATIVE DUE TO SUSPENSION MODIFICATION LIGHT TRUCK: 1985-86 F-250, F-350 1985-89 E-250, E-350 ISSUE: High brake pedal efforts or increased front brake lining wear may be caused by aftermarket suspension modifications. The modified suspension may affect the performance of the height sensing proportioning valve. Figure 2 Figure 3 ACTION: Inspect the truck to determine if the suspension has been modified. Compare the rear suspension (springs) to the suspension specifications Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Pad: > 892516 > Dec > 89 > Front Brakes Premature Lining Wear/Hard Pedal > Page 5122 shown in the Light Truck Facts Book and the spring codes listed on the vehicle certification label, Figure 2 and 3. If the suspension has been modified or will be modified, use the following procedure. If the suspension has not been modified, replace the height sensing proportioning valve as outlined in TSB 88-12-20. Figure 1 1. Remove the nut from the valve shaft and remove the leading arm of the linkage assembly, Figure 1. Save the nut. 2. Remove the two (2) nuts from the differential housing bolts and remove the linkage bracket, Figure 1. 3. Return the linkage to the customer. Figure 4 4. Rotate the valve shaft one (1) full turn in either direction. Position the shaft with the flat at the bottom and parallel with the ground, Figure 3. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Pad: > 892516 > Dec > 89 > Front Brakes Premature Lining Wear/Hard Pedal > Page 5123 Figure 5 5. Rotate the valve shaft counter-clockwise 90~ so that the flat of the shaft is vertical, Figure 5. Figure 6 6. Place the valve shaft positioner, (E9TZ-2W125-A) over the valve shaft as shown in Figure 6. Make sure the shaft flat fits into the "D"-slot of the positioner and that the shroud is fully seated over the valve casting. 7. Re-install the nut saved in Step 1 on the valve shaft. Hold the shaft positioner and tighten the nut to a torque of 8-10 lb.ft. (11-14 N-m). 8. Install an "Authorized Modification" decal on the brake booster listing the modification as follows: "HSPV REAR BRAKE OPERATION MODIFIED". Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Pad: > 892516 > Dec > 89 > Front Brakes Premature Lining Wear/Hard Pedal > Page 5124 Obtain an Authorized Modifications Decal and list the date, dealer number, and summary of alterations performed. Select a prominent place adjacent to the Vehicle Emission Control Information Decal suitable for installing the Authorized Modifications Decal. Clean the area, install the decal, and cover it with a clear plastic decal shield. PART NUMBER PART NAME CLASS E9TZ-2W125-A Valve Shaft Positioner C OTHER APPLICABLE ARTICLES: 88-12-20 WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION DESCRIPTION TIME 892516A Modify Height Sensing 0.6 Hr. Valve DEALER CODING BASIC PART NO. CONDITION CODE 2B547 53 OASIS CODES: 3050, 3051 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Pad: > 86813 > Apr > 86 > Front Disc Brakes Squealing Noise Brake Pad: All Technical Service Bulletins Front Disc Brakes - Squealing Noise Article No. 86-8-13 BRAKES - FRONT DISC - SQUEAL LIGHT TRUCK 1980-86 E100/350, F100/350, BRONCO If the subject vehicles are experiencing a brake squeal concern, they should be serviced by installing insulator pads. Information in TSB 85-3-10 should not be used, this new service action supersedes the previous article with updated information. The following procedures and precautions should be observed when servicing front brake squeal concerns. ^ Remove the caliper and clean the sliding surfaces with a wire brush. Apply a light coating of ESAM1C172-A(D7AZ-19590-A) lubricant to both surfaces. Be careful not to get lube on rotors or linings. Wipe any excess lube off after assembly. Visually inspect rotors for any obvious damage or scoring. ^ Check the front wheel bearing end play adjustment. Adjust the front wheel bearings using the procedures included in the Light Truck Shop Manual, Sections 11-10 and 11-12. NOTE: The disc brake caliper and pads must be removed from the spindle prior to adjusting the front wheel bearings. ^ Clean lining and rotor surfaces. Remove any uneven glaze buildup on lining and rotor braking surfaces by sanding with medium to fine sandpaper or emery cloth. Uniform rotor sanding can be accomplished by holding the paper against the rotor braking surface while manually turning the rotor. ^ Remove any loose insulator material from the pad backing plates with sandpaper or an appropriate solvent. This procedure applies only to the following models: 1980-86 E100/150, F100/150, Bronco, F250 4x2 under 6900 lbs. GVW (single piston calipers). ^ Install the service insulator (E1TZ-2B321-A) to the backing plate of the OUTBOARD pad and lining assembly (both L.H. and R.H. brake). Bond the insulator to the back side of the brake pad assembly with ESA-M1C140-A1 (D7AZ-19554-C) adhesive. Apply adhesive to the light color side of each insulator. Assure that insulator is centered on backing plate and that directions for applying adhesive are followed. This procedure is for 1980-86 F250 4x2 over 6900 lbs. GVW, F250 4x4, F350, E250/350 (dual piston calipers). ^ Install the service insulator (E1TZ-2B321-B) to the back side of the INBOARD pad and lining assembly (both L.H. and R.H. brake). Bond the insulator to the backing plate and lining assembly using the previously listed procedure. ^ Install the service shim (E6TZ-2B321-A) to the back side of the outboard pad and lining assembly (both L.H. and R.H. brake) by clipping the shim over the straight edge of the backing plate. Be sure the shim is fully seated and centered on the straight edge of the backing plate. NOTE: For dual piston caliper application only. ^ Reinstall caliper to the spindle assembly. NOTE: DO NOT replace linings unless required for wear or additional concerns (Shop Manual, Section 12-24). PART NUMBER PART NAME CLASS E1TZ-2B321-A Insulator BM E1TZ-2B321-B Insulator BM E6TZ-2B321-A Shim B D7AZ-19590-A Lubricant A D7AZ-19554-C Adhesive AM OTHER APPLICABLE ARTICLES: Supersedes 85-3-10 WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION: SP2321A86A - 1980-85 TIME: 1.1 Hrs. OPERATION: SP2321A86B - 1986 TIME: 1.0 Hr. DLR. CODING: Basic Part No. 2001 - Code: 56 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Pad: > 90226 > Oct > 90 > Brakes - Intermittent Brake Squeal Brake Pad: All Technical Service Bulletins Brakes - Intermittent Brake Squeal Article No. 90-22-6 ^ BRAKES - OCCASIONAL OR INTERMITTENT "SQUEAL" ^ NOISE - BRAKES - OCCASIONAL OR INTERMITTENT SQUEAL" FORD: 1985-86 LTD 1985-88 EXP 1985-91 CROWN VICTORIA, ESCORT, MUSTANG, TEMPO, THUNDERBIRD 1986-91 TAURUS LINCOLN-MERCURY: 1985-86 CAPRI, MARQUIS 1985-87 LYNX 1985-91 CONTINENTAL, COUGAR, GRAND MARQUIS, MARK VII, TOPAZ, TOWN CAR 1986-91 SABLE 1987-91 TRACER 1991 CAPRI MERKUR: 1985-89 XR4TI LIGHT TRUCK: 1985-90 BRONCO II 1985-91 BRONCO, ECONOLINE, F-150-350 SERIES, RANGER 1986-91 AEROSTAR 1988-91 F SUPER DUTY 1991 EXPLORER This TSB article is being republished in its entirety to expand the model and model year coverage. ISSUE: Occasional or intermittent brake squeal may be cause by the brake friction material generating noise and heat in order to dissipate energy. This occasional or intermittent squeal may be a normal condition and requires no corrective action. ACTION: If a customer is concerned about occasional or intermittent brake squeal, it should be explained that brake friction materials inherently generate noise and heat in order to dissipate energy. As a result, an occasional squeal condition may be normal, and could be affected by cold, heat, wetness, snow, salt, mud etc. NOTE: THIS OCCASIONAL OR INTERMITTENT SQUEAL IS NOT A FUNCTIONAL PROBLEM AND DOES NOT INDICATE ANY LOSS OF BRAKE EFFECTIVENESS. OTHER APPLICABLE ARTICLES: None SUPERSEDES: 87-16-7 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 301000, 702000, 702100 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Installation Brake Pad: Service and Repair Installation Installing Anti-Rattle Clip 1. Place a new anti-rattle clip on the lower end of the inner pad. Be sure the tabs on the clip are positioned properly and the clip is fully seated. Installing Inner Shoe And Anti-Rattle Clip 2. Position the inner pad and anti-rattle clip in the pad abutment with the anti-rattle clip tab against the pad abutment and the loop-type spring away from the rotor. Compress the anti-rattle clip and slide the upper end of the pad in position. 3. Install the outer pad. Crimp or bend outer pad tabs to prevent pads from rattling in caliper. 4. Install the caliper on the spindle, making sure the mounting surfaces are free of dirt and lubricate the caliper grooves with disc brake caliper grease. Caliper Pin Installation 5. Position pin with the pin retention tabs oriented adjacent to the spindle groove. NOTE: Do not use the bolt and nut with the new pin. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Installation > Page 5136 6. Tap the pin on the outboard end with a hammer. Continue tapping the pin inward until the retention tabs on the sides of the pin contact the spindle face. Repeat procedure for the lower pin. Correct Caliper Pin Installation CAUTION: During the installation procedure do not allow the tabs of the caliper pin to be tapped too far into the spindle groove. If this happens it will be necessary to tap the other end of the caliper pin until the tabs snap into place. The tabs on each end of the caliper pin must be free to catch on the spindle flanks. 7. If removed, install the brake hose to the caliper and perform brake bleeding procedures. 8. Install the wheel and tire assembly. 9. Lower the vehicle, check the brake fluid level and fill as necessary. Check brakes for proper operation. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Installation > Page 5137 Brake Pad: Service and Repair Removal 1. To avoid overflow when the caliper piston is compressed into the caliper piston bore, remove a portion of brake fluid from master cylinder disc brake reservoir. Properly dispose the removed fluid. 2. Raise and support vehicle. Remove wheel and tire assembly. Bottoming Caliper Piston 3. Install an eight inch C-clamp on caliper. Tighten clamp to bottom caliper piston in cylinder bore. Remove the clamp. NOTE: Do not use screwdriver or other edged tool to pry piston from rotor. 4. Clean excess dirt from area around pin tabs. 5. Tap upper caliper pin towards inboard side until pin tabs touch the spindle face. 6. Insert a screwdriver into the slot provided behind the pin tabs on the inboard side of the pin. Compressing Pin Tabs 7. Use needle nose pliers to compress the outboard end of the pin while prying at the same time with the screwdriver, until tabs slip into the spindle groove. 8. Place one end of a punch (approximately 7/16 inch diameter) against the end of the caliper pin and drive the caliper pin out of the caliper slide groove. 9. Repeat removal procedure for lower pin. 10. Remove the caliper from the rotor. If the caliper is to be removed for service, remove the brake hose from the caliper. If the caliper is not going to be removed, secure it to the vehicle to avoid damage to the brake hose. 11. Remove the outer brake pad. Remove the anti-rattle clips and the inner brake pad. For additional information See: Brake Caliper/Fundamentals and Basics/Removal Notes Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Customer Interest: > 872414 > Dec > 87 > Brakes - Shudder and Vibration On Application Brake Rotor/Disc: Customer Interest Brakes - Shudder and Vibration On Application Article No. 87-24-14 BRAKE - ROTORS - SHUDDER AND VIBRATION DURING APPLICATION - CRACKED ROTOR ASSEMBLY VIBRATION AND SHUDDER - DURING BRAKE APPLICATION - CRACKED ROTOR LIGHT TRUCK: 1980-87 E-250/350, F-250/350 ISSUE: Shudder and vibration during brake application may be caused by cracks in the braking surface of the front disc brake rotors. Units that may be affected are 1980-87 E-250/350 and 4 x 2 F-250/350 vehicles with single rear wheels (SRW) and 1980-87 E-350 and 4 x 2 F-350 vehicles with dual rear wheels (DRW). ACTION: To correct this, install new design heavy-duty brake rotors. Refer to the Application Chart below for the correct service part numbers. PART NUMBER PART NAME CLASS E0TZ-1102-J Disc Brake Rotor B E0TZ-1102-K Disc Brake Rotor B E0TZ-1102-L Disc Brake Rotor B E7TZ-1102-C Disc Brake Rotor B E7TZ-1102-D Disc Brake Rotor B OTHER APPLICABLE ARTICLES: Supersedes 87-16-16 WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION: SP872414A TIME: 1.0 Hr. DLR. CODING: Basic Part No. 1102 - Code: 01 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Rotor/Disc: > 90199 > Sep > 90 > Lug Nuts Proper Torqueing Procedure Brake Rotor/Disc: All Technical Service Bulletins Lug Nuts - Proper Torqueing Procedure ^ BRAKE SHUDDER - ROTOR DISTORTED - OVERTIGHTENED LUG NUTS ^ WHEEL - NUT INSTALLATION - SERVICE TIP Article No. 90-19-9 FORD: 1986-91 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS, TEMPO, THUNDERBIRD 1988-91 FESTIVA 1989-91 PROBE LINCOLN-MERCURY: 1986 CAPRI 1986-87 LYNX 1986-91 CONTINENTAL, COUGAR, GRAND MARQUIS, MARK VII, SABLE, TOPAZ, TOPAZ, TOWN CAR 1987-89 TRACER 1991 CAPRI, TRACER MERKUR: 1985-88 XR4TI 1988-89 SCORPIO LIGHT TRUCK: 1986-90 BRONCO II 1986-91 AEROSTAR, BRONCO, ECONOLINE, F-150-350 SERIES, RANGER 1988-91 F SUPER DUTY 1991 EXPLORER ISSUE: The use of a power impact wrench to install wheel nuts provides minimal torque control. Undertightening may allow the lug nuts to loosen, and can result in the wheel separating from the vehicle. Overtightening of wheel nuts may cause brake rotor distortion that could result in a brake shudder. Overtightening may cause distortion of the wheel. This can result in a change in the diameter of the center (axle) hole and make it difficult to remove from the axle it is mounted on or difficult or impossible to install on another axle with a smaller center hole diameter. ACTION: Use a manual torque wrench to tighten wheel nuts. Refer to the approriate Shop Manual for specific torque values. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 306000, 301000 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Rotor/Disc: > 872414 > Dec > 87 > Brakes Shudder and Vibration On Application Brake Rotor/Disc: All Technical Service Bulletins Brakes - Shudder and Vibration On Application Article No. 87-24-14 BRAKE - ROTORS - SHUDDER AND VIBRATION DURING APPLICATION - CRACKED ROTOR ASSEMBLY VIBRATION AND SHUDDER - DURING BRAKE APPLICATION - CRACKED ROTOR LIGHT TRUCK: 1980-87 E-250/350, F-250/350 ISSUE: Shudder and vibration during brake application may be caused by cracks in the braking surface of the front disc brake rotors. Units that may be affected are 1980-87 E-250/350 and 4 x 2 F-250/350 vehicles with single rear wheels (SRW) and 1980-87 E-350 and 4 x 2 F-350 vehicles with dual rear wheels (DRW). ACTION: To correct this, install new design heavy-duty brake rotors. Refer to the Application Chart below for the correct service part numbers. PART NUMBER PART NAME CLASS E0TZ-1102-J Disc Brake Rotor B E0TZ-1102-K Disc Brake Rotor B E0TZ-1102-L Disc Brake Rotor B E7TZ-1102-C Disc Brake Rotor B E7TZ-1102-D Disc Brake Rotor B OTHER APPLICABLE ARTICLES: Supersedes 87-16-16 WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION: SP872414A TIME: 1.0 Hr. DLR. CODING: Basic Part No. 1102 - Code: 01 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Rotor/Disc: > 90199 > Sep > 90 > Lug Nuts - Proper Torqueing Procedure Brake Rotor/Disc: All Technical Service Bulletins Lug Nuts - Proper Torqueing Procedure ^ BRAKE SHUDDER - ROTOR DISTORTED - OVERTIGHTENED LUG NUTS ^ WHEEL - NUT INSTALLATION - SERVICE TIP Article No. 90-19-9 FORD: 1986-91 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS, TEMPO, THUNDERBIRD 1988-91 FESTIVA 1989-91 PROBE LINCOLN-MERCURY: 1986 CAPRI 1986-87 LYNX 1986-91 CONTINENTAL, COUGAR, GRAND MARQUIS, MARK VII, SABLE, TOPAZ, TOPAZ, TOWN CAR 1987-89 TRACER 1991 CAPRI, TRACER MERKUR: 1985-88 XR4TI 1988-89 SCORPIO LIGHT TRUCK: 1986-90 BRONCO II 1986-91 AEROSTAR, BRONCO, ECONOLINE, F-150-350 SERIES, RANGER 1988-91 F SUPER DUTY 1991 EXPLORER ISSUE: The use of a power impact wrench to install wheel nuts provides minimal torque control. Undertightening may allow the lug nuts to loosen, and can result in the wheel separating from the vehicle. Overtightening of wheel nuts may cause brake rotor distortion that could result in a brake shudder. Overtightening may cause distortion of the wheel. This can result in a change in the diameter of the center (axle) hole and make it difficult to remove from the axle it is mounted on or difficult or impossible to install on another axle with a smaller center hole diameter. ACTION: Use a manual torque wrench to tighten wheel nuts. Refer to the approriate Shop Manual for specific torque values. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 306000, 301000 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Page 5160 Brake Rotor/Disc: Specifications Nominal Thickness 1.19 in Minimum Allowable Thickness 1.12 in Maximum Variation (Parallelism) 0.0005 in Lateral Runout 0.003 in Rotor Surface Finish 15 To 80 in Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Page 5161 Brake Rotor/Disc: Testing and Inspection PURPOSE In the manufacturing of the brake rotor all the tolerances regarding surface finish, parallelism, and lateral runout are held very closely. The maintenance of these tolerances provide the surface necessary to prevent brake roughness. Light scoring of the rotor surface not in excess of 0.38 mm (0.015-inch) in depth is normal. This condition does not affect the brake operation. Some discoloration or wear of the disc surface is normal and does not require re-surfacing when linings are replaced. SPECIFICATIONS - See: Specifications LATERAL RUNOUT Lateral runout is the movement of the rotor from side to side as it rotates on the spindle. This could also be referred to as "rotor wobble". This movement causes the brake pad and piston to be knocked back into it's bore. This results in additional pedal travel and a vibration during braking. Checking Lateral Runout 1. Tighten the wheel bearings to eliminate all freeplay. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Page 5162 2. Attach a dial indicator to a solid non-rotating portion of the hub assembly or suspension. - The point of the styles must contact the rotor face about 25 mm (1-inch) from the rotor edge. 3. Move the rotor one complete rotation and observe the dial indicator. 4. Rotate the bezel on the dial indicator such that "0" is at the low deflection point. 5. Again rotate the rotor at least one complete turn and observe the needle deflection. Total needle deflection will equal lateral runout. 6. Readjust the wheel bearings. MINIMUM THICKNESS The thickness of a rotor is important for two reasons: 1. Rotors which are too thin are not able to properly absorb and release heat during heavy braking. This results in reduced braking capacity and brake fade. 2. Rotors worn below minimum thickness in combination with worn pads/linings can result in the caliper piston extending too far becoming cocked or jammed. Rotor thickness should be measured at the thinnest point on the rotor. Any rotor which is worn below its minimum thickness should be replaced. For accurate measurements, it is best to remove the caliper to allow for complete access to the inboard side of the rotor. For more information on how to use a disc brake micrometer see Fundamentals and Basics. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Page 5163 PARALLELISM Parallelism is the measurement of the thickness of the rotor at 12 or more points around the circumference of the rotor. All measurements must be made at the same distance in from the edge of the rotor. Lack Of Parallelism Lack Of Parallelism MACHINING Since accurate control of the rotor tolerances is necessary for proper performance of the disc brakes, machining of the rotor should be done only with precision equipment. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Page 5164 All brake rotors have a minimum thickness dimension cast into them. This dimension is the minimum wear dimension and not a refinish dimension. Do not use a brake rotor that will not meet the specifications, after refinishing. Replace with a new brake rotor. NOTE: 1 inch = 25.4mm, so if your micrometer measures in inches and the specified thickness on the disc is in millimeters, convert millimeters to inches by dividing the specified number of millimeters by 25.4. Example: Specification on disc is 17.8 mm. Dividing 17.8mm by 25.4mm/in = 17.8/25.4 = 0.70 inches. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Installation Brake Rotor/Disc: Service and Repair Installation Front Hub And Rotor Assembly Wheel bearing lubricant is a lithium-base grease. Sodium-base grease is not compatible with lithium-base grease and should not be intermixed. Therefore, do not lubricate front and/or rear wheel bearings without first identifying the type of original wheel bearing lubricant. Usage of incompatible bearing lubricants may result in premature lubricant breakdown. 1. If a new hub and rotor will be installed, remove the protective coating, any dirt or grease deposits with brake parts cleaner or degreaser. 2. Pack the inside of the hub with lithium-base grease or equivalent. Fill the hub until the grease is flush with the inside diameters of both bearing cups. Pack the bearing cones and rollers with wheel bearing grease. Use a bearing packer for this operation. If a packer is not available, work as much lubricant as possible between the rollers and cages. Lubricate the cone surfaces with grease. Installing Grease Seal (Typical) 3. Place the inner bearing cone and roller in the inner cup and install the new grease seal. Be sure that the seal is fully seated. 4. Install the hub and rotor on the wheel spindle. Keep the hub centered on the spindle to prevent damage to the grease retainer or the spindle threads. 5. Install the outer bearing cone and roller and the flat washer on the spindle, then install the adjusting nut, and adjust the wheel bearing. 6. Install the retainer, new cotter pin, and grease cap. 7. Install the caliper. For additional information see Installation Notes. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Installation > Page 5167 Brake Rotor/Disc: Service and Repair Removal 1. Raise the vehicle until the tire clears the floor and remove the wheel and tire assembly. 2. Remove the brake caliper and secure to the underbody to prevent damage to the brake hose. It is not necessary to disconnect the hose from the caliper. Do not let the caliper hang with its weight on the brake hose or the hose may become stretched, twisted or ruptured. Front Hub And Rotor Assembly 3. Remove the grease cap, cotter pin, retainer adjusting nut and washer. 4. Remove the outer bearing cone and roller. 5. Pull the hub and rotor off the spindle and remove and discard the grease seal. 6. Remove the inner bearing cone and roller from the hub. Remove all traces of old lubricant from bearings, hub and axle spindle. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Installation > Page 5168 Brake Rotor/Disc: Service and Repair Servicing Each time the brakes are serviced, the disc brake rotor should be checked for scoring, runout, parallelism and thickness. ROTOR MACHINING Do not machine, cut or true up new front disc brake hub and rotors prior to installation on vehicle. Making a light cut on a new front disc brake hub and rotor may cause excessive runout and result in brake shudder several thousand miles later. It is best to clean oil film off new front disc brake hub and rotor with Brake Cleaner or equivalent install it on vehicle. Never use a brake lathe that cuts only one face of the front disc brake hub and rotor at a time. It must be a simultaneous straddle cut. All front disc brake hub and rotor refinishing must adhere to the rule that equal amounts of front disc brake hub and rotor stock are removed from each braking surface each time a front disc brake hub and rotor is refinished. On-vehicle brake lathes, machine the front disc brake hub and rotor while it is on the hub and is turning on the same axis as the hub. This procedure reduces front disc brake hub and rotor lateral runout to near zero by cutting the front disc brake hub and rotor perpendicular to the axis of the hub, therefore cancelling the affect of stacked tolerance of the front disc brake hub and rotor and front wheel spindle. Follow the on-vehicle brake lathe manufacturer's instructions on machining procedures. A bench-mounted disc brake lathe machines the disc brake hub and rotor to the axis of the lathe arbor and will not reduce total lateral runout associated with stacked tolerances of the front disc brake hub and rotor and front wheel spindle. Follow manufacturer's instructions on machining procedures. With both types of brake lathes, set cutting tool to just contact the high spots on the front disc brake hub and rotor then adjust cutting tool to the minimum depth required to clean up the front disc brake hub and rotor face. The total material removed (combination of both sides) must not exceed the minimum discard thickness that is marked on the inside of the front disc brake hub and rotor. To improve initial brake pedal feel and surface finish on a machined front disc brake hub and rotor, lightly sand rotor surface with 120 grit paper prior to road testing. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Backing Plate > Component Information > Service and Repair Backing Plate: Service and Repair REMOVAL 1. Remove the wheel and brake drum. Disconnect the brake tube from the wheel cylinder and plug the end of the brake tube to prevent air from entering the system. 2. Remove brake linings and wheel cylinder. 3. Disconnect the parking brake lever from the cable. Remove the cable from the backing plate. 4. Remove the brake backing plate after the axle shaft has been removed. INSTALLATION 1. Position the brake backing plate on the retaining bolts on the axle housing flange. 2. Install the parking brake cable from the backing plate. Connect the parking brake lever to the cable. 3. Install the wheel cylinder and brake linings. 4. Connect the brake tube to the wheel cylinder and remove the air from the system by brake bleeding. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Specifications Brake Drum: Specifications Inside Diameter 11.031 in Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Specifications > Page 5176 Brake Drum: Testing and Inspection VISUAL INSPECTION Inspect the drum for cracks. If any large, through-the-drum cracks are located the drum must be replaced. NOTE: Cracks in drums are often difficult to locate. To quickly determine if a drum is cracked lightly drop the drum (from a height of 4-5 inches) onto a flat hard surface. A cracked drum will make a dull thud sound while a good drum will make a ringing sound. Inspect for signs of overheating. An overheated drum will often be discolored (blue/gold), warped, or heat checked. Heat checks are small cracks in the drum friction surface. Heat checks can be removed by resurfacing. NOTE: The cause of the overheating should be determined prior to replacing the shoes/linings or drums. Inspect for scoring. Any grooves or scores in excess of 0.008 inches should be resurfaced. SPECIFICATIONS - See: Specifications MAXIMUM DIAMETER Purpose The thickness of the drum friction surface is directly proportional to the drums ability to absorb and release heat during braking. As the drum becomes thinner due to normal wear and resurfacing it looses its ability to absorb and release heat and is more prone to brake fade, distortion, and cracking. As the drum wears the inside diameter of the drum increases. The amount of drum thickness lost to wear is equal to 1/2 the increase in diameter. There are two specifications related to drum thickness. Discard Diameter - This is the maximum diameter at which it becomes unsafe to operate. A drum which has reached this thickness should not be machined and should be discarded. Maximum Refinish - This is the maximum diameter to which a drum may be machined or resurfaced to. This diameter is smaller (thicker) than the Discard diameter because it assumes the drum will need to have a sufficient thickness left, after machining, to allow for further wear from a new set of shoes/linings. Which One Should Be Used? If you install a new pair of shoes with the drum diameter at or less than the "Maximum Refinish" specification the drums should have a sufficient thickness to last the normal life of the new shoes/linings. The "Discard Diameter" should be used to determine if a drum needs to be replaced at the present time of inspection. If you install a new pair of shoes with the drums machined at or near "Discard Diameter", within a short time the drums will be too thin Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Specifications > Page 5177 (unsafe) and the new shoes/linings will be subject to overheating and brake fade. How To Measure NOTE: For additional information on how to use a drum micrometer see Fundamentals and Basics. - A drum micrometer is used to measure the drum diameter. - The micrometer scale should be initially set to the original (new) thickness of the drum. - The base of the micrometer should be placed in the deepest groove in the drum and held steady while the measuring point is swiveled to find the maximum diameter. - The base and measuring point should be kept at the same depth in the drum. Drum Micrometer - The measurement should be repeated at 3 or more places around the circumference of the drum to determine if the drum is out of round. If the measurements differ by more than 0.004 inches the drum should be resurfaced. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Specifications > Page 5178 NOTE: A drum which is out of round will cause a pedal pulsation to be felt upon braking. - The measurement should also be repeated at various depths of the drum to check for a bellmouth condition. If the measurements differ by more than .010 inches the drum should be resurfaced. NOTE: 1 inch = 25.4mm, so if your micrometer measures in inches and the specified thickness on the disc is in millimeters, convert millimeters to inches by dividing the specified number of millimeters by 25.4. Example: Specification on disc is 17.8 mm. Dividing 17.8mm by 25.4mm/in = 17.8/25.4 = 0.70 inches. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Service and Repair > Removal and Installation Brake Drum: Service and Repair Removal and Installation For additional information see Notes, Warnings, and Hints. REMOVAL 1. Raise the vehicle so the wheel is clear of the floor. Install safety stands under the axle. CAUTION: Use of a drum puller or a torch Is not recommended. Drum distortion may result. 2. Remove the wheel and tire assembly. Remove the spring retaining nuts and remove the brake drum. 3. If the brake drum is rusted to the axle shaft pilot diameter, use coarse sandpaper to remove the rust build-up, then remove the brake drum. 4. Check the surface of the brake drum. If worn or if brake drum is suspected of having excessive runout, the brake drum should be machined. After machining, check maximum diameter (stamped on the outside of the brake drum). Brake drum must be replaced if diameter is outside maximum limit. Retracting Brake Shoes If the brake drum will not come off, insert a narrow screwdriver through the brake adjusting hole in the brake backing plate, and disengage the brake shoe adjusting lever from the brake adjuster screw. While holding the brake shoe adjusting lever away from the brake adjuster screw, loosen the brake adjuster screw with the brake adjusting tool. Loosen the brake adjuster screw only if the brake drum cannot be removed. Do not burr, chip, or damage the notches in the brake adjuster screw or the self-adjusting mechanism will not function properly. If the brake adjuster screw was loosened, check to be sure the brake shoe adjusting lever is still properly seated In the shoe web. INSTALLATION 1. Remove the protective coating from a new brake drum with brake parts cleaner. 2. Adjust the brakes. 3. Install the brake drum onto the axle shaft flange or rear hub. 4. Install the retaining clips securely. Install the wheel on the axle shaft flange or rear hub studs against the brake drum, and tighten to specification. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Service and Repair > Removal and Installation > Page 5181 Brake Drum: Service and Repair Servicing Minor scores should be removed with sandpaper. Grooves and large scores can only be removed by machining with special equipment, as long as the braking surface is within specifications stamped on brake drum outer surface. Any brake drum sufficiently out of round to cause vehicle vibration or noise while braking, or showing taper should also be machined, removing only enough stock to true up the brake drum. After a brake drum is machined, wipe braking surface diameter with a cloth soaked in denatured alcohol. If one brake drum is machined, the other should also be machined to the same diameter to maintain equal braking forces. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Technical Service Bulletins > Brakes - Intermittent Brake Squeal Brake Shoe: Technical Service Bulletins Brakes - Intermittent Brake Squeal Article No. 90-22-6 ^ BRAKES - OCCASIONAL OR INTERMITTENT "SQUEAL" ^ NOISE - BRAKES - OCCASIONAL OR INTERMITTENT SQUEAL" FORD: 1985-86 LTD 1985-88 EXP 1985-91 CROWN VICTORIA, ESCORT, MUSTANG, TEMPO, THUNDERBIRD 1986-91 TAURUS LINCOLN-MERCURY: 1985-86 CAPRI, MARQUIS 1985-87 LYNX 1985-91 CONTINENTAL, COUGAR, GRAND MARQUIS, MARK VII, TOPAZ, TOWN CAR 1986-91 SABLE 1987-91 TRACER 1991 CAPRI MERKUR: 1985-89 XR4TI LIGHT TRUCK: 1985-90 BRONCO II 1985-91 BRONCO, ECONOLINE, F-150-350 SERIES, RANGER 1986-91 AEROSTAR 1988-91 F SUPER DUTY 1991 EXPLORER This TSB article is being republished in its entirety to expand the model and model year coverage. ISSUE: Occasional or intermittent brake squeal may be cause by the brake friction material generating noise and heat in order to dissipate energy. This occasional or intermittent squeal may be a normal condition and requires no corrective action. ACTION: If a customer is concerned about occasional or intermittent brake squeal, it should be explained that brake friction materials inherently generate noise and heat in order to dissipate energy. As a result, an occasional squeal condition may be normal, and could be affected by cold, heat, wetness, snow, salt, mud etc. NOTE: THIS OCCASIONAL OR INTERMITTENT SQUEAL IS NOT A FUNCTIONAL PROBLEM AND DOES NOT INDICATE ANY LOSS OF BRAKE EFFECTIVENESS. OTHER APPLICABLE ARTICLES: None SUPERSEDES: 87-16-7 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 301000, 702000, 702100 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Technical Service Bulletins > Page 5186 Brake Shoe: Adjustments Fig. 1 Drum Brake Assembly Fig. 3 Left Rear 10 Inch Drum The rear brake shoes, Figs. 2 and 3, adjust automatically when the vehicle is driven forward or reverse and the brakes are applied sharply several times. Manual adjustment is required only when brake shoes are replaced. When adjusting rear brakes, ensure that parking brake is properly adjusted and that equalizer is operating freely. With Drums Removed 1. With drums removed, clean areas where shoes contact backing plate, then apply suitable lubricant to these contact areas, ensuring that lubricant does not contaminate linings. 2. Using suitable brake shoe adjusting gauge, adjust gauge to inside diameter of brake drum. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Technical Service Bulletins > Page 5187 Fig. 4 Checking Brake Lining Clearance 3. Reverse tool and adjust shoes until they contact gauge, ensuring that gauge is parallel to vehicle and at centerline of axle, Fig. 4. Holding automatic adjusting lever aside, rotate adjusting screw as necessary. 4. Install drums, wheels and retaining nuts, then complete adjustment by applying brakes several times while driving vehicle in reverse. 5. Check brake operation by making several stops in forward gear. Repeat step 4, if necessary. With Drums Installed 1. Raise and support rear of vehicle. 2. Remove cover from adjusting hole located at bottom of backing plate. Fig. 5 Adjusting Rear Drum Brakes 3. Using a small screwdriver to hold adjusting lever away from star wheel, rotate adjusting screw star wheel until brake shoes are locked against drum, Fig. 5. 4. Back-off brake adjusting screw approximately 10 to 12 notches so that brake drum rotates freely without drag. If brake drum does not rotate freely, remove drum and clean and inspect drum brake components. 5. After adjusting both drum brakes lower vehicle and apply brakes several times to position brake shoes. 6. Road test vehicle to ensure brakes operate properly. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Service and Repair > Installation Brake Shoe: Service and Repair Installation Exploded View Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Service and Repair > Installation > Page 5190 Fig. 1 Drum Brake Assembly 1. Assemble parking brake lever on secondary shoe and secure with spring washer and retaining clip. 2. Apply light coating of suitable lubricant at points where brake shoes contact backing plate. 3. Position brake shoes on backing plate, then install hold down spring pins, springs, and cups. For additional information see Brake Spring Removal and Installation Notes. 4. Install parking brake link, spring, and washer, then connect parking brake cable to parking brake lever. 5. Install anchor pin plate, then place cable anchor over anchor pin with crimped side facing backing plate. 6. Install primary shoe to anchor spring. 7. Install cable guide on secondary shoe web with flanged holes fitted into hole in secondary shoe web, then thread cable around cable guide groove. Ensure that cable is positioned in groove and not between guide and shoe web. 8. Install secondary shoe to anchor spring. Ensure that all parts lay flat on anchor pin. 9. Remove clamp from wheel cylinder. 10. Apply suitable lubricant to threads and socket end of adjusting screw, turn adjusting screw into adjusting pivot nut to end of threads and back off 1/2 turn, then place adjusting socket on screw and install assembly between shoe ends with adjusting screw closer to secondary shoe. Socket end of each adjusting screw is stamped ``R'' or ``L'' to indicate use on right or left side of vehicle. Adjusting pivot nuts can be identified by number of lines machined around body of nut. Two lines indicate righthand nut and one line indicates lefthand nut. 11. Hook cable hook into hole in adjusting lever from outboard plate side. Adjusting levers are stamped ``R'' or ``L'' to indicate use on righthand or lefthand brake assembly. 12. Place hooked end of adjuster spring in large hole in primary shoe web and connect looped end of spring to adjuster lever hole. 13. Pull adjuster lever, cable, and automatic adjuster spring down toward rear to engage pivot hook in large hole in secondary shoe web, then ensure that adjusting mechanism works properly. 14. Install brake drums. For additional information see Notes, Warnings, and Hints. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Service and Repair > Installation > Page 5191 Brake Shoe: Service and Repair Removal Exploded View Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Service and Repair > Installation > Page 5192 Fig. 1 Drum Brake Assembly 1. Raise and support vehicle. 2. Remove wheel and tire assembly. 3. Remove brake drum. 4. Install suitable clamp over ends of wheel cylinder. 5. Contract brake shoes as follows: Backing Off Brake Adjustment a. Disengage adjusting lever from adjusting screw. b. Move outboard side of adjusting screw upward and back off pivot nut as far as it will go. 6. Pull adjusting lever, cable, and automatic adjuster spring down and toward rear to unhook pivot hook from large hole in secondary shoe web. Do not pry pivot hook out of hole. 7. Remove automatic adjuster spring and adjusting lever. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Service and Repair > Installation > Page 5193 Spring Replacement (Typical) 8. Using suitable tool, remove secondary shoe to anchor spring, then the primary shoe to anchor spring. For additional information see Brake Spring Removal and Installation Notes. 9. Unhook cable anchor and remove anchor pin plate. 10. Remove cable guide from secondary shoe. 11. Remove shoe hold-down springs, shoes, adjusting screw, pivot nut, and socket. Note color and position of each hold down spring for proper assembly. 12. Remove parking brake link and spring. Disconnect parking brake cable from parking brake lever. 13. Remove brake secondary shoe and disassemble parking brake lever from shoe by removing retaining clip and spring washer. For additional information see Notes, Warnings, and Hints. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component Information > Service and Repair > Removal Wheel Cylinder: Service and Repair Removal 1. Raise vehicle on hoist and position suitable safety stands under vehicle. 2. Remove wheel and tire assembly. 3. Remove the brake drum. Remove brake linings. Remove the wheel cylinder brake shoe links. 4. Disconnect the rear brake tube from the wheel cylinder. 5. Remove the brake cylinder retaining bolts and lockwashers. Remove the wheel cylinder from the backing plate. For additional information see Notes, Warnings, and Hints. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component Information > Service and Repair > Removal > Page 5198 Wheel Cylinder: Service and Repair Rebuild For additional information see Notes, Warnings, and Hints. Rear Wheel Cylinder DISASSEMBLY 1. Remove the rubber boots from the ends of the brake cylinder. 2. Remove the pistons, cups and piston cup spring. 3. Remove the wheel cylinder bleeder screw. Ensure the bleeder screw is not plugged. ASSEMBLY 1. Coat all wheel cylinder parts with clean brake fluid or brake assembly lube. 2. Install the bleeder screw into the wheel cylinder. 3. Place the wheel cylinder piston cup spring, cups and pistons into the wheel cylinder. 4. Install a boot and wheel cylinder brake shoe link over each end of the wheel cylinder. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component Information > Service and Repair > Removal > Page 5199 Wheel Cylinder: Service and Repair Installation 1. Place wheel cylinder on the brake backing plate. Install the retaining bolts and lockwashers. 2. Connect the brake tube to the wheel cylinder. 3. Install wheel cylinder brake shoe links and brake linings. Install the brake drum and wheel and tire assembly. 4. Adjust the brakes. See: Brake Shoe/Adjustments 5. Perform system brake bleeding procedures. Check pedal operation before moving the vehicle. For additional information see Notes, Warnings, and Hints. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Manual Bleeding Brake Bleeding: Service and Repair Manual Bleeding NOTE: Bleed primary and secondary hydraulic brake systems separately, bleeding longest line first on each system. Do not allow reservoir to run dry during bleeding operation. Never reuse fluid that has been drained from hydraulic system. 1. Loosen master cylinder to hydraulic line nuts and wrap shop cloths around tubing below fitting to absorb escaping brake fluid. 2. Depress brake pedal slowly by hand to floor of cab, forcing air trapped in master cylinder out at fitting. 3. Hold pedal down and tighten fittings, then release brake pedal. NOTE: Releasing brake pedal before fittings are tightened will allow air to enter the master cylinder. 4. Repeat steps 1 through 3 until air ceases to escape at fittings and brake pedal is firm. 5. Bleed rear brakes as follows: RR, LR, RF, LF WARNING: Do not bleed the brakes with the drums removed. The wheel-cylinders will over-extend and eject the pistons. a. Pump pedal several times, then hold pedal down firmly. WARNING: Do not Full Stroke the brake pedal, this may damage the master cylinder. Place a 2 inch block of wood under the brake pedal to prevent Full Stroking. b. With pedal firmly depressed, open bleeder screw on one rear brake until pedal fades to floor, then close bleeder valve. NOTE: Do not release the brake pedal until the bleeder valve is fully shut. c. Repeat procedure until a continuous flow of brake fluid is released from bleeder valve. d. Repeat steps 5a through 5c on other rear brake. 6. Bleed front brakes using same procedure as for rear brakes. 7. Fill master cylinder reservoirs to 1/4 inch from top of reservoirs. 9. Check brake operation and ensure pedal is firm, road test vehicle. For additional information see Bleeding Notes. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Manual Bleeding > Page 5205 Brake Bleeding: Service and Repair Master Cylinder Bleeding 1. Support the master cylinder body in a vise, and fill both fluid reservoirs with heavy duty DOT 3 brake fluid. 2. Install plugs in the front and rear brake outlet ports. Bleed the rear brake outlet system first. 3. Loosen the plug in the rear brake outlet port. Depress the primary piston slowly to force the air out of the master cylinder. Tighten plug while piston is depressed or air will enter the master cylinder. 4. Repeat this procedure until air ceases to exit at the outlet port. 5. Repeat steps 3 and 4 for the front brake outlet port with the rear brake outlet plugged. 6. Tighten the plugs and try to depress the piston. Depressing the piston should be harder after all air is expelled. 7. Install the cover and diaphragm assembly making sure the cover retainer is tightened securely. Remove the plugs. For additional information see Bench Bleeding. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Manual Bleeding > Page 5206 Brake Bleeding: Service and Repair Pressure Bleeding Be sure the bleeder tank contains enough of the specified brake fluid to complete the bleeding operation. Charge the tank with approximately 69-206 kPa (10-30 psi). Never exceed 345 kPa (50 psi). Never use brake fluid that has been drained from the hydraulic system. Bleed the longest lines first 1. Clean all dirt from the master cylinder reservoir cap. 2. Remove the master cylinder reservoir cap and fill the master cylinder reservoir with the specified brake fluid. Install the pressure bleeder adapter tool on the master cylinder, and attach the bleeder tank hose to the fitting on the adapter. NOTE: Master cylinder pressure bleeder adapter tools are available from the manufacturers of pressure bleeding equipment. Follow the manufacturer's instructions when installing the adapter. 3. Place a 3/8 inch box wrench on the bleeder fitting on the right rear brake wheel cylinder. Attach a bleeder tube snugly to the bleeder fitting. 4. Open the valve on the bleeder tank and admit pressurized brake fluid to the master cylinder reservoir. 5. Submerge the free end of the tube in a container partially filled with clean brake fluid, and loosen the bleeder fitting. 6. When air bubbles no longer appear in the fluid at the submerged end of the bleeder tube, close the bleeder fitting and remove the tube. 7. Repeat Steps 3 through 6 at the opposite wheel cylinder. On front brakes, bleed the right front caliper first. 8. When the bleeding operation is completed, close the bleeder tank valve and remove the tank hose from the adapter fitting. 9. Remove the pressure bleeder adapter tool. Fill the master cylinder reservoirs with the specified brake fluid to within 3 mm (1/8 in) from the top of the filler neck. Install the master cylinder cover. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Technical Service Bulletins > Customer Interest for Brake Caliper: > 88137 > Jun > 88 > Brake Caliper Rattling Noise Brake Caliper: Customer Interest Brake Caliper - Rattling Noise BRAKE - CALIPER "RATTLING" NOISE - VEHICLES BUILT BEFORE 3/01/88 BRAKE - CALIPER PINS - SERVICE REMOVAL TOOL NOISE - "RATTLE" FROM BRAKE CALIPER - VEHICLES BUILT BEFORE 3/01 /88 Article No. 88-13-7 LIGHT TRUCK: 1983-88 RANGER 1984-88 BRONCO II 1986-88 AEROSTAR, BRONCO, E SERIES, F SERIES 1988 F-SUPER DUTY ISSUE: A "rattling" noise may be heard coming from the front disc brake calipers. The caliper pins may eventually take a set under certain load conditions allowing the disc brake caliper to "rattle". The "rattling" noise is more likely to develop on units that are driven off-road or operated on rough roads. ACTION: To correct this, install new design caliper pins. A new caliper pin removal tool can be made to aid in removal of the pins. Refer to the caliper pin application chart on this page for the correct service part number. FIGURE 8 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Technical Service Bulletins > Customer Interest for Brake Caliper: > 88137 > Jun > 88 > Brake Caliper Rattling Noise > Page 5215 FIGURE 9 FIGURE 10 FIGURE 11 The caliper pin removal tool is recommended for use on all the above listed vehicles, including 1988 Super Duty, Figures 8 through 11. This caliper pin tool can be made from a 1/2 inch diameter rod 7 inches long. Simply grind or cut a "V" notch in one (1) end. The "V" notch is used to compress the pin retention tabs while the tool is also used to drive the pin out of the caliper slide groove. This tool replaces a pair of pliers and screwdriver as outlined in the Shop Manual service procedure. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Technical Service Bulletins > Customer Interest for Brake Caliper: > 88137 > Jun > 88 > Brake Caliper Rattling Noise > Page 5216 The idea for this tool was submitted for the Best Idea Contest by Joseph L. Kaiser, Bauer Ford Inc., Brookville, Indiana. See "Service Life", Winter 1987 issue for featured article. CALIPER PIN APPLICATION CHART Part Number Part Name Vehicle Usage E8TZ-2C150-A Caliper Pin Super Duty E8TZ-2C150-B Caliper Pin Ranger, Bronco II, Aerostar, Bronco, E Series, F Series PART NUMBER PART NAME CLASS E8TZ-2C150-A Caliper Pin B E8TZ-2C150-B Caliper Pin B OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION: 881307A - Both sides TIME: 0.5 Hr. DLR. CODING: Basic Part No. 2C150 Condition Code: 33 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Caliper: > 88137 > Jun > 88 > Brake Caliper - Rattling Noise Brake Caliper: All Technical Service Bulletins Brake Caliper - Rattling Noise BRAKE - CALIPER "RATTLING" NOISE - VEHICLES BUILT BEFORE 3/01/88 BRAKE - CALIPER PINS - SERVICE REMOVAL TOOL NOISE - "RATTLE" FROM BRAKE CALIPER - VEHICLES BUILT BEFORE 3/01 /88 Article No. 88-13-7 LIGHT TRUCK: 1983-88 RANGER 1984-88 BRONCO II 1986-88 AEROSTAR, BRONCO, E SERIES, F SERIES 1988 F-SUPER DUTY ISSUE: A "rattling" noise may be heard coming from the front disc brake calipers. The caliper pins may eventually take a set under certain load conditions allowing the disc brake caliper to "rattle". The "rattling" noise is more likely to develop on units that are driven off-road or operated on rough roads. ACTION: To correct this, install new design caliper pins. A new caliper pin removal tool can be made to aid in removal of the pins. Refer to the caliper pin application chart on this page for the correct service part number. FIGURE 8 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Caliper: > 88137 > Jun > 88 > Brake Caliper - Rattling Noise > Page 5222 FIGURE 9 FIGURE 10 FIGURE 11 The caliper pin removal tool is recommended for use on all the above listed vehicles, including 1988 Super Duty, Figures 8 through 11. This caliper pin tool can be made from a 1/2 inch diameter rod 7 inches long. Simply grind or cut a "V" notch in one (1) end. The "V" notch is used to compress the pin retention tabs while the tool is also used to drive the pin out of the caliper slide groove. This tool replaces a pair of pliers and screwdriver as outlined in the Shop Manual service procedure. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Caliper: > 88137 > Jun > 88 > Brake Caliper - Rattling Noise > Page 5223 The idea for this tool was submitted for the Best Idea Contest by Joseph L. Kaiser, Bauer Ford Inc., Brookville, Indiana. See "Service Life", Winter 1987 issue for featured article. CALIPER PIN APPLICATION CHART Part Number Part Name Vehicle Usage E8TZ-2C150-A Caliper Pin Super Duty E8TZ-2C150-B Caliper Pin Ranger, Bronco II, Aerostar, Bronco, E Series, F Series PART NUMBER PART NAME CLASS E8TZ-2C150-A Caliper Pin B E8TZ-2C150-B Caliper Pin B OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION: 881307A - Both sides TIME: 0.5 Hr. DLR. CODING: Basic Part No. 2C150 Condition Code: 33 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Technical Service Bulletins > Page 5224 Brake Caliper: Description and Operation Fig. 3 Exploded view of disc brake caliper assembly These models use the LD (Light Duty) pin rail sliding caliper type system, in which the single piston caliper slides on two pins attaching the caliper to the spindle assembly. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Inspection Brake Caliper: Service and Repair Inspection For additional information see Installation Notes. See: Fundamentals and Basics Installing Anti-Rattle Clip 1. Place a new anti-rattle clip on the lower end of the inner pad. Be sure the tabs on the clip are positioned properly and the clip is fully seated. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Inspection > Page 5227 Anti-Rattle Clip Position 2. Position the inner pad and anti-rattle clip in the pad abutment with the anti-rattle clip tab against the pad abutment and the loop-type spring away from the rotor. Compress the anti-rattle clip and slide the upper end of the pad in position. 3. Install the outer pad. Crimp or bend outer pad tabs to prevent pads from rattling in caliper. 4. Install caliper on the spindle. Make sure the mounting surfaces are free of dirt and lubricate the caliper grooves with disc brake caliper grease. Caliper Pin Installation 5. Position pin with the pin retention tabs oriented adjacent to the spindle groove. NOTE: Do not use the bolt and nut with the new pin. 6. Tap the pin on the outboard end with a hammer. Continue tapping the pin inward until the retention tabs on the sides of the pin contact the spindle face. Repeat procedure for the lower pin. Correct Caliper Pin Installation CAUTION: During the installation procedure do not allow the tabs of the caliper pin to be tapped too far into the spindle groove. If this happens Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Inspection > Page 5228 it will be necessary to tap the other end of the caliper pin until the tabs snap into place. The tabs on each end of the caliper pin must be free to catch on the spindle flanks. 7. If removed, install the brake hose to the caliper and perform brake bleeding procedures. Caliper Inlet Block 8. Install the wheel and tire assembly. 9. Lower the vehicle, check the brake fluid level and fill as necessary. Check brakes for proper operation. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Inspection > Page 5229 Brake Caliper: Service and Repair Rebuild NOTE: Do not use a screwdriver or any similar tool to pry piston into or out of the bore to prevent chipping or scuffing damage to the phenolic piston. DISASSEMBLY Disc Brake Caliper Disassembled 1. Remove the caliper assembly from the vehicle. Remove outer brake shoe to avoid damage to lining material. Substitute shoe with a piece of wood of similar size and shape, or use a worn out shoe and lining assembly. Place a cloth over the piston before applying air pressure to prevent damage to the piston. 2. Apply air pressure to the fluid port in the caliper with a rubber-tipped nozzle to remove the piston. If the piston is seized and cannot be forced from the caliper, tap lightly around the piston while applying air pressure. NOTE: Use care because the piston can develop considerable force from pressure build-up. 3. Remove the dust boot from the caliper assembly. 4. Remove the rubber piston seal from the cylinder and discard it. NOTE: Do not remove the steel ring from the piston. CLEANING and INSPECTION Clean all metal parts with isopropyl alcohol. Clean out and dry the grooves and passageways with compressed air. Make sure that caliper bore and component parts are thoroughly clean. Use a wire brush to remove any rust or corrosion from the machined surfaces of the caliper housing. NOTE: Do not use a wire brush in the cylinder bore. Check the cylinder bore and piston for damage or excessive wear. Replace the piston if it is pitted, scored or worn. Do not replace phenolic pistons for cosmetic surface irregularities or small chips between the piston groove and pad face. Use a wire brush to clean corrosion from the boot groove and the machined surfaces of the spindle assembly. Replace the anti-rattle clip, piston seal and dust boot with new components. ASSEMBLY 1. Apply a film of clean brake fluid to the new caliper piston seal, and install it in the cylinder bore. Be sure the seal does not become twisted but is firmly seated in the groove. 2. Install a new dust boot by setting the flange squarely in the outer groove of the caliper bore. 3. Coat the piston with brake fluid, and install the piston in the cylinder bore. Spread the dust boot over the piston as it is installed. Seat the dust boot in the piston groove, behind the pressed-on steel ring. 4. Install the caliper over the rotor. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Inspection > Page 5230 Brake Caliper: Service and Repair Removal 1. To avoid overflow when the caliper piston is compressed into the caliper piston bore, remove a portion of brake fluid from master cylinder disc brake reservoir. Properly dispose the removed fluid. 2. Raise and support vehicle. Remove wheel and tire assembly. Bottoming Caliper Piston 3. Install an eight inch C-clamp on caliper. Tighten clamp to bottom caliper piston in cylinder bore. Remove the clamp. NOTE: Do not use screwdriver or other edged tool to pry piston from rotor. 4. Clean excess dirt from area around pin tabs. 5. Tap upper caliper pin towards inboard side until pin tabs touch the spindle face. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Inspection > Page 5231 6. Insert a screwdriver into the slot provided behind the pin tabs on the inboard side of the pin. Compressing Pin Tabs 7. Use needle nose pliers to compress the outboard end of the pin while prying at the same time with the screwdriver, until tabs slip into the spindle groove. 8. Place one end of a punch (approximately 7/16 inch diameter) against the end of the caliper pin and drive the caliper pin out of the caliper slide groove. 9. Repeat removal procedure for lower pin. 10. Remove the caliper from the rotor. If the caliper is to be removed for service, remove the brake hose from the caliper. If the caliper is not going to be removed, secure it to the vehicle to avoid damage to the brake hose. Caliper Inlet Block 11. Remove the outer brake pad. Remove the anti-rattle clips and the inner brake pad. For additional information see Removal Notes. See: Fundamentals and Basics Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Fundamentals and Basics > Removal Notes Brake Caliper: Fundamentals and Basics Removal Notes When Removing the Caliper, Remember... - Prior to removing the calipers, remove/siphon brake fluid from master-cylinder until the reservoir is only 1/3 full. - Brake fluid will remove paint and damage electrical connections. Use a drip pan and fender covers to protect the vehicle's finish and electrical system. - Always replace all brake linings on an axle. Never replace only one wheel. Unequal lining thickness between wheels on the same axle will result in a strong steering pull when the brakes are applied. - Work on one side at a time. If you forget how to reassemble the parts you can always use the other side as a model. - When forcing the piston back into the caliper, open the bleeder valve first. Corrosion and other deposits accumulate inside of the caliper. If the bleeder valve is not opened when the piston is forced back into the caliper, these deposits will be forced back through the brake lines and into the master-cylinder. When pushing the pistons back into the caliper with the bleeder screw open, a stream of brake fluid will be expelled from the bleeder screw for 2-3 feet. Use a drip pan and be careful not to "shoot" brake fluid onto the vehicle's finish. A cleaner method is to use a piece of clear plastic hose and a glass or plastic jar to catch the expelled fluid. - Upon removal, Do Not allow the calipers to hang by the flexible brake hoses. The brake hoses can be damaged easily by this practice. These hoses are double walled, damage to the interior pressure hose will not be visible. - Do not depress the brake pedal with either caliper removed from the rotor. The caliper pistons will be inadvertently expelled from the caliper. If this occurs rebuild or replace the caliper, do not attempt to insert the piston back into the caliper. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Fundamentals and Basics > Removal Notes > Page 5234 Brake Caliper: Fundamentals and Basics Installation Notes WHEN INSTALLING CALIPERS AND PADS, REMEMBER... - Clean and lubricate caliper slide joint/pins with high temperature silicone grease: Unlike drum brakes, disc brakes do not utilize a spring to withdraw the pads/linings when the brake pedal is released. Disc brakes rely on the elasticity of the piston seals, and the unrestricted movement of the caliper slide assemblies to release the brakes. If the slide joints/pins are not cleaned and lubricated properly the disc brake linings will drag upon the release of the brake pedal. This will result in overheated brakes and premature brake wear. Disc Brake Mechanical Force Diagram NOTE: Floating calipers require free and unrestricted movement on the caliper mounting. Floating or sliding calipers have pistons only on one side of the rotor. The first part of the piston's travel forces the inner pad against the rotor, then further travel forces the movable part of the caliper to pull the outer pad against the rotor. High temperature silicone lubricant must be used. Low temperature grease can melt and contaminate the pads and rotors, or can bake into a very hard substance which binds the slides. Petroleum based grease can cause the slide boots to soften and swell. Work on one side at a time. If you forget how to reassemble the parts you can always use the other side as a model. Anti-squeal Coating - Apply an anti-squeal coating to the back side of the pads/linings. This coatings acts as an insulator to dampen high frequency vibrations that are generated during normal braking. These compounds are highly effective in preventing brake squeal. - Many professional repair shops recommend always rebuilding or replacing the calipers when replacing the brake linings, because: When the pistons are forced back into the calipers, the piston seals are dragged across any corrosion or abrasives that may be deposited on the inside of the caliper. Damage to the seals may not be initially evident. As the new brake linings begin to wear, the piston is gradually withdrawn from the caliper. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Fundamentals and Basics > Removal Notes > Page 5235 This results in the piston seals again being dragged across the layer of corrosion and deposits. Calipers which are not rebuilt or replaced have a higher probability of sticking or leaking. - Check to ensure the bleeder screw is not frozen prior to reinstalling caliper. Freeing a stuck bleeder screw is much easier with the caliper removed from the vehicle. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Pressure Sensor/Switch > Component Information > Locations Brake Fluid Pressure Sensor/Switch: Locations RH Frame Member Attached To LH Frame Member Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Technical Service Bulletins > Brake Hoses - Wet Appearance Brake Hose/Line: Technical Service Bulletins Brake Hoses - Wet Appearance Article No. 91-18-9 09/05/91 ^ BRAKES-HYDRAULIC-RUBBER BRAKE HOSES ARE WET FROM SWEATING ^ BRAKES-HYDRAULIC-RUBBER HOSES-FLUID LEAK TESTING PROCEDURE LIGHT TRUCK: 1985-90 BRONCO II 1985-92 BRONCO, ECONOLINE, F-150, F-250, F-350, RANGER 1986-92 AEROSTAR 1988-92 F SUPER DUTY, F-47, F-63, F-59 1991-92 EXPLORER This TSB article is being republished in its entirety to include 1992 model vehicles. ISSUE: The wet appearance of the outer cover of rubber brake hoses is called "sweating." This is a normal condition for neoprene rayon braid hose. The "sweating" condition is not evidence of a brake fluid leak and will not result in a loss of pressure in the system. ACTION: No action is required for a normal "sweating" brake hose. However, to test for a hydraulic fluid leak, proceed as follows: 1. Check the brake fluid level in the master cylinder. If necessary, add brake fluid. 2. Wipe off the hose(s) in question with a clean cloth and an all purpose cleaner, then dry. 3. With the engine running, fully depress the brake twice and hold for two (2) minutes. ^ If the pedal goes down, check all of the connections for leaks and repair as required. ^ If the pedal goes down and no visible leaks are seen, then the master cylinder is leaking internally and must be replaced or rebuilt. Refer to the appropriate Light Truck or Medium/Heavy Truck Shop Manual, Section 6 or 12 (Light Truck) and Section 12 (Med./Hvy Truck) for service details. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 90-11-9 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 301000 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Technical Service Bulletins > Customer Interest for Brake Proportioning/Combination Valve: > 892516 > Dec > 89 > Front Brakes - Premature Lining Wear/Hard Pedal Brake Proportioning/Combination Valve: Customer Interest Front Brakes - Premature Lining Wear/Hard Pedal Article No. 89-25-16 ^ BRAKES - FRONT - PREMATURE LINING WEAR ^ BRAKES - REAR HEIGHT SENSING PROPORTIONING VALVE - INOPERATIVE DUE TO SUSPENSION MODIFICATION LIGHT TRUCK: 1985-86 F-250, F-350 1985-89 E-250, E-350 ISSUE: High brake pedal efforts or increased front brake lining wear may be caused by aftermarket suspension modifications. The modified suspension may affect the performance of the height sensing proportioning valve. Figure 2 Figure 3 ACTION: Inspect the truck to determine if the suspension has been modified. Compare the rear suspension (springs) to the suspension specifications Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Technical Service Bulletins > Customer Interest for Brake Proportioning/Combination Valve: > 892516 > Dec > 89 > Front Brakes - Premature Lining Wear/Hard Pedal > Page 5251 shown in the Light Truck Facts Book and the spring codes listed on the vehicle certification label, Figure 2 and 3. If the suspension has been modified or will be modified, use the following procedure. If the suspension has not been modified, replace the height sensing proportioning valve as outlined in TSB 88-12-20. Figure 1 1. Remove the nut from the valve shaft and remove the leading arm of the linkage assembly, Figure 1. Save the nut. 2. Remove the two (2) nuts from the differential housing bolts and remove the linkage bracket, Figure 1. 3. Return the linkage to the customer. Figure 4 4. Rotate the valve shaft one (1) full turn in either direction. Position the shaft with the flat at the bottom and parallel with the ground, Figure 3. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Technical Service Bulletins > Customer Interest for Brake Proportioning/Combination Valve: > 892516 > Dec > 89 > Front Brakes - Premature Lining Wear/Hard Pedal > Page 5252 Figure 5 5. Rotate the valve shaft counter-clockwise 90~ so that the flat of the shaft is vertical, Figure 5. Figure 6 6. Place the valve shaft positioner, (E9TZ-2W125-A) over the valve shaft as shown in Figure 6. Make sure the shaft flat fits into the "D"-slot of the positioner and that the shroud is fully seated over the valve casting. 7. Re-install the nut saved in Step 1 on the valve shaft. Hold the shaft positioner and tighten the nut to a torque of 8-10 lb.ft. (11-14 N-m). 8. Install an "Authorized Modification" decal on the brake booster listing the modification as follows: "HSPV REAR BRAKE OPERATION MODIFIED". Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Technical Service Bulletins > Customer Interest for Brake Proportioning/Combination Valve: > 892516 > Dec > 89 > Front Brakes - Premature Lining Wear/Hard Pedal > Page 5253 Obtain an Authorized Modifications Decal and list the date, dealer number, and summary of alterations performed. Select a prominent place adjacent to the Vehicle Emission Control Information Decal suitable for installing the Authorized Modifications Decal. Clean the area, install the decal, and cover it with a clear plastic decal shield. PART NUMBER PART NAME CLASS E9TZ-2W125-A Valve Shaft Positioner C OTHER APPLICABLE ARTICLES: 88-12-20 WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION DESCRIPTION TIME 892516A Modify Height Sensing 0.6 Hr. Valve DEALER CODING BASIC PART NO. CONDITION CODE 2B547 53 OASIS CODES: 3050, 3051 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Proportioning/Combination Valve: > 892516 > Dec > 89 > Front Brakes - Premature Lining Wear/Hard Pedal Brake Proportioning/Combination Valve: All Technical Service Bulletins Front Brakes - Premature Lining Wear/Hard Pedal Article No. 89-25-16 ^ BRAKES - FRONT - PREMATURE LINING WEAR ^ BRAKES - REAR HEIGHT SENSING PROPORTIONING VALVE - INOPERATIVE DUE TO SUSPENSION MODIFICATION LIGHT TRUCK: 1985-86 F-250, F-350 1985-89 E-250, E-350 ISSUE: High brake pedal efforts or increased front brake lining wear may be caused by aftermarket suspension modifications. The modified suspension may affect the performance of the height sensing proportioning valve. Figure 2 Figure 3 ACTION: Inspect the truck to determine if the suspension has been modified. Compare the rear suspension (springs) to the suspension specifications Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Proportioning/Combination Valve: > 892516 > Dec > 89 > Front Brakes - Premature Lining Wear/Hard Pedal > Page 5259 shown in the Light Truck Facts Book and the spring codes listed on the vehicle certification label, Figure 2 and 3. If the suspension has been modified or will be modified, use the following procedure. If the suspension has not been modified, replace the height sensing proportioning valve as outlined in TSB 88-12-20. Figure 1 1. Remove the nut from the valve shaft and remove the leading arm of the linkage assembly, Figure 1. Save the nut. 2. Remove the two (2) nuts from the differential housing bolts and remove the linkage bracket, Figure 1. 3. Return the linkage to the customer. Figure 4 4. Rotate the valve shaft one (1) full turn in either direction. Position the shaft with the flat at the bottom and parallel with the ground, Figure 3. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Proportioning/Combination Valve: > 892516 > Dec > 89 > Front Brakes - Premature Lining Wear/Hard Pedal > Page 5260 Figure 5 5. Rotate the valve shaft counter-clockwise 90~ so that the flat of the shaft is vertical, Figure 5. Figure 6 6. Place the valve shaft positioner, (E9TZ-2W125-A) over the valve shaft as shown in Figure 6. Make sure the shaft flat fits into the "D"-slot of the positioner and that the shroud is fully seated over the valve casting. 7. Re-install the nut saved in Step 1 on the valve shaft. Hold the shaft positioner and tighten the nut to a torque of 8-10 lb.ft. (11-14 N-m). 8. Install an "Authorized Modification" decal on the brake booster listing the modification as follows: "HSPV REAR BRAKE OPERATION MODIFIED". Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Proportioning/Combination Valve: > 892516 > Dec > 89 > Front Brakes - Premature Lining Wear/Hard Pedal > Page 5261 Obtain an Authorized Modifications Decal and list the date, dealer number, and summary of alterations performed. Select a prominent place adjacent to the Vehicle Emission Control Information Decal suitable for installing the Authorized Modifications Decal. Clean the area, install the decal, and cover it with a clear plastic decal shield. PART NUMBER PART NAME CLASS E9TZ-2W125-A Valve Shaft Positioner C OTHER APPLICABLE ARTICLES: 88-12-20 WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION DESCRIPTION TIME 892516A Modify Height Sensing 0.6 Hr. Valve DEALER CODING BASIC PART NO. CONDITION CODE 2B547 53 OASIS CODES: 3050, 3051 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Technical Service Bulletins > Page 5262 Brake Proportioning/Combination Valve: Description and Operation EXCEPT AEROSTAR, BRONCO II & 1983---87 RANGER These vehicles use a pressure differential valve, a metering valve (1980---84) and a proportioning valve which are combined in a single unit. These valves sense unbalanced pressure between front and rear brakes. Loss of pressure in either the primary or secondary brake system causes pressure differential valve to move off center and illuminate brake warning light. After system is replaced and brakes are bled, the valve centers itself, turning off warning light. The brake warning light switch is mounted on top of the valve body casting above the pressure differential valve tapered shoulder groove. When the valve is centered, spring loaded switch plunger fits into the tapered shoulder groove. The switch contacts are open, interrupting electrical continuity to the brake warning light on the instrument panel. The metering valve is located in the front end of the control valve housing between the front brake system inlet port and the right and left front brake outlet ports. This valve regulates hydraulic fluid pressure to the front disc brakes. The proportioning valve used on some models is located at the bottom of the housing between the rear brake system inlet and outlet ports. This valve regulates rear brake system hydraulic pressure. A plug and tube seat is pressed into the rear end of the central bore. A hole through the center of the plug and tube seal directs hydraulic fluid from the valve to the rear brake system outlet port. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Load Compensator, Rear Wheel Brakes > Component Information > Technical Service Bulletins > Height Sensing Proportioning Valve - Service Procedure Load Compensator: Technical Service Bulletins Height Sensing Proportioning Valve - Service Procedure Article No. 85-21-14 BRAKE - VEHICLE HEIGHT SENSING PROPORTIONING VALVE SERVICE PROCEDURE LIGHT TRUCK 1985-86 F & E-250/350 All F & E-250/350 vehicies built after May 1, 1985 will be equipped with a brake height sensing valve. Figure 16 - Sensing Proportioning Valve/Service Procedure The valve is located on the number five crossmember and is activated through a linkage system that is connected to the axle housing cover of the rear axle assembly. See Figure 16. The following service procedure is recommended for removing and installing the valve assembly. 1. Raise vehicle on hoist and allow the rear suspension and rear axle to hang in full rebound position. (Rear shock absorbers, if so equipped, must be connected to the rear axle.) Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Load Compensator, Rear Wheel Brakes > Component Information > Technical Service Bulletins > Height Sensing Proportioning Valve - Service Procedure > Page 5267 2. Remove both rear wheels and tires. 3. Remove linkage assembly (2C193) from the valve (2B547). 4. Remove the brake hose (2282). 5. Remove valve (2B547) from mounting bracket (2B526) and replace with new valve (2B547). 6. Position and attach the sensing valve (2B547) to mounting bracket (2B526) with two bolts. Torque bolts to 14-22 ft.lbs. 7. Connect linkage assembly (2C193) to the sensing valve shaft. Squeeze the plastic bushing of the link assembly onto the serrated section of the valve shaft using large groove-joint type pliers. 8. Install nut (379930) securing link assembly to valve shaft. Torque nut to 8-10 ft.lbs. 9. Install rear brake hose assembly (2282) to the sensing valve (2B547) with the existing bolt (385116) and two new washers (388949). Torque bolt to 17-25 ft.lbs. 10. Bleed brake system and correct any leakage. 11. Install wheels and tires. 12. Lower vehicle. 13. Road test to confirm repair. NOTE: The valve will automatically become operational when the vehicle's suspension is in the "curb condition". When servicing other rear suspension components (axle assembly, rear springs, fuel tank, etc.), remove the two nuts attaching the sensing valve linkage (2C193)to the rear axle cover plate. This will eliminate the need to replace the brake valve. If the linkage assembly is disconnected from the height sensing valve, a new sensing valve must also be installed. NOTE: Any change to the vehicle rear suspension which will alter "curb" ride height (e.g. increased capacity leaf springs, addition of spacers, etc.) may change the function of the height sensing valve and alter the system braking performance. The new sensing valve assembly will have the shaft preset and secured internally. If the valve shaft of the valve turns freely - DO NOT USE. The height/load sensing brake proporting valve (2B547) is not to be repaired or disassembled. It must be replaced as a complete assembly. If the linkage assembly (2C193) is damaged or broken and requires replacement, a new sensing valve must also be installed. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION: SP2547B85 TIME: 1.6 Hrs. DLR. CODING: Basic Part No. 2B547 - Code: 42 NOTE: Reimbursable under warranty only if the height sensing valve is defective. Height sensing valves replaced because of damaged or broken linkage assembly (2C193) are not reimbursable under warranty. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Specifications Brake Master Cylinder: Specifications Master Cylinder Attaching Nuts ........................................................................................................................................................ 18-33 Nm (13-25 lb ft) Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Specifications > Page 5271 Brake Master Cylinder: Description and Operation Master Cylinder The dual master cylinder contains a double hydraulic cylinder with two fluid reservoirs, and primary and secondary hydraulic pistons. The dual master cylinder performs in the following manner: Rear wheel brakes - are connected to the secondary outlet port and are actuated by the secondary piston assembly. Front wheel brakes - are connected to the primary outlet port (nearest the dash panel) and are actuated by the primary piston assembly. Both primary and secondary pistons function together. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Specifications > Page 5272 Brake Master Cylinder: Testing and Inspection INSPECTION Inspect for Leakage NOTE: The master cylinder should be cleaned thoroughly prior to inspection (several days preferably). Spilled brake fluid can be easily confused with leakage. Piston Seals Leakage around the piston seals will seep out from the end of the cylinder and leak down the outside of the brake booster. - Inspect for signs of seepage or bubbled paint on the brake booster. - If any leakage is detected the master cylinder should be replaced or overhauled Brake Line Fittings While someone is applying pressure to the brake pedal, inspect the brake line fittings on the master cylinder for leakage. - If the fittings are leaking they should be disassembled and inspected. Reservoir to Cylinder Gasket Inspect the gasket for signs of leakage or hardening and cracking. - Overhaul or replace the master cylinder if any leakage is indicated. Inspect for Oil Contamination. - Inspect the rubber gasket on the inside of the master cylinder lid. If the gasket is swollen or bloated, the brake fluid is contaminated with oil. - Siphon or scoop a small amount of brake fluid out of the master cylinder and place into a styrofoam cup filled 2/3 of the way with water. Brake fluid will mix with the water while oil contaminants will float on the surface and dissolve the styrofoam. NOTE: If any oil contamination is present ALL brake components containing rubber seals will need to be replaced or overhauled. This includes the master cylinder, both front brake calipers, both rear wheel-cylinders, and all flexible brake hoses. Verify Hold-Down Bolts Are Tight While someone is applying and releasing pressure to the brake pedal, verify the the master cylinder is tightly secured to the brake booster. - Retighten hold-down bolts if necessary. Functional Checks WARNING: Always bleed the entire brake system and verify the rear brakes are properly adjusted prior to diagnosing a master cylinder as defective. For additional information see Master-Cylinder / Brake Pedal Relationship. Check Related Systems - Check for proper brake booster operation 1. With the engine "OFF", depress and release the brake pedal 4-5 times (this bleeds off the vacuum reserve in the booster). 2. Depress the brake pedal firmly and start the engine. If the pedal goes down slightly the brake booster is assisting in brake operation. If the pedal does not go down slightly the brake booster is not assisting in brake operation and should be diagnosed for problems. - Check and adjust rear brakes. - Check all brake lines and brake assemblies for leakage. Repair all deficiencies with related systems prior to diagnosing the master cylinder as defective. Check Brake Pedal Travel (Non-Antilock Brake Systems Only) Fully depress the brake pedal and check for the following: The pedal should have a 75% reserve. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Specifications > Page 5273 Pedal Reserve Checks - The pedal should be firm and not leak down. Replace the master cylinder if all of the following conditions exist: The brake pedal is not firm with a 75% reserve and - There were no problems with any of the related systems and - The entire brake system has been bled and - The rear brakes are properly adjusted. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Specifications > Page 5274 Brake Master Cylinder: Adjustments Fig.1 Checking Master Cylinder Pushrod Length Check the distance from the outer end of the booster assembly push rod to the front face of the brake booster assembly. Turn the push rod adjusting screw in or out as required to obtain the specified length. For additional information see Fundamentals and Basics. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Removal Brake Master Cylinder: Service and Repair Removal 1. With the engine turned off, push the brake pedal down to expel vacuum from the brake booster system. 2. Disconnect the hydraulic lines from the brake master cylinder. 3. Remove the brake booster-to-master cylinder retaining nuts. Remove the master cylinder from the brake booster. For additional information see Notes, Warnings, and Hints. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Removal > Page 5277 Brake Master Cylinder: Service and Repair Installation Fig.1 Checking Master Cylinder Pushrod Length 1. Before installing the master cylinder, check the distance from the outer end of the booster assembly push rod to the front face of the brake booster assembly. Turn the push rod adjusting screw in or out as required to obtain the specified length. 2. Position the master cylinder assembly over the booster push rod and onto the two studs on the booster assembly. Install the attaching nuts and tighten to 18-33 Nm (13-25 lb ft). 3. Connect the hydraulic brake system lines to the master cylinder. 4. Bleed the master cylinder. Bleed the hydraulic brake system. Centralize the differential valve. Fill the dual master cylinder reservoirs with brake fluid to within 6.35 mm (1/4 inch) of the top. Install the gasket and reservoir cover. Refer to Brake Bleeding. For additional information see Fundamentals and Basics. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Removal > Page 5278 Brake Master Cylinder: Service and Repair Rebuild DISASSEMBLY 1. Clean the outside of the master cylinder and remove the filler cover and gasket. Drain and discard any brake fluid that remains in the cylinder. Removing Snap Ring 2. Depress the primary piston and remove snap ring from retaining groove at the rear of the master cylinder bore. 3. Remove primary piston assembly from the master cylinder bore and inspect for seal damage or twisting. Record condition of piston assembly on repair order and discard assembly. 4. Remove the secondary piston assembly by directing compressed air into the outlet port at the blind end of the bore while plugging the other outlet port. Inspect for seal damage or twisting. Record condition of piston assembly on repair order and discard assembly. 5. Inspect the master cylinder bore for signs of etching, pitting, scoring or other damage. a. If bore is damaged, discard and replace with new master cylinder assembly. Do not attempt to hone bore. b. If bore is not damaged, rebuild master cylinder assembly using the proper repair kit and the procedure outlined below. ASSEMBLY Master Cylinder 1. Clean the master cylinder body with clean isopropyl alcohol to remove any contamination. 2. Dip the repair kit piston assemblies in clean heavy duty brake fluid or brake assembly lube to lubricate seals. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Removal > Page 5279 3. Carefully insert the complete secondary piston assembly in the master cylinder bore. 4. Carefully insert the primary piston assembly in the master cylinder bore. 5. Depress the primary piston and install the snap ring in the cylinder bore groove. 6. On manual brake vehicles, install the push rod retainer onto the push rod and install into the primary piston. Make sure the retainer is properly seated and holding the push rod securely. 7. Install the cover and gasket on the master cylinder assembly and secure into position with the retainer. For additional information see Fundamentals and Basics. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Page 5280 Brake Master Cylinder: Tools and Equipment BASIC SERVICE (Removal and Installation) - Fender cover (servicing and bleeding a master-cylinder can be a messy process) CAUTION: DOT 3 or 4 brake fluid is very corrosive to the vehicles finish and electrical connections. - Drip pan. - Complete set of combination wrenches or sockets. - Brake bleeding device: - Pressure bleeder or - Vacuum bleeder or - One-man brake bleeder kit or - Length of clear plastic hose (3/16 inch ID) and a glass jar. Brake Bleeding Setup - Small ruler or depth gauge (for adjusting the pushrod) - Brake adjusting tool (rear brake adjustment should be checked) - Clean shop towels. OPTIONAL - Master Cylinder brake bleeding kit (contains plastic fittings and hoses used for bleeding master cylinders) - Suction bulb (for removing brake fluid from reservoir) IF MASTER-CYLINDER IS OVERHAULED - Snap-ring pliers - Small pry bar (for separating the reservoir from the cylinder) - Cylinder hone (cast iron cylinders only) - Feeler gauges (for checking piston to cylinder clearance). Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component Information > Service and Repair > Removal Wheel Cylinder: Service and Repair Removal 1. Raise vehicle on hoist and position suitable safety stands under vehicle. 2. Remove wheel and tire assembly. 3. Remove the brake drum. Remove brake linings. Remove the wheel cylinder brake shoe links. 4. Disconnect the rear brake tube from the wheel cylinder. 5. Remove the brake cylinder retaining bolts and lockwashers. Remove the wheel cylinder from the backing plate. For additional information see Notes, Warnings, and Hints. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component Information > Service and Repair > Removal > Page 5285 Wheel Cylinder: Service and Repair Rebuild For additional information see Notes, Warnings, and Hints. Rear Wheel Cylinder DISASSEMBLY 1. Remove the rubber boots from the ends of the brake cylinder. 2. Remove the pistons, cups and piston cup spring. 3. Remove the wheel cylinder bleeder screw. Ensure the bleeder screw is not plugged. ASSEMBLY 1. Coat all wheel cylinder parts with clean brake fluid or brake assembly lube. 2. Install the bleeder screw into the wheel cylinder. 3. Place the wheel cylinder piston cup spring, cups and pistons into the wheel cylinder. 4. Install a boot and wheel cylinder brake shoe link over each end of the wheel cylinder. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component Information > Service and Repair > Removal > Page 5286 Wheel Cylinder: Service and Repair Installation 1. Place wheel cylinder on the brake backing plate. Install the retaining bolts and lockwashers. 2. Connect the brake tube to the wheel cylinder. 3. Install wheel cylinder brake shoe links and brake linings. Install the brake drum and wheel and tire assembly. 4. Adjust the brakes. See: Drum Brake System/Brake Shoe/Adjustments 5. Perform system brake bleeding procedures. Check pedal operation before moving the vehicle. For additional information see Notes, Warnings, and Hints. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Pedal > Component Information > Adjustments Parking Brake Pedal: Adjustments Parking Brake Assembly Adjust the drum brakes before adjusting the parking brake cables. See: Drum Brake System/Brake Shoe/Adjustments Initial Adjustment Procedure (Use this procedure when a new tension limiter is installed). Cable Tension Limiter Assembly 1. Depress the parking brake pedal fully to the last detent position. 2. Grip the Tension Limiter housing to prevent it from spinning and tighten the equalizer nut 63.50mm +\- 3.175mm (2 1/2 inch +\- 1/8 inch) up the rod. 3. Check to make sure cinch strap has slipped (less than 34.925mm or 1 3/8 inch remaining). Field Adjustment (Use this procedure to correct a slack system if new tension limiter is not installed) 1. Make sure brake drums are cold for correct adjustment. 2. Release the parking brake control. 3. Grip the tension limiter housing to prevent it from spinning and tighten the equalizer nut 6 full turns past its original position on the threaded rod. 4. Fully depress pedal to the last detent position and check for proper rear cable tension of 1556 N or (350 lbs). If tension is low repeat steps 2 and 3. 5. Release parking brake and check for rear wheel drag. NOTE: The tension limiter will reset the parking brake tension anytime the system is disconnected provided the distance between the bracket and the cinch strap hook is reduced during adjustment. When the cinch strap hook contacts the bracket, the system tension will increase significantly and over tensioning may result. If all available adjustment travel has been used, the tension limiter must be replaced. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Pedal > Component Information > Adjustments > Page 5291 6. Place the parking brake pedal in the fully released position, then check the slack in the parking brake two rear cables. The cables should be tight enough to provide full application of the rear brake shoes, when the parking brake lever or foot pedal is placed in the fully applied position, yet loose enough to ensure complete release of the brake shoes when the lever is in the released position. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Warning Switch > Component Information > Locations Parking Brake Warning Switch: Locations On Parking Brake Bracket Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Description and Operation Vacuum Brake Booster: Description and Operation The single and tandem vacuum boosters are self contained vacuum hydraulic power braking units. These are vacuum suspended units that use vacuum and atmospheric pressure for their power. On gasoline engine vehicles, vacuum is supplied through a fitting in the intake manifold. On diesel engine vehicles, vacuum is supplied through a vacuum pump. The three basic elements of the booster are the vacuum power chamber, mechanically actuated booster check valve and a hydraulic dual master cylinder which supplies hydraulic pressure to the brake system. The vacuum power chamber consists of a front and rear shell, diaphragm, diaphragm plate, hydraulic pushrod and vacuum diaphragm return spring. The mechanically actuated booster check valve controls the degree of power brake application in accordance with foot pressure applied to the valve operating rod through the brake pedal linkage. This valve is integral with the vacuum power diaphragm. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Description and Operation > Page 5299 Vacuum Brake Booster: Service and Repair 1. Disconnect battery ground cable. 2. Disconnect stop lamp switch electrical connectors. 3. Support underside of master cylinder, then remove power brake unit-to-master cylinder attaching nuts. 4. Remove vacuum hose between manifold and power brake unit, or power brake unit check valve. Remove check valve, if equipped. 5. Separate power brake unit and master cylinder, leaving master cylinder supported far enough away to allow removal of power brake unit. 6. On models equipped with push rod mounted stop lamp switch, remove retaining pin, then slide switch, push rod, spacers and bushing off brake pedal pin. 7. On models equipped with brake pedal mounted stop lamp switch, remove attaching bolt, nut and plastic bushing, then disconnect power brake unit push rod from brake pedal. 8. Remove power brake unit attaching bolts and the power brake unit. 9. Reverse procedure to install. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Pressure Sensor/Switch > Component Information > Locations Brake Fluid Pressure Sensor/Switch: Locations RH Frame Member Attached To LH Frame Member Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Locations Parking Brake Warning Switch: Locations On Parking Brake Bracket Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Clutch Pedal Position Switch <--> [Clutch Switch] > Component Information > Testing and Inspection Clutch Pedal Position Switch: Testing and Inspection Manual Transmission Vehicles Only This switch functions magnetically. Do not use magnetized tools near this switch. 1. If the switch is open when the clutch pedal is released, speed control will not operate. This must be corrected before making any other tests. Use only a multimeter of 5000 ohm/volt rating or higher when performing the clutch switch test. 2. Disconnect switch pigtail connector from speed control harness connector and connect an ohmmeter to the two switch connector terminals. 3. With clutch pedal in the fully released position, the resistance should be less than 5 ohms. With clutch pedal fully depressed, the circuit should be open. 4. If switch does not function as described, remove and replace switch. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Technical Service Bulletins > Customer Interest for Ignition Switch: > 932410 > Nov > 93 > Instrument Cluster Warning Lights - Dimly Lit Ignition Switch: Customer Interest Instrument Cluster Warning Lights - Dimly Lit Article No. 93-24-10 11/24/93 ^ LAMP - MALFUNCTION OF FOUR PIN LOW OIL LEVEL RELAY - VEHICLES BUILT AFTER 8/1/92 OR 1983-1993 VEHICLES THAT HAVE HAD SERVICE REPLACEMENT IGNITION SWITCHES AFTER 8/1/92 ^ LAMPS - INSTRUMENT CLUSTER WARNING LIGHTS DIMLY LIT - VEHICLES BUILT AFTER 8/1/92 OR 1983-1993 VEHICLES THAT HAVE HAD SERVICE REPLACEMENT IGNITION SWITCHES AFTER 8/1/92 FORD: 1983 FAIRMONT 1983-89 CROWN VICTORIA, ESCORT 1983-93 MUSTANG, THUNDERBIRD 1983-94 PROBE 1984-86 LTD 1984-94 TEMPO LINCOLN-MERCURY: 1983 LN7, ZEPHYR 1983-87 CONTINENTAL, LYNX 1983-89 GRAND MARQUIS, TOWN CAR 1983-93 COUGAR 1984-86 CAPRI, MARQUIS 1984-94 TOPAZ LIGHT TRUCK: 1983-91 BRONCO 1983-93 ECONOLINE, F-150-350 SERIES, RANGER 1986-91 AEROSTAR 1991-93 EXPLORER ISSUE: The instrument cluster warning light(s) may be dimly lit or there may be a malfunction of the four pin low oil relay on vehicles so equipped. This could be due to the ignition switch. ACTION: If the vehicle displays the subject symptoms and meets the following conditions, replace the ignition switch. Refer to the appropriate Car or Light Truck Service Manual (Section 13-04 for 1983-1990 Cars, Section 11-04 for 1991-1993 Cars and Section 13-05 for 1983-1990 Light Trucks, Section 11-05 for 1991-1993 Light Trucks) for removal and installation procedures. Refer to the Parts Block in this article for correct parts usage. CONDITIONS ^ The vehicle has 14401 wiring attached to the P2 terminal of the ignition switch. Refer to the wiring schematic and/or Electrical And Vacuum Troubleshooting Manual (EVTM) for the concern vehicle. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Technical Service Bulletins > Customer Interest for Ignition Switch: > 932410 > Nov > 93 > Instrument Cluster Warning Lights - Dimly Lit > Page 5320 ^ The vehicle is equipped with one of the ignition switches identified in the Ignition Switch Part Number Chart. NOTE: THE SERVICE PART NUMBERS FOR THE REPLACEMENT IGNITION SWITCHES WILL HAVE THE SAME PART NUMBERS AS THOSE REPLACED. THE NEW SWITCH HAS BEEN IMPROVED TO CORRECT THE SUBJECT ISSUE. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of The Bumper To Bumper For 1992/93 Models, Basic Warranty Coverage For All Other Models Except Lincolns. Major Component Warranty Coverage For Lincolns OPERATION DESCRIPTION TIME 932410A Replace Ignition Switch - 0.5 Hr. All Light and Compact Trucks DEALER CODING BASIC PART NO. CONDITION CODE 11572 X1 OASIS CODES: 201000, 201100, 206000 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch: > 932410 > Nov > 93 > Instrument Cluster Warning Lights - Dimly Lit Ignition Switch: All Technical Service Bulletins Instrument Cluster Warning Lights - Dimly Lit Article No. 93-24-10 11/24/93 ^ LAMP - MALFUNCTION OF FOUR PIN LOW OIL LEVEL RELAY - VEHICLES BUILT AFTER 8/1/92 OR 1983-1993 VEHICLES THAT HAVE HAD SERVICE REPLACEMENT IGNITION SWITCHES AFTER 8/1/92 ^ LAMPS - INSTRUMENT CLUSTER WARNING LIGHTS DIMLY LIT - VEHICLES BUILT AFTER 8/1/92 OR 1983-1993 VEHICLES THAT HAVE HAD SERVICE REPLACEMENT IGNITION SWITCHES AFTER 8/1/92 FORD: 1983 FAIRMONT 1983-89 CROWN VICTORIA, ESCORT 1983-93 MUSTANG, THUNDERBIRD 1983-94 PROBE 1984-86 LTD 1984-94 TEMPO LINCOLN-MERCURY: 1983 LN7, ZEPHYR 1983-87 CONTINENTAL, LYNX 1983-89 GRAND MARQUIS, TOWN CAR 1983-93 COUGAR 1984-86 CAPRI, MARQUIS 1984-94 TOPAZ LIGHT TRUCK: 1983-91 BRONCO 1983-93 ECONOLINE, F-150-350 SERIES, RANGER 1986-91 AEROSTAR 1991-93 EXPLORER ISSUE: The instrument cluster warning light(s) may be dimly lit or there may be a malfunction of the four pin low oil relay on vehicles so equipped. This could be due to the ignition switch. ACTION: If the vehicle displays the subject symptoms and meets the following conditions, replace the ignition switch. Refer to the appropriate Car or Light Truck Service Manual (Section 13-04 for 1983-1990 Cars, Section 11-04 for 1991-1993 Cars and Section 13-05 for 1983-1990 Light Trucks, Section 11-05 for 1991-1993 Light Trucks) for removal and installation procedures. Refer to the Parts Block in this article for correct parts usage. CONDITIONS ^ The vehicle has 14401 wiring attached to the P2 terminal of the ignition switch. Refer to the wiring schematic and/or Electrical And Vacuum Troubleshooting Manual (EVTM) for the concern vehicle. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch: > 932410 > Nov > 93 > Instrument Cluster Warning Lights - Dimly Lit > Page 5326 ^ The vehicle is equipped with one of the ignition switches identified in the Ignition Switch Part Number Chart. NOTE: THE SERVICE PART NUMBERS FOR THE REPLACEMENT IGNITION SWITCHES WILL HAVE THE SAME PART NUMBERS AS THOSE REPLACED. THE NEW SWITCH HAS BEEN IMPROVED TO CORRECT THE SUBJECT ISSUE. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of The Bumper To Bumper For 1992/93 Models, Basic Warranty Coverage For All Other Models Except Lincolns. Major Component Warranty Coverage For Lincolns OPERATION DESCRIPTION TIME 932410A Replace Ignition Switch - 0.5 Hr. All Light and Compact Trucks DEALER CODING BASIC PART NO. CONDITION CODE 11572 X1 OASIS CODES: 201000, 201100, 206000 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Technical Service Bulletins > Page 5327 Ignition Switch: Service and Repair Fig. 3 Ignition switch replacement 1. Disconnect battery ground cable. 2. Remove steering column shroud and lower the steering column. 3. Disconnect electrical connector from switch, then remove 2 switch attaching nuts. 4. Lift switch up to disengage actuator rod, then remove switch from vehicle, Fig. 3. 5. Reverse procedure to install. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Service and Repair Neutral Safety Switch: Service and Repair Fig. 8 Neutral safety switch replacement. Exc. automatic overdrive transmission EXC. AUTOMATIC OVERDRIVE TRANSMISSION 1. Disconnect battery ground cable. 2. Remove downshift linkage rod return spring from low-reverse servo cover. 3. Apply penetrating oil to outer lever attaching nut, then remove transmission downshift outer lever attaching nut and lever. 4. Remove neutral safety switch attaching bolts, then disconnect electrical connectors and remove switch from vehicle. 5. To install, position switch on transmission and secure with attaching bolts. Do not tighten bolts at this time. 6. Place transmission manual lever in neutral position, then insert a .091 inch gauge pin through gauge pin holes, Fig. 8. 7. Tighten switch attaching bolts, then remove gauge pin. 8. Install outer downshift lever and retaining nut. 9. Install downshift linkage rod return spring between lever and retaining clip on low-reverse servo cover. 10. Reconnect electrical connectors, then check operation of switch. W/AUTOMATIC OVERDRIVE TRANSMISSION 1. Disconnect battery ground cable. 2. Raise and support vehicle. 3. Disconnect electrical connector at neutral safety switch, lifting connector straight up. 4. Using suitable socket, remove neutral safety switch and O-ring seal. 5. Reverse procedure to install, installing new O-ring seal. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations Starter Relay: Locations Component Locations - RH Fender Apron On RH fender apron Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Technical Service Bulletins > Body/Frame - Arc Welding Precautions Battery Cable: Technical Service Bulletins Body/Frame - Arc Welding Precautions Article No. 90-11-6 EEC IV-ELECTRONIC CONTROL MODULES AND PROCESSORS-POSSIBLE DAMAGE FROM ARC WELDING FORD: 1985-90 CROWN VICTORIA, ESCORT, MUSTANG, TEMPO, THUNDERBIRD 1986-90 TAURUS LINCOLN-MERCURY: 1985-86 CAPRI 1985-90 CONTINENTAL, COUGAR, GRAND MARQUIS, MARK VII, TOPAZ, TOWN CAR 1986-90 SABLE MERKUR: 1985-89 XR4Ti 1988-90 SCORPIO LIGHT TRUCK: 1985-90 BRONCO II, BRONCO, ECONOLINE, F-150, F-250, F-350, RANGER 1986-90 AEROSTAR 1989-90 F SUPER DUTY 1991 EXPLORER ISSUE: Electronic control modules, including EEC processors, may be damaged if the negative battery ground cable is not disconnected before arc welding is done to the vehicle, This occurs because the arc welding process can produce high electrical currents in the body of a vehicle when the negative battery ground cable is left connected. ACTION: If arc welding procedures are to be performed, be sure to disconnect the battery ground cable, CAUTION: DISCONNECT THE NEGATIVE BATTERY GROUND CABLE BEFORE USING ANY ELECTRIC WELDING EQUIPMENT OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 2800, 680000 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Diode Trio, Alternator > Component Information > Testing and Inspection Diode Trio: Testing and Inspection Fig. 9 Regulator plug. Jumper wire connection Test Procedure 1. Disconnect electric choke, if equipped. 2. Disconnect voltage regulator wiring connector. 3. Connect a jumper wire between the ``A'' and ``F'' terminals of the voltage regulator wiring connector, Fig. 9. 4. Connect voltmeter to battery clamps. Then, start and idle engine. 5. Observe and note voltmeter reading. 6. Move the voltmeter positive lead to the alternator ``S'' terminal and note voltage reading. Test Results 1. If voltmeter reading is within {1/2} of battery voltage, the diodes are satisfactory. 2. If voltmeter reading is approximately 1.5 volts, the alternator has a shorted negative diode or a grounded stator winding. 3. If voltmeter reading is approximately 1.5 volts less than battery voltage, the alternator has a shorted positive diode. 4. If voltage reading is approximately 1 to 1.5 volts less than {1/2} battery voltage, the alternator has an open positive diode. 5. If voltage reading is 1 to 1.5 volts above {1/2} battery voltage, the alternator has an open negative diode. 6. Reconnect electric choke into circuit after tests are completed, if equipped. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Rectifier Diode / Bridge, Alternator > Component Information > Testing and Inspection Rectifier Diode / Bridge: Testing and Inspection Fig. 13 Testing diode trio Fig. 14 Alternator w/integral regulator rectifier short or grounded & stator grounded test RECTIFIER SHORT OR GROUNDED & STATOR GROUNDED TEST Using a suitable ohmmeter, connect one probe to the alternator BAT terminal, Figs. 13 and 14, and the other probe to the STA terminal (rear blade terminal). Then, reverse the ohmmeter probes and repeat the test. A reading of about 6.5 ohms should be obtained in one direction and no needle movement with the probes reversed. A reading in both directions indicates a bad positive diode, a grounded positive diode plate or a grounded BAT terminal. Perform the same test using the STA and GND (ground) terminals of the alternator. A reading in both directions indicates either a bad negative diode, a grounded stator winding, a grounded stator terminal, a grounded positive diode plate, or a grounded BAT terminal. Infinite readings (no needle movement) in all four probe positions in the preceding tests indicates an open STA terminal lead connection inside the alternator. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Rectifier Diode / Bridge, Alternator > Component Information > Testing and Inspection > Page 5348 Fig. 15 Testing rectifier bridge diodes FIELD OPEN OR SHORT CIRCUIT TEST Exc. Alternators W/Integral Regulators Using a suitable ohmmeter, connect the alternator field terminal with one probe and the ground terminal with the other probe, Fig. 15. Then, spin the alternator pulley. The ohmmeter reading should be between 2.4 and 25 ohms on 1980 units, 2.4 and 100 ohms on all 1981-85 units and 1986-87 models less IAR system, and should fluctuate while the pulley is turning. An infinite reading (no meter movement) indicates an open brush lead, worn or stuck brushes, or a bad rotor assembly. An ohmmeter reading of less than 2.4 ohms indicates a grounded brush assembly, a grounded field terminal or a bad rotor. Fig. 16 Alternator w/integral regulator field open or short circuit test Alternators W/Integral Regulators 1. Using a suitable ohmmeter, connect regulator A blade terminal with one probe and the regulator ``F'' screw head with the other probe, Fig. 16. 2. Spin the alternator pulley and note meter reading, then reverse probes and repeat step 1. In one probe direction ohmmeter reading should be between 2.2 and 100 ohms and may fluctuate while pulley is turning. In the other direction, reading should fluctuate between 2.2 and approximately 9 ohms. 3. An infinite reading (no meter movement) in one direction and approximately 9 ohms in the other, indicates an open brush lead, worn or stuck brushes, defective rotor or a loose regulator to brush holder attaching screw. 4. An ohmmeter reading less than 2.2 ohms in both directions indicates a shorted or defective regulator. 5. An ohmmeter reading significantly over 9 ohms in both directions indicates a defective regulator or loose ``F'' terminal screw. 6. Connect alternator rear housing with one ohmmeter probe and touch the other probe to the regulator ``F'' terminal. Reverse probes and repeat test. Ohmmeter reading should be infinite in one probe direction and approximately 9 ohms in the other. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Rectifier Diode / Bridge, Alternator > Component Information > Testing and Inspection > Page 5349 7. If ohmmeter reads less than infinite at either point, a grounded brush lead, grounded rotor or defective regulator is indicated. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Stator, Alternator > Component Information > Testing and Inspection Stator: Testing and Inspection Fig. 13 Testing diode trio Fig. 14 Alternator w/integral regulator rectifier short or grounded & stator grounded test RECTIFIER SHORT OR GROUNDED & STATOR GROUNDED TEST Using a suitable ohmmeter, connect one probe to the alternator BAT terminal, Figs. 13 and 14, and the other probe to the STA terminal (rear blade terminal). Then, reverse the ohmmeter probes and repeat the test. A reading of about 6.5 ohms should be obtained in one direction and no needle movement with the probes reversed. A reading in both directions indicates a bad positive diode, a grounded positive diode plate or a grounded BAT terminal. Perform the same test using the STA and GND (ground) terminals of the alternator. A reading in both directions indicates either a bad negative diode, a grounded stator winding, a grounded stator terminal, a grounded positive diode plate, or a grounded BAT terminal. Infinite readings (no needle movement) in all four probe positions in the preceding tests indicates an open STA terminal lead connection inside the alternator. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Stator, Alternator > Component Information > Testing and Inspection > Page 5353 Fig. 15 Testing rectifier bridge diodes FIELD OPEN OR SHORT CIRCUIT TEST Exc. Alternators W/Integral Regulators Using a suitable ohmmeter, connect the alternator field terminal with one probe and the ground terminal with the other probe, Fig. 15. Then, spin the alternator pulley. The ohmmeter reading should be between 2.4 and 25 ohms on 1980 units, 2.4 and 100 ohms on all 1981-85 units and 1986-87 models less IAR system, and should fluctuate while the pulley is turning. An infinite reading (no meter movement) indicates an open brush lead, worn or stuck brushes, or a bad rotor assembly. An ohmmeter reading of less than 2.4 ohms indicates a grounded brush assembly, a grounded field terminal or a bad rotor. Fig. 16 Alternator w/integral regulator field open or short circuit test Alternators W/Integral Regulators 1. Using a suitable ohmmeter, connect regulator A blade terminal with one probe and the regulator ``F'' screw head with the other probe, Fig. 16. 2. Spin the alternator pulley and note meter reading, then reverse probes and repeat step 1. In one probe direction ohmmeter reading should be between 2.2 and 100 ohms and may fluctuate while pulley is turning. In the other direction, reading should fluctuate between 2.2 and approximately 9 ohms. 3. An infinite reading (no meter movement) in one direction and approximately 9 ohms in the other, indicates an open brush lead, worn or stuck brushes, defective rotor or a loose regulator to brush holder attaching screw. 4. An ohmmeter reading less than 2.2 ohms in both directions indicates a shorted or defective regulator. 5. An ohmmeter reading significantly over 9 ohms in both directions indicates a defective regulator or loose ``F'' terminal screw. 6. Connect alternator rear housing with one ohmmeter probe and touch the other probe to the regulator ``F'' terminal. Reverse probes and repeat test. Ohmmeter reading should be infinite in one probe direction and approximately 9 ohms in the other. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Stator, Alternator > Component Information > Testing and Inspection > Page 5354 7. If ohmmeter reads less than infinite at either point, a grounded brush lead, grounded rotor or defective regulator is indicated. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Starting and Charging > Charging System > Voltage Regulator > Component Information > Specifications Voltage Regulator: Specifications Measure battery voltage and record figure. With engine operating off idle and all secondary electrical systems turned off, regulated voltage should be no greater than 2 volts above recorded figure. Turn on headlights and set heater blower to high. Regulated voltage off idle should be no less than 0.5 volts above recorded figure. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Starting and Charging > Charging System > Voltage Regulator > Component Information > Specifications > Page 5358 Voltage Regulator: Locations RH Fender Apron RH Fender Apron Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Starting and Charging > Starting System > Clutch Pedal Position Switch <--> [Clutch Switch] > Component Information > Testing and Inspection Clutch Pedal Position Switch: Testing and Inspection Manual Transmission Vehicles Only This switch functions magnetically. Do not use magnetized tools near this switch. 1. If the switch is open when the clutch pedal is released, speed control will not operate. This must be corrected before making any other tests. Use only a multimeter of 5000 ohm/volt rating or higher when performing the clutch switch test. 2. Disconnect switch pigtail connector from speed control harness connector and connect an ohmmeter to the two switch connector terminals. 3. With clutch pedal in the fully released position, the resistance should be less than 5 ohms. With clutch pedal fully depressed, the circuit should be open. 4. If switch does not function as described, remove and replace switch. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Resistor <--> [Ignition Ballast Resistor] > Component Information > Specifications Ignition Resistor: Specifications BALLAST RESISTOR: Wire Type - Resistance: 1.1 Ohms + or - .05 Ohms Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Resistor <--> [Ignition Ballast Resistor] > Component Information > Specifications > Page 5366 Ignition Resistor: Locations The Ballast Resistor is a wire type and is in-line with the ignition wiring harness located near the steering column. NOTE: Verify vehicle has a ballast resistor by referencing wiring diagram. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Resistor <--> [Ignition Ballast Resistor] > Component Information > Specifications > Page 5367 Ignition Resistor: Description and Operation The ballast resistor, (wire type), maintains a specific resistance between the positive (Batt.) terminal of the ignition coil connector and the wiring harness connector. It is not in operation during engine cranking enabling the coil to receive a hotter signal for starting. Once the engine is running, the resistor is used to protect the coil from voltage overload. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Resistor <--> [Ignition Ballast Resistor] > Component Information > Specifications > Page 5368 Ignition Resistor: Testing and Inspection 1. Disconnect module connector with red and white wires then, ignition coil connector. 2. Using a suitable ohmmeter, measure resistance between Batt. terminal of ignition coil connector and wiring harness connector wire that joins red wire in module connector. 3. If resistance is 0.8---1.6 ohms, ballast resistor is satisfactory. If resistance is less than 0.8 ohms or greater than 1.6 ohms, replace ballast resistor. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Diagrams > Diagram Information and Instructions Ignition Lock: Diagram Information and Instructions Symbol Identification Wire Color Code Identification Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Diagrams > Diagram Information and Instructions > Page 5373 NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Diagrams > Diagram Information and Instructions > Page 5374 Ignition Lock: Connector Views For Connector Views, please refer to: Ignition Switch/Diagrams, Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Service and Repair > Ignition Lock Cylinder Assembly (With Key) Ignition Lock: Service and Repair Ignition Lock Cylinder Assembly (With Key) Ignition Lock Cylinder Assembly (With Key) Removal 1. Disconnect the battery ground cable. 2. Remove the steering wheel trim pad and the steering wheel for Non-Tilt Steering Columns only. 3. Place the gear shift in PARK (with automatic transmission) and turn the lock cylinder with the ignition key to ON position. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Service and Repair > Ignition Lock Cylinder Assembly (With Key) > Page 5377 4. Place 3.17mm (1/8 inch) diameter wire pin or small drift punch and depress the retaining pin while pulling out on the lock cylinder to remove it from the column housing. The pin is located inside the column near.the base of the lock cylinder on Non- Tilt Steering Column. On Tilt-Steering Columns the pin is located adjacent to the Hazard Warning Button. Installation 1. Lubricate the lock cylinder with grease. 2. To install the lock cylinder, turn the lock cylinder to the ON position and depress the retaining pin, then insert the lock cylinder into its housing in the flange casting. Assure that the cylinder is fully seated and aligned into the interlocking washer before turning the key to the OFF position. This action will permit the cylinder retaining pin to extend into the cylinder casting housing hole. 3. Using the ignition key, rotate the lock cylinder to insure correct mechanical operation in all positions. 4. Install the steering wheel and trim pads on Non-Tilt Steering Columns only. 5. Connect the battery ground cable. 6. Check for proper start in Park or Neutral. Also check to make certain that the start circuit cannot be actuated in the Drive and Reverse positions. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Service and Repair > Ignition Lock Cylinder Assembly (With Key) > Page 5378 Ignition Lock: Service and Repair Ignition Lock Cylinder Assembly (Without Key) Ignition Lock Cylinder (Without Key) NOTE: The following procedure applies to vehicles where the ignition lock is inoperative and the lock cylinder cannot be rotated due to a lost or broken ignition key and the key number not known or the lock cylinder cap is damaged and/or broken to the extent that the lock cylinder cannot be rotated. Removal 1. Disconnect the battery ground cable. 2. Remove the steering wheel and pad assembly. 3. Remove the turn signal lever from the steering column. 4. To gain access to the ignition switch remove the steering column trim shrouds from the steering column. Detach and lower the steering column assembly from the brake pedal support bracket. 5. Remove the ignition switch and key warning buzzer terminal and pin it in the LOCK position. 6. Remove the turn signal switch from the column assembly. 7. Remove the upper bearing snap ring and the (2) T-bolt retaining nuts that secure the flange casting to the outer tube. Remove the entire flange casting assembly, the upper shaft bearing, the lock cylinder assembly, the ignition switch actuator and the ignition switch actuator rod by pulling the assembly over the end of the steering column shaft. 8. Remove the lock actuator insert, the T-bolts, and the PRND21 insert on automatic transmissions or the key release lever assembly on 4-speed transmissions. 9. Replace the above assembly with a new assembly consisting of: (1) Flange (1) Lock Cylinder Assembly (1) Lock Gear, Steering Column Lock (1) Bearing, Steering Column Lock (1) Retainer, Steering Column Upper Bearing Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Service and Repair > Ignition Lock Cylinder Assembly (With Key) > Page 5379 (1) Actuator Assembly, Steering Column Lock 10. Install the key release lever assembly on 4-speed equipped vehicles and the PRND21 insert on vehicles with automatic transmission. Install the T-bolts and lock actuator insert. NOTE: Retain the ignition switch actuating rod from the removed casting assembly and use it with the new flange casting assembly. Installation 1. Reassemble the above parts, install a new upper shaft bearing and set the actuator to drive gear. 2. Install the turn signal-hazard warning switch and key warning buzzer. 3. Install the ignition switch, check and/or adjust for proper function. 4. Install the steering column assembly to the brake pedal support bracket. 5. Install the steering column trim shrouds, steering wheel and pad assembly. 6. Install the turn signal lever. 7. Using the ignition key, rotate the lock cylinder to insure correct mechanical operation in all positions. 8. Connect the battery ground cable. 9. Check for proper start in Park and Neutral. Also check to make certain that the start circuit cannot be actuated in the Drive and Reverse positions. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Service and Repair > Ignition Lock Cylinder Assembly (With Key) > Page 5380 Ignition Lock: Service and Repair Ignition Lock Cylinder - Tilt Steering Column Ignition Lock Cylinder-Tilt Steering Column Removal 1. Disconnect the battery ground cable. Remove the steering column trim shrouds. 2. Tape the gap between the steering wheel hub and the cover casting. Cover the entire circumference of the casting. Also cover the adjacent seat and floor area with a suitable covering to protect the surrounding interior upholstery. Pull out the hazard flasher switch and tape it down toward the floor to provide clearance for drilling out the lock cylinder retainer pin. 3. The tilt column lock cylinder retaining pin is located on the outside of the steering column cover casting adjacent to the hazard flasher button. 4. Tilt the steering column to the full up position and prepunch the lock cylinder retaining pin with a prick punch. Using a 3.17mm (1/8 inch) diameter drill with a right angle drive, drill out the retaining pin, going no deeper than 12.7mm (1 /2 inch). NOTE: When drilling out the retaining pin, take care not to damage the cover cast housing or the hazard flasher switch. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Service and Repair > Ignition Lock Cylinder Assembly (With Key) > Page 5381 5. Tilt the steering column to the full down position. Place a chisel at the base of the ignition lock cylinder cap, and, using a hammer, strike the chisel with sharp blows to break the cap away from the lock cylinder. 6. Using a 9.8mm (3/8 inch) diameter drill, drill down the middle of the ignition lock key slot approximately 45mm (1-3/4 inch) until the lock cylinder breaks loose from the steering column cover casting. Remove the lock cylinder, and the drill shavings from the base of the cover cast housing. 7. Remove the steering wheel and pad. 8. Remove the turn signal lever from the column and then remove the two attaching screws from the turn signal switch and one attaching screw from the key warning buzzer terminal. Lift the turn signal switch up and over the end of the steering shaft but do not disconnect it from the wiring harness. 9. Remove the four attaching screws from the cover casting and lift the casting over the end of the steering shaft allowing the turn signal switch to pass through the cover casting. The removal of the cover casting will expose the upper actuator. Remove the upper actuator. 10. Remove the drive gear, snap ring and washer from the cover casting along with the upper actuator mentioned above. Thoroughly clean the components in an acceptable cleaning solution. Carefully inspect all components for any damage resulting from the drilling operation. If any of the components show signs of damage, they must be replaced. Clean the removed cover casting with compressed air to remove any drill shavings or foreign particles and carefully inspect it for damage. If the cover casting is damaged, replace it with a new one primed and painted to match the existing column. Installation 1. Lubricate the tang of the lock cylinder with grease. 2. Attach the upper actuator to the lower actuator and lubricate the upper actuator. Reassemble the cover casting, upper actuator, turn signal switch and lever, lock drive gear, lock cylinder, steering wheel and pad, and the steering column trim shrouds. 3. Using the ignition key, rotate the lock cylinder to insure correct mechanical operation in all positions Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Service and Repair > Ignition Lock Cylinder Assembly (With Key) > Page 5382 4. Connect the battery ground cable. 5. Check for proper start in Park or Neutral. Also check to make certain that the start circuit cannot be actuated in the Drive and Reverse positions. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Service and Repair > Ignition Lock Cylinder Assembly (With Key) > Page 5383 Ignition Lock: Service and Repair Ignition Lock Drive Gear Ignition Lock Drive Gear Removal 1. Remove the lock cylinder assembly. 2. Insert a flat-bladed screwdriver in the recess of the drive gear at the bottom of the lock cylinder housing. Turn the lock drive gear Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Service and Repair > Ignition Lock Cylinder Assembly (With Key) > Page 5384 counterclockwise three notches. 3. Remove the snap ring, washer and lock drive gear from the lock cylinder housing. Note the position of the drive gear to the rack teeth. Installation 1. Install the lock drive gear in the housing in the same position as noted during removal. Installation is correct if the last tooth on the drive gear is meshed with the last tooth on the rack. Install the washer and snap ring. 2. Using the screwdriver blade, turn the drive gear clockwise three notches. 3. Install the lock cylinder. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch: > 932410 > Nov > 93 > Instrument Cluster Warning Lights - Dimly Lit Ignition Switch: All Technical Service Bulletins Instrument Cluster Warning Lights - Dimly Lit Article No. 93-24-10 11/24/93 ^ LAMP - MALFUNCTION OF FOUR PIN LOW OIL LEVEL RELAY - VEHICLES BUILT AFTER 8/1/92 OR 1983-1993 VEHICLES THAT HAVE HAD SERVICE REPLACEMENT IGNITION SWITCHES AFTER 8/1/92 ^ LAMPS - INSTRUMENT CLUSTER WARNING LIGHTS DIMLY LIT - VEHICLES BUILT AFTER 8/1/92 OR 1983-1993 VEHICLES THAT HAVE HAD SERVICE REPLACEMENT IGNITION SWITCHES AFTER 8/1/92 FORD: 1983 FAIRMONT 1983-89 CROWN VICTORIA, ESCORT 1983-93 MUSTANG, THUNDERBIRD 1983-94 PROBE 1984-86 LTD 1984-94 TEMPO LINCOLN-MERCURY: 1983 LN7, ZEPHYR 1983-87 CONTINENTAL, LYNX 1983-89 GRAND MARQUIS, TOWN CAR 1983-93 COUGAR 1984-86 CAPRI, MARQUIS 1984-94 TOPAZ LIGHT TRUCK: 1983-91 BRONCO 1983-93 ECONOLINE, F-150-350 SERIES, RANGER 1986-91 AEROSTAR 1991-93 EXPLORER ISSUE: The instrument cluster warning light(s) may be dimly lit or there may be a malfunction of the four pin low oil relay on vehicles so equipped. This could be due to the ignition switch. ACTION: If the vehicle displays the subject symptoms and meets the following conditions, replace the ignition switch. Refer to the appropriate Car or Light Truck Service Manual (Section 13-04 for 1983-1990 Cars, Section 11-04 for 1991-1993 Cars and Section 13-05 for 1983-1990 Light Trucks, Section 11-05 for 1991-1993 Light Trucks) for removal and installation procedures. Refer to the Parts Block in this article for correct parts usage. CONDITIONS ^ The vehicle has 14401 wiring attached to the P2 terminal of the ignition switch. Refer to the wiring schematic and/or Electrical And Vacuum Troubleshooting Manual (EVTM) for the concern vehicle. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch: > 932410 > Nov > 93 > Instrument Cluster Warning Lights - Dimly Lit > Page 5393 ^ The vehicle is equipped with one of the ignition switches identified in the Ignition Switch Part Number Chart. NOTE: THE SERVICE PART NUMBERS FOR THE REPLACEMENT IGNITION SWITCHES WILL HAVE THE SAME PART NUMBERS AS THOSE REPLACED. THE NEW SWITCH HAS BEEN IMPROVED TO CORRECT THE SUBJECT ISSUE. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of The Bumper To Bumper For 1992/93 Models, Basic Warranty Coverage For All Other Models Except Lincolns. Major Component Warranty Coverage For Lincolns OPERATION DESCRIPTION TIME 932410A Replace Ignition Switch - 0.5 Hr. All Light and Compact Trucks DEALER CODING BASIC PART NO. CONDITION CODE 11572 X1 OASIS CODES: 201000, 201100, 206000 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Component Information > Technical Service Bulletins > Customer Interest for Ignition Switch: > 932410 > Nov > 93 > Instrument Cluster Warning Lights - Dimly Lit Ignition Switch: Customer Interest Instrument Cluster Warning Lights - Dimly Lit Article No. 93-24-10 11/24/93 ^ LAMP - MALFUNCTION OF FOUR PIN LOW OIL LEVEL RELAY - VEHICLES BUILT AFTER 8/1/92 OR 1983-1993 VEHICLES THAT HAVE HAD SERVICE REPLACEMENT IGNITION SWITCHES AFTER 8/1/92 ^ LAMPS - INSTRUMENT CLUSTER WARNING LIGHTS DIMLY LIT - VEHICLES BUILT AFTER 8/1/92 OR 1983-1993 VEHICLES THAT HAVE HAD SERVICE REPLACEMENT IGNITION SWITCHES AFTER 8/1/92 FORD: 1983 FAIRMONT 1983-89 CROWN VICTORIA, ESCORT 1983-93 MUSTANG, THUNDERBIRD 1983-94 PROBE 1984-86 LTD 1984-94 TEMPO LINCOLN-MERCURY: 1983 LN7, ZEPHYR 1983-87 CONTINENTAL, LYNX 1983-89 GRAND MARQUIS, TOWN CAR 1983-93 COUGAR 1984-86 CAPRI, MARQUIS 1984-94 TOPAZ LIGHT TRUCK: 1983-91 BRONCO 1983-93 ECONOLINE, F-150-350 SERIES, RANGER 1986-91 AEROSTAR 1991-93 EXPLORER ISSUE: The instrument cluster warning light(s) may be dimly lit or there may be a malfunction of the four pin low oil relay on vehicles so equipped. This could be due to the ignition switch. ACTION: If the vehicle displays the subject symptoms and meets the following conditions, replace the ignition switch. Refer to the appropriate Car or Light Truck Service Manual (Section 13-04 for 1983-1990 Cars, Section 11-04 for 1991-1993 Cars and Section 13-05 for 1983-1990 Light Trucks, Section 11-05 for 1991-1993 Light Trucks) for removal and installation procedures. Refer to the Parts Block in this article for correct parts usage. CONDITIONS ^ The vehicle has 14401 wiring attached to the P2 terminal of the ignition switch. Refer to the wiring schematic and/or Electrical And Vacuum Troubleshooting Manual (EVTM) for the concern vehicle. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Component Information > Technical Service Bulletins > Customer Interest for Ignition Switch: > 932410 > Nov > 93 > Instrument Cluster Warning Lights - Dimly Lit > Page 5399 ^ The vehicle is equipped with one of the ignition switches identified in the Ignition Switch Part Number Chart. NOTE: THE SERVICE PART NUMBERS FOR THE REPLACEMENT IGNITION SWITCHES WILL HAVE THE SAME PART NUMBERS AS THOSE REPLACED. THE NEW SWITCH HAS BEEN IMPROVED TO CORRECT THE SUBJECT ISSUE. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of The Bumper To Bumper For 1992/93 Models, Basic Warranty Coverage For All Other Models Except Lincolns. Major Component Warranty Coverage For Lincolns OPERATION DESCRIPTION TIME 932410A Replace Ignition Switch - 0.5 Hr. All Light and Compact Trucks DEALER CODING BASIC PART NO. CONDITION CODE 11572 X1 OASIS CODES: 201000, 201100, 206000 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Component Information > Technical Service Bulletins > Page 5400 Ignition Switch: Service and Repair Fig. 3 Ignition switch replacement 1. Disconnect battery ground cable. 2. Remove steering column shroud and lower the steering column. 3. Disconnect electrical connector from switch, then remove 2 switch attaching nuts. 4. Lift switch up to disengage actuator rod, then remove switch from vehicle, Fig. 3. 5. Reverse procedure to install. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Service and Repair Neutral Safety Switch: Service and Repair Fig. 8 Neutral safety switch replacement. Exc. automatic overdrive transmission EXC. AUTOMATIC OVERDRIVE TRANSMISSION 1. Disconnect battery ground cable. 2. Remove downshift linkage rod return spring from low-reverse servo cover. 3. Apply penetrating oil to outer lever attaching nut, then remove transmission downshift outer lever attaching nut and lever. 4. Remove neutral safety switch attaching bolts, then disconnect electrical connectors and remove switch from vehicle. 5. To install, position switch on transmission and secure with attaching bolts. Do not tighten bolts at this time. 6. Place transmission manual lever in neutral position, then insert a .091 inch gauge pin through gauge pin holes, Fig. 8. 7. Tighten switch attaching bolts, then remove gauge pin. 8. Install outer downshift lever and retaining nut. 9. Install downshift linkage rod return spring between lever and retaining clip on low-reverse servo cover. 10. Reconnect electrical connectors, then check operation of switch. W/AUTOMATIC OVERDRIVE TRANSMISSION 1. Disconnect battery ground cable. 2. Raise and support vehicle. 3. Disconnect electrical connector at neutral safety switch, lifting connector straight up. 4. Using suitable socket, remove neutral safety switch and O-ring seal. 5. Reverse procedure to install, installing new O-ring seal. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Starter Armature > Component Information > Testing and Inspection > Armature & Field Grounded Circuit Test Starter Armature: Testing and Inspection Armature & Field Grounded Circuit Test Fig. 4 Field grounded circuit test connections 1. Connect jumper lead to positive battery terminal. 2. Connect negative voltmeter lead to negative battery terminal. 3. Touch positive voltmeter lead to commutator and jumper wire to armature. 4. If voltmeter indicates voltage, armature windings are grounded. 5. Make connections as shown, Fig. 4. If voltmeter indicates voltage, field windings are grounded. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Starter Armature > Component Information > Testing and Inspection > Armature & Field Grounded Circuit Test > Page 5409 Starter Armature: Testing and Inspection Armature Open Circuit Test An open circuit in the armature can sometimes be detected by examining commutator for signs of burning. A spot burned on the commutator is caused by an arc formed every time a commutator segment connected to the open circuit winding passes under a brush. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Starter Brush > Component Information > Technical Service Bulletins > Starter Motor Brushes - Replacement Revision Technical Service Bulletin # 9211B1 Date: 920605 Starter Motor Brushes - Replacement Revision Article No. 92-11B-1 06/05/92 ^ SHOP MANUAL - 1982 THROUGH 1991 AS APPLICABLE - STARTER - POSITIVE ENGAGEMENT - STARTER MOTOR BRUSHES REPLACEMENT PROCEDURE FOR 4-INCH STARTERS REVISED/ADDED ^ SHOP MANUAL - 1990 AND 1991 AS APPLICABLE - STARTER - POSITIVE ENGAGEMENT STARTER SIZE SPECFICATION REVISED FORD: 1989 CROWN VICTORIA, ESCORT, TEMPO 1989-90 THUNDERBIRD 1989-91 MUSTANG, TAURUS LINCOLN-MERCURY: 1989 CONTINENTAL, GRAND MARQUIS, MARK VII, TOPAZ, TOWN CAR 1989-90 COUGAR 1989-91 SABLE LIGHT TRUCK: 1982-91 BRONCO, ECONOLINE, F-150-350 SERIES 1983-91 RANGER 1984-90 BRONCO II 1986-91 AEROSTAR 1988-91 F SUPER DUTY ISSUE: The procedure for Starter Motor Brushes Replacement applicable to vehicles with 4-inch starters only is missing or incorrect in the "Starter-Positive Engagement" section of certain Shop Manuals. Additionally, the 1990 and 1991 Light Truck Shop Manuals incorrectly show a 3-inch starter in the Specifications Chart; the correct size is 4-inch. The following Shop Manuals are affected in the Sections indicated: ^ 1989 Domestic Car Lines: Section 28-02 ^ 1990 Mustang, Taurus/Sable, Thunderbird/Cougar: Section 28-02 ^ 1991 Mustang, Taurus/Sable: Section 28-02 ^ 1986 through 1988 Aerostar: Section 11-02 ^ 1989 Aerostar, Ranger, Bronco II: Section 03-06 ^ 1990 and 1991 Aerostar, Ranger, Bronco II: Section 03-06A ^ 1983 Ranger/1984 Bronco II (Reprint), 1984 through 1988 Ranger/Bronco II, 1982 through 1990 Light Truck-Engine: Section 28-02 ^ 1991 Light Truck-Engine: Section 03-06A ACTION: Refer to Disassembly and Assembly in this TSB article for the additional information. NOTE: THIS TSB ARTICLE INCLUDES REVISED PAGES FROM THE 1989, 1990 AND 1991 CAR SHOP MANUALS LISTED ABOVE, THE 1991 COMPACT TRUCK SHOP MANUAL AND THE 1990 AND 1991 LIGHT TRUCK SHOP MANUALS. ALTHOUGH NOT SHOWN, THE REVISIONS APPLY TO ALL LIGHT TRUCK AND COMPACT TRUCK MANUALS LISTED ABOVE. NOTE: THE PROCEDURE IN THIS TSB ARTICLE APPLIES TO VEHICLES WITH 4-INCH STARTERS ONLY. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Starter Brush > Component Information > Technical Service Bulletins > Starter Motor Brushes - Replacement Revision > Page 5414 290000 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Starter Brush > Component Information > Technical Service Bulletins > Starter Motor Brushes - Replacement Revision > Page 5415 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Starter Brush > Component Information > Technical Service Bulletins > Starter Motor Brushes - Replacement Revision > Page 5416 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Starter Brush > Component Information > Technical Service Bulletins > Starter Motor Brushes - Replacement Revision > Page 5417 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Starter Brush > Component Information > Technical Service Bulletins > Starter Motor Brushes - Replacement Revision > Page 5418 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Starter Brush > Component Information > Technical Service Bulletins > Starter Motor Brushes - Replacement Revision > Page 5419 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Starter Brush > Component Information > Technical Service Bulletins > Starter Motor Brushes - Replacement Revision > Page 5420 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Starter Brush > Component Information > Technical Service Bulletins > Starter Motor Brushes - Replacement Revision > Page 5421 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Starter Brush > Component Information > Technical Service Bulletins > Starter Motor Brushes - Replacement Revision > Page 5422 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Starter Brush > Component Information > Technical Service Bulletins > Starter Motor Brushes - Replacement Revision > Page 5423 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Starter Brush > Component Information > Technical Service Bulletins > Starter Motor Brushes - Replacement Revision > Page 5424 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Starter Brush > Component Information > Technical Service Bulletins > Starter Motor Brushes - Replacement Revision > Page 5425 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Starter Brush > Component Information > Technical Service Bulletins > Starter Motor Brushes - Replacement Revision > Page 5426 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Starter Brush > Component Information > Technical Service Bulletins > Starter Motor Brushes - Replacement Revision > Page 5427 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Starter Brush > Component Information > Technical Service Bulletins > Starter Motor Brushes - Replacement Revision > Page 5428 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Starter Brush > Component Information > Technical Service Bulletins > Starter Motor Brushes - Replacement Revision > Page 5429 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Starter Brush > Component Information > Technical Service Bulletins > Starter Motor Brushes - Replacement Revision > Page 5430 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Starter Brush > Component Information > Technical Service Bulletins > Starter Motor Brushes - Replacement Revision > Page 5431 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Starter Brush > Component Information > Technical Service Bulletins > Starter Motor Brushes - Replacement Revision > Page 5432 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Starter Brush > Component Information > Technical Service Bulletins > Starter Motor Brushes - Replacement Revision > Page 5433 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Starter Brush > Component Information > Technical Service Bulletins > Starter Motor Brushes - Replacement Revision > Page 5434 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations Starter Relay: Locations Component Locations - RH Fender Apron On RH fender apron Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Circuit Breaker > Component Information > Locations Circuit Breaker: Locations Circuit Location Amps Power Door Locks.....................Fuse Panel................30 Power Windows........................Fuse Panel................20 Power Tailgate Window................Fuse Panel................25 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Circuit Breaker > Component Information > Locations > Page 5442 Circuit Breaker: Testing and Inspection BRONCO & F-100---350 SERIES The circuit breaker is located in the wiper control switch on all rotary switches. For slide wiper control switches, the circuit breaker is located in the fuse panel. All pin terminal switches have a circuit breaker rating of 8 {1/4} amps. All blade terminal switches have a rating of 7 amps. Two separate tests are necessary to check for correct circuit breaker operation when circuit breaker is part of wiper switch. Fig. 3 Testing circuit breaker. Bronco & F-100---350 Series Test 1 1. Short tester leads together and adjust current draw until it equals circuit breaker rating. 2. Connect switch to tester, Fig. 3. 3. Leave switch connected to tester for 10 minutes, holding current reading on multimeter at rated current. If circuit breaker opens, replace wiper switch assembly. Test 2 1. Short tester leads together and adjust current draw until it equals circuit breaker rating. 2. Connect switch to tester, Fig. 3. 3. Hold current reading on multimeter at twice the rated current of circuit breaker. If it takes more than 30 seconds for tester reading to drop to zero, replace wiper switch assembly. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Diode > Component Information > Technical Service Bulletins > Electrical Diode - Identification and Replacement Diode: Technical Service Bulletins Electrical Diode - Identification and Replacement Article No. 96-24-6 11/18/96 WIRING - ELECTRICAL DIODE IDENTIFICATION AND SERVICE REPLACEMENTS FORD: 1984-86 LTD 1984-88 EXP 1984-94 TEMPO 1984-97 CROWN VICTORIA, ESCORT, MUSTANG, THUNDERBIRD 1986-97 TAURUS 1989-97 PROBE 1994-97 ASPIRE 1995-97 CONTOUR LINCOLN-MERCURY: 1984-86 MARQUIS 1984-87 LYNX 1984-92 MARK VII 1984-94 TOPAZ 1984-97 CONTINENTAL, COUGAR, GRAND MARQUIS, TOWN CAR 1986-97 SABLE 1987-89 TRACER 1991-94 CAPRI 1991-97 TRACER 1995-97 MYSTIQUE MERKUR: 1985-89 XR4TI 1988-90 SCORPIO LIGHT TRUCK: 1983-97 RANGER 1984-90 BRONCO II 1984-97 ECONOLINE, F-150-350 SERIES 1986-97 AEROSTAR 1991-97 EXPLORER 1995-97 WINDSTAR MEDIUM/HEAVY TRUCK: 1984-91 C SERIES, CL-CLT-9000 SERIES 1984-97 F & B SERIES, L SERIES 1986-97 CARGO SERIES 1996-97 AEROMAX, LOUISVILLE This TSB article is being republished in its entirety to update the applicable model years. ISSUE: Electrical system concerns that are due to diode failure may be serviced with an approved Ford service diode. Some electrical diodes used in early production vehicles are color coded for the purpose of size identification while others are stamped with a manufacture number. All Ford service diodes and current production diodes are identified by manufacture number. ACTION: If service is required, refer to the appropriate model/year Electrical and Vacuum Troubleshooting Manual (EVTM) to determine the size and location of the diode(s). Refer to the following Electrical Diode Application Chart for the correct service part number. NOTE: IF THE DIODE REQUIRING REPLACEMENT DOES NOT HAVE THE SAME RATING AS LISTED IN THE APPLICATION CHART, USE THE NEXT HIGHER RATED DIODE. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Diode > Component Information > Technical Service Bulletins > Electrical Diode - Identification and Replacement > Page 5447 ELECTRICAL DIODE APPLICATION CHART PART NUMBER PART NAME E8DZ-10C912-A Diode - 1.0 Amp - 400V E8DZ-10C912-B Diode - 6.0 Amp - 400V OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 89-2-8 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 203000, 203200, 2770 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Diode > Component Information > Technical Service Bulletins > Page 5448 Diode: Locations LH Quarter Panel Area (F150-350) Above LH Quarter Window Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Locations Component Locations - Top Front Of Engine Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations Fuse Block: Locations Under LH side of instrument panel, near parking brake. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions Fuse Block: Diagram Information and Instructions Symbol Identification Wire Color Code Identification Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5457 NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5458 Fig. 1 Fuse Panel Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fusible Link > Component Information > Locations > Fuse Link C Fusible Link: Locations Fuse Link C LH Side Of Dash Panel To Junction Block Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fusible Link > Component Information > Locations > Fuse Link C > Page 5463 Fusible Link: Locations Fuse Link D RH Fender Apron At Starter Relay Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fusible Link > Component Information > Locations > Fuse Link C > Page 5464 Fusible Link: Locations Fuse Link E RH Fender Apron At Starter Relay Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fusible Link > Component Information > Locations > Fuse Link C > Page 5465 Fusible Link: Locations Fuse Link F RH Fender Apron At Starter Relay Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fusible Link > Component Information > Locations > Fuse Link C > Page 5466 Fusible Link: Locations Fuse Link C LH Side Of Dash Panel To Junction Block Fuse Link D RH Fender Apron Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fusible Link > Component Information > Locations > Fuse Link C > Page 5467 At Starter Relay Fuse Link E RH Fender Apron At Starter Relay Fuse Link F RH Fender Apron At Starter Relay Fuse Link G Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fusible Link > Component Information > Locations > Fuse Link C > Page 5468 RH Fender Apron At Starter Relay Fuse Link H RH Fender Apron At Starter Relay Fuse Link I Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fusible Link > Component Information > Locations > Fuse Link C > Page 5469 RH Fender Apron At Starter Relay Fuse Link L RH Fender Apron & Dash Panel. Near Dash Panel Applicable to: Diesel Engine Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fusible Link > Component Information > Locations > Fuse Link C > Page 5470 Fuse Link M RH Fender Apron & Dash Panel. Near Dash Panel Applicable to: Diesel Engine Fuse Link R Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fusible Link > Component Information > Locations > Fuse Link C > Page 5471 RH Fender Apron & Dash Panel. Near Voltage Regulator Applicable to: Diesel Engine Fuse Link V Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fusible Link > Component Information > Locations > Fuse Link C > Page 5472 RH Fender Apron & Dash Panel. Near Voltage Regulator Applicable to: Diesel Engine Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Locations Multiple Junction Connector: Locations LH Side Of Dash Panel On LH Dash Panel Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Power and Ground Distribution > Circuit Breaker > Component Information > Locations Circuit Breaker: Locations Circuit Location Amps Power Door Locks.....................Fuse Panel................30 Power Windows........................Fuse Panel................20 Power Tailgate Window................Fuse Panel................25 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Power and Ground Distribution > Circuit Breaker > Component Information > Locations > Page 5480 Circuit Breaker: Testing and Inspection BRONCO & F-100---350 SERIES The circuit breaker is located in the wiper control switch on all rotary switches. For slide wiper control switches, the circuit breaker is located in the fuse panel. All pin terminal switches have a circuit breaker rating of 8 {1/4} amps. All blade terminal switches have a rating of 7 amps. Two separate tests are necessary to check for correct circuit breaker operation when circuit breaker is part of wiper switch. Fig. 3 Testing circuit breaker. Bronco & F-100---350 Series Test 1 1. Short tester leads together and adjust current draw until it equals circuit breaker rating. 2. Connect switch to tester, Fig. 3. 3. Leave switch connected to tester for 10 minutes, holding current reading on multimeter at rated current. If circuit breaker opens, replace wiper switch assembly. Test 2 1. Short tester leads together and adjust current draw until it equals circuit breaker rating. 2. Connect switch to tester, Fig. 3. 3. Hold current reading on multimeter at twice the rated current of circuit breaker. If it takes more than 30 seconds for tester reading to drop to zero, replace wiper switch assembly. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Power and Ground Distribution > Diode > Component Information > Technical Service Bulletins > Electrical Diode - Identification and Replacement Diode: Technical Service Bulletins Electrical Diode - Identification and Replacement Article No. 96-24-6 11/18/96 WIRING - ELECTRICAL DIODE IDENTIFICATION AND SERVICE REPLACEMENTS FORD: 1984-86 LTD 1984-88 EXP 1984-94 TEMPO 1984-97 CROWN VICTORIA, ESCORT, MUSTANG, THUNDERBIRD 1986-97 TAURUS 1989-97 PROBE 1994-97 ASPIRE 1995-97 CONTOUR LINCOLN-MERCURY: 1984-86 MARQUIS 1984-87 LYNX 1984-92 MARK VII 1984-94 TOPAZ 1984-97 CONTINENTAL, COUGAR, GRAND MARQUIS, TOWN CAR 1986-97 SABLE 1987-89 TRACER 1991-94 CAPRI 1991-97 TRACER 1995-97 MYSTIQUE MERKUR: 1985-89 XR4TI 1988-90 SCORPIO LIGHT TRUCK: 1983-97 RANGER 1984-90 BRONCO II 1984-97 ECONOLINE, F-150-350 SERIES 1986-97 AEROSTAR 1991-97 EXPLORER 1995-97 WINDSTAR MEDIUM/HEAVY TRUCK: 1984-91 C SERIES, CL-CLT-9000 SERIES 1984-97 F & B SERIES, L SERIES 1986-97 CARGO SERIES 1996-97 AEROMAX, LOUISVILLE This TSB article is being republished in its entirety to update the applicable model years. ISSUE: Electrical system concerns that are due to diode failure may be serviced with an approved Ford service diode. Some electrical diodes used in early production vehicles are color coded for the purpose of size identification while others are stamped with a manufacture number. All Ford service diodes and current production diodes are identified by manufacture number. ACTION: If service is required, refer to the appropriate model/year Electrical and Vacuum Troubleshooting Manual (EVTM) to determine the size and location of the diode(s). Refer to the following Electrical Diode Application Chart for the correct service part number. NOTE: IF THE DIODE REQUIRING REPLACEMENT DOES NOT HAVE THE SAME RATING AS LISTED IN THE APPLICATION CHART, USE THE NEXT HIGHER RATED DIODE. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Power and Ground Distribution > Diode > Component Information > Technical Service Bulletins > Electrical Diode - Identification and Replacement > Page 5485 ELECTRICAL DIODE APPLICATION CHART PART NUMBER PART NAME E8DZ-10C912-A Diode - 1.0 Amp - 400V E8DZ-10C912-B Diode - 6.0 Amp - 400V OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 89-2-8 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 203000, 203200, 2770 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Power and Ground Distribution > Diode > Component Information > Technical Service Bulletins > Page 5486 Diode: Locations LH Quarter Panel Area (F150-350) Above LH Quarter Window Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Locations Component Locations - Top Front Of Engine Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations Fuse Block: Locations Under LH side of instrument panel, near parking brake. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions Fuse Block: Diagram Information and Instructions Symbol Identification Wire Color Code Identification Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5495 NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5496 Fig. 1 Fuse Panel Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Power and Ground Distribution > Fusible Link > Component Information > Locations > Fuse Link C Fusible Link: Locations Fuse Link C LH Side Of Dash Panel To Junction Block Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Power and Ground Distribution > Fusible Link > Component Information > Locations > Fuse Link C > Page 5501 Fusible Link: Locations Fuse Link D RH Fender Apron At Starter Relay Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Power and Ground Distribution > Fusible Link > Component Information > Locations > Fuse Link C > Page 5502 Fusible Link: Locations Fuse Link E RH Fender Apron At Starter Relay Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Power and Ground Distribution > Fusible Link > Component Information > Locations > Fuse Link C > Page 5503 Fusible Link: Locations Fuse Link F RH Fender Apron At Starter Relay Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Power and Ground Distribution > Fusible Link > Component Information > Locations > Fuse Link C > Page 5504 Fusible Link: Locations Fuse Link C LH Side Of Dash Panel To Junction Block Fuse Link D RH Fender Apron Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Power and Ground Distribution > Fusible Link > Component Information > Locations > Fuse Link C > Page 5505 At Starter Relay Fuse Link E RH Fender Apron At Starter Relay Fuse Link F RH Fender Apron At Starter Relay Fuse Link G Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Power and Ground Distribution > Fusible Link > Component Information > Locations > Fuse Link C > Page 5506 RH Fender Apron At Starter Relay Fuse Link H RH Fender Apron At Starter Relay Fuse Link I Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Power and Ground Distribution > Fusible Link > Component Information > Locations > Fuse Link C > Page 5507 RH Fender Apron At Starter Relay Fuse Link L RH Fender Apron & Dash Panel. Near Dash Panel Applicable to: Diesel Engine Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Power and Ground Distribution > Fusible Link > Component Information > Locations > Fuse Link C > Page 5508 Fuse Link M RH Fender Apron & Dash Panel. Near Dash Panel Applicable to: Diesel Engine Fuse Link R Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Power and Ground Distribution > Fusible Link > Component Information > Locations > Fuse Link C > Page 5509 RH Fender Apron & Dash Panel. Near Voltage Regulator Applicable to: Diesel Engine Fuse Link V Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Power and Ground Distribution > Fusible Link > Component Information > Locations > Fuse Link C > Page 5510 RH Fender Apron & Dash Panel. Near Voltage Regulator Applicable to: Diesel Engine Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Locations Multiple Junction Connector: Locations LH Side Of Dash Panel On LH Dash Panel Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Customer Interest: > 892110 > Oct > 89 > Steering - Pull or Drift Alignment: Customer Interest Steering - Pull or Drift Article No. 89-21-10 ^ STEERING - PULL OR DRIFT - CASTER SPLIT - NEW SERVICE ADJUSTERS - 4X4 MODELS ^ SUSPENSION - FRONT - NEW SERVICE CASTER ADJUSTERS - 4X4 MODELS LIGHT TRUCK: 1980-89 BRONCO, F-150, F-250, F-350 1983-89 RANGER 1984-89 BRONCO II Figure 1 This TSB article is being republished in its entirety to correct the service parts for the Caster Adjusters. ISSUE: Two new alignment adjusters are now available for service. These new parts provide one degree of caster adjustment along with one degree of camber. Steering pull may be caused by caster split. The affected trucks are 4x4 Twin Traction Beam vehicles. ACTION: Use the following procedure to determine the position of the service adjuster sleeve. Refer to the appropriate Light Truck Shop Manual, Section 14-21 for installation details. The new alignment adjusters are similiar to the current camber adjusters. The one exception is the rotational position of the adjuster sleeve to obtain the desired adjustment. ADJUSTER SLEEVE APPLICATION FOR RANGER BRONCO II, BRONCO, AND F-150 1. Measure and record the alignment readings. 2. Determine what alignment adjuster sleeves are on the truck. NOTE: IF AFTERMARKET ADJUSTER SLEEVES HAVE BEEN INSTALLED, IT WILL BE NECESSARY TO FIND OUT WHAT CASTER AND CAMBER SLEEVES WERE USED. If the adjuster sleeve is not marked or cannot be identified, install a 0 degree adjuster sleeve to use as a reference point. 3. Determine what adjuster sleeve change is required. Take your desired alignment (what you want to end up with) and compare it to the readings taken in Step 1 to determine the change. 4. Pick the adjuster sleeve that will get you the closest to the desired alignment. 5. Install and position the adjuster sleeve, Figure 1. Refer to the appropriate Light Truck Shop Manual, Section 14-21 for service details. See the following caster adjuster sleeve chart and camber adjuster sleeve chart for the correct service parts. CAMBER ADJUSTER SLEEVE APPLICATION CHART Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Customer Interest: > 892110 > Oct > 89 > Steering - Pull or Drift > Page 5523 SERVICE PART APPLICATION VALUE NUMBER F Series/Bronco - 0~ E0TZ-3B440-A 4x4 1/2~ E0TZ-3B440-B 1~ E0TZ-3B440-C 1-1/2~ E0TZ-3B440-D Ranger/ Bronco II - 0~ E3TZ-3B440-A 4x4 1/2~ E3TZ-3B440-B 1~ E3TZ-3B440-C 1-1/2~ E3TZ-3B440-D ADJUSTER ORIENTATION CHART CAMBER CASTER CAMBER CASTER POSITION LEFT LEFT RIGHT RIGHT OF SLOT SIDE SIDE SIDE SIDE 45~ +1~ -1~ -1~ -1~ 135~ -1~ -1~ + 1~ -1~ 225~ -1~ +1~ +1~ +1~ 315~ +1~ +1~ -1~ +1~ 6. Recheck the alignment to make sure you arrived at the desired values. CASTER WEDGE APPLICATION: F-250/350 4X4 The caster angle on the F-250 4x4 can be adjusted by inserting a wedge between the spring and the axle. Refer to the appropriate model year Light Truck Shop Manual, page 14-01-14 for installation details. See the following application chart for the correct service part. CASTER WEDGE APPLICATION CHART SERVICE PART APPLICATION VALUE NUMBER F-250/350 - 0~ E0TZ-5A313-A 4x4 1~ E0TZ-5A313-C 2~ E0TZ-5A313-B NOTE: F-350 4X4 TWIN TRACTION BEAM - CASTER AND CASTER SPLITS ARE ADJUSTABLE USING WEDGES. F-350 4X4 MONOBEAM - CASTER SPLITS ARE NOT ADJUSTABLE. A CASTER CHANGE FOR BOTH WHEELS IS ACCOMPLISHED USING WEDGES. PART NUMBER PART NAME CLASS E9TZ-3B440-F Caster Adjuster - B F-Series/Bronco E9TZ-3B440-G Caster Adjuster - B Ranger/Bronco II E0TZ-3B440-A Camber Adjuster - AM F-Series/Bronco E0TZ-3B440-B Camber Adjuster - AM Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Customer Interest: > 892110 > Oct > 89 > Steering - Pull or Drift > Page 5524 F-Series/Bronco E0TZ-3B440-C Camber Adjuster - AM F-Series/Bronco E0TZ-3B440-D Camber Adjuster - AM F-Series/Bronco E3TZ-3B440-A Camber Adjuster - BM Ranger/Bronco II E3TZ-3B440-B Camber Adjuster - AM Ranger/Bronco II E3TZ-3B440-C Camber Adjuster - AM Ranger/Bronco II E3TZ-3B440-D Camber Adjuster - AM Ranger/Bronco II E0TZ-5A313-A Caster Wedge C E0TZ-5A313-B Caster Wedge BM E0TZ-5A313-C Caster Wedge RM OTHER APPLICABLE ARTICLES: 87-4-16 SUPERSEDES: 89-19-13, date 9/20 89 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 3100, 3200, 3300 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Customer Interest: > 87416 > Feb > 87 > Steering - Pulling or Drifting Alignment: Customer Interest Steering - Pulling or Drifting ^ STEERING - PULL OR DRIFT - CASTER Article No. ADJUSTMENT SERVICE KIT 87-4-16 ^ SUSPENSION - FRONT - CASTER ADJUSTMENT SERVICE KIT LIGHT TRUCK 1980-86 F-150 (4x4), BRONCO ISSUE: A steering drift or pull may be caused by excessive front wheel side-to-side caster angle differences. ACTION: If a front axle alignment check shows excessive (more than 3/4 degree split) side-to-side caster angle difference causing the vehicle to drift or pull, install a new caster adjustment kit (E0TZ-3K064-A) which allows the front axle side-to-side caster angles to be changed up to 2-1/2 degrees in 1/2 degree increments. New front axle to radius arm brackets must also be replaced when the caster kit is installed. Refer to the following service procedure for step-by-step instructions. NOTE THE FOLLOWING INFORMATION BEFORE DOING WORK ON THE VEHICLE. To correct caster side-to-side difference of up to 1- 1/2 degrees, install a caster adjuster plate on the radius arm that has the lower caster reading. Adjuster plates are identified R.H. and L.H. To correct caster side-to-side difference more than 1-1/2 degrees, install the caster plate on both radius arms. Installing both plates will allow a caster split change of 2-1/2 degrees (+1-1/2 degrees on the low caster side, -1 degree on the high caster side). 1. Remove radius arm from vehicle. Figure 14 - Article 87-4-16 2. Locate the template, included in the kit, on the bottom flange of radius arm over the existing holes, as shown in Figure 14. NOTE: Right arm adjustment is shown. One template is used to modify both right and left hand arms. When modifying right arm, position template with printed side down (printed side up for left arm). Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Customer Interest: > 87416 > Feb > 87 > Steering - Pulling or Drifting > Page 5529 Figure 14 - Article 87-4-16 Figure 15 - Article 87-4-16 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Customer Interest: > 87416 > Feb > 87 > Steering - Pulling or Drifting > Page 5530 Figure 16 - Article 87-4-16 3. With template secure, punch mark radius arm at the small hole in the template, as shown in Figures 14 and 15. Mark radius arm, and diegrind a slot at the axle attaching hole the same size as the slot in the template, see Figure 16. De-burr the surface; avoid rounding the edges of the slot. Figure 13 - Article 87-4-16 4. Use a No. 6 drill to make a .204 inch diameter through hole at the punch mark. Line up the caster adjuster plate on the radius arm to obtain the required change in caster, see Figure 13. Figure 17 - Article 87-4-16 NOTE: Each hole changes caster approximately 1/2 degree + or - from the "0" index hole. 5. Install the tap screw to 120 in.lbs. (13 N-m) torque. 6. Reinstall radius arm with a new bracket (front axle to radius arm). The new bracket has a larger "jaw" spacing to fit over caster adjuster plate. ^ For non-quad shock vehicles, install bracket E7TZ-3B446-A. ^ For quad shock vehicles, install bracket E7TZ-18112-A, R.H. or E7TZ-18113-A, L.H. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Customer Interest: > 87416 > Feb > 87 > Steering - Pulling or Drifting > Page 5531 Figure 18 - Article 87-4-16 7. Tighten upper stud/bolt to 240-260 ft.lbs. (325-352 N-m) torque, Figure 18. 8. Tighten lower bolt to 320-340 ft.lbs. (434-461 N-m) torque, Figure 18. 9. Tighten front axle radius arm bracket bolts to 20-26 ft.lbs. (27-35 N-m) torque, Figure 18. 10. Arc weld caster adjuster plate to radius arm with a 1/4 inch-long bead along two sides of the plate. 11. Reset toe to specification. PART NUMBER PART NAME CLASS E0TZ-3K064-A Caster Kit CG E7TZ-3B446-A Bracket - Radius Arm C E7TZ-18112-A Bracket - Radius Arm CG E7TZ-18113-A Bracket - Radius Arm CG OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual OPERATION: SP870416A - Caster kit one side TIME: 2.1 Hrs. OPERATION: SP870416B - Caster kit both sides TIME: 3.5 Hrs. DLR. CODING: Basic Part No. FRONT - Code: 07 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Customer Interest: > 86622 > Mar > 86 > Steering - Vehicle Drifting/Pulling Alignment: Customer Interest Steering - Vehicle Drifting/Pulling Article No. 86-6-22 STEERING - DRIFT/PULL - RUBBER BALL SOCKET LINKAGE WIND-UP LIGHT TRUCK 1985-86 E, F SERIES, BRONCO Complaints of drifts and pulls on certain 1985-86 E, F Series and Bronco models may be caused by the installation procedure of the steering linkage. BECAUSE THE RUBBER TENDS TO RETURN TO ITS INSTALLED POSITION, IT IS IMPERATIVE THAT THE INSTALLATION BE ACCOMPLISHED WITH THE FRONT WHEELS AND THE PITMAN ARM IN THE STRAIGHT AHEAD POSITION, AND THE STUD SEATED IN THE TAPERED HOLE PRIOR TO TIGHTENING THE NUTS. Care should be taken with the installation to prevent a drift condition. To diagnose if a preload in the rubber is causing the drift, the following procedure is recommended: 1. Loosen the studs in the tapered holes at the pitman arm and the left and right spindles (i.e., disengage the stud from the hole so that it is no longer seated). 2. Hand install the nuts so that the stud is free to turn inside the tapered hole. 3. INSTALL COTTER PINS IN ALL THE STUDS. 4. Drive the vehicle. If it no longer drifts, then it can be assumed that the rubber was causing the drift. If it continues to drift, the condition is NOT being caused by the rubber ball sockets. 5. In either case, do not replace the steering linkage. Reinstall the linkage as follows: F Series and Bronco 1. Ensure the pitman arm and wheels are in the straight ahead position. (The pitman arm is exactly straight ahead when the clear vision is at 0~.) 2. Lock the steering wheel straight ahead and loose assemble the steering linkage to the pitman arm and then to the spindles. 3. Being careful not to change the position of the pitman arm, torque the steering linkage nuts to 65 ft.lbs. (88.1 N-m) The recommended sequence for tightening is: 1) the pitman arm, 2) the right side spindle and 3) the left side spindle. 4. Install all the cotter pins by advancing the nut to the next castellation. 5. Adjust the toe-in if necessary. Econoline 1. Ensure that the wheels are in the straight ahead position. 2. Loose assemble the steering linkage to the spindles and the pitman arm. 3. Being careful not to move the wheels from the straight ahead position, torque the steering linkage nuts to 65 ft.lbs. The recommended tightening sequence is: 1) the right side spindle, 2) the pitman arm and 3) the left side spindle. 4. Install all the cotter pins by advancing the nut to the next castellation. 5. Adjust the toe-in and reset the clear vision if necessary. The above procedure will eliminate any of the drift being caused by the rubber ball sockets. If the vehicle still drifts, refer to Section 19 of the Light Truck Shop Manual for further diagnosis. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION: SP3008A86A - F Series and Bronco TIME: 1.4 Hrs. OPERATION: SP3008A86B - Econoline TIME: 1.5 Hrs. DLR. CODING: Basic Part No. 3304 - Code: 36 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Customer Interest: > 851915 > Sep > 85 > Steering - Drift/Pull Alignment: Customer Interest Steering - Drift/Pull Article No. 85-19-15 STEERING - DRIFT/PULL CASTER SPLIT ADJUSTMENT LIGHT TRUCK 1980-86 F250-350 4x2; 1976-86 E100-350 A side-to-side front wheel caster difference greater than 3/4 degree can contribute to a vehicle drift or pull in the direction of the side with less caster. The service kit (E5TZ-3K064-A) can be used to increase the front wheel caster angle on either or both wheels to balance the caster split to correct a vehicle drift/pull concern. The kit contains complete parts and instructions needed to modify the front radius arm and mount a metal cam on the bottom flange of the radius arm. The kit can increase caster from 1/2 degree to 3 degrees, in 1/2 degree increments. It is not designed to decrease caster. To increase front wheel caster angle of subject vehicles and/or to balance a caster split, the following procedure is suggested: 1. Remove the radius arm from the vehicle as shown in Section 14-21 of the Reference Shop Manual and choose the appropriate paper template applicable to the vehicle model. Figure 8 - POSITIONING TEMPLATE TO LOWER FLANGE OF RADIUS ARM 2. Locate the template (3B474) on the bottom flange of the radius arm. Refer to Figure 8 for a typical arm modification for the right hand radius arm. One template per vehicle model is used to modify both the right and left hand radius arms. When modifying the right hand arm, position the Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Customer Interest: > 851915 > Sep > 85 > Steering - Drift/Pull > Page 5540 template with the printed side downward. The template locates off of one of two existing holes in the radius arm. The E100-350 template is shaped to match the contours of the radius arm. Figure 9 - HOLE DRILLING INSTRUCTIONS - CAM ATTACHMENT TO LOWER FLANGE RADIUS ARM 3. With template secure, make a punch mark at the center of the small hole inside the printed circle. Scribe the slot printed/cut-out on the template and die-grind out the slot at the axle-attaching hole the same size as the slot in the template and de-burr the surface avoiding rounding the edges of the slot. Refer to Figure 9. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Customer Interest: > 851915 > Sep > 85 > Steering - Drift/Pull > Page 5541 Figure 10 - ATTACHMENT OF ADJUSTING CAM TO RADIUS ARM 4. Drill a 0.228 inch diameter hole at the punch mark. Use this hole to mount the adjusting cam with the 1/4-20 self-tapping screw supplied. Refer to Figure 10. 5. Figure 10 shows a typical cam installation. Each hole in the cam represents a 1/2 degree caster increase. A caster increase of approximately 2 degrees for the E100-350, for example, will be obtained by mounting the cam with the selftapping screw in the No. 2 hole of the cam to the lower flange of the radius arm. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Customer Interest: > 851915 > Sep > 85 > Steering - Drift/Pull > Page 5542 Figure 11 - TYPICAL INSTALLATION - FRONT AND RADIUS ARM 6. Figure 11 shows a typical vehicle installation. TORQUE BOLT "A" AND NUT "B" TO 270-330 FT. LBS. When increasing caster 2 degrees or more, the ears of the radius arm should be bent upward slightly to help install and seat the axles. Do not use heat to bend. 7. Reset front wheel toe after installation is complete. AFTER THE DESIRED ALIGNMENT IS ASSURED THE CAM MUST BE WELDED TO THE ARM ARC WELD ONE INCH MINIMUM LENGTH ALONG TWO SIDES OF THE CAM. NOTE: The metal adjusting cam plate has a Ford logo stamped on it to identify it for E100- 150 and F250-350 4x2 vehicles only on vehicles with a front stabilizer bar. The bar mounting bracket may be reworked to provide clearance for the self-tapping screw. Do not use parts from kit E4TZ3K064-A on these vehicles. PART NUMBER PART NAME CLASS E5TZ-3K064-A Kit Caster Adjustment C OTHER APPLICABLE ARTICLES: 85-13-12 WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION: SP3360B85L TIME: Left - F Series: 2.4 Hrs. Econoline: 2.8 Hrs. OPERATION: SP3360B85R TIME: Right - F Series: 2.4 Hrs. Econoline: 2.8 Hrs. OPERATION: SP3360B85T TIME: Both - F Series: 3.8 Hrs. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Customer Interest: > 851915 > Sep > 85 > Steering - Drift/Pull > Page 5543 Econoline: 4.6 Hrs. OPERATION: 3001A TIME: 0.5 Hr. - Check caster camber and toe-in DLR. CODING: Basic Part No. 3A360 - Code: 36 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 892110 > Oct > 89 > Steering - Pull or Drift Alignment: All Technical Service Bulletins Steering - Pull or Drift Article No. 89-21-10 ^ STEERING - PULL OR DRIFT - CASTER SPLIT - NEW SERVICE ADJUSTERS - 4X4 MODELS ^ SUSPENSION - FRONT - NEW SERVICE CASTER ADJUSTERS - 4X4 MODELS LIGHT TRUCK: 1980-89 BRONCO, F-150, F-250, F-350 1983-89 RANGER 1984-89 BRONCO II Figure 1 This TSB article is being republished in its entirety to correct the service parts for the Caster Adjusters. ISSUE: Two new alignment adjusters are now available for service. These new parts provide one degree of caster adjustment along with one degree of camber. Steering pull may be caused by caster split. The affected trucks are 4x4 Twin Traction Beam vehicles. ACTION: Use the following procedure to determine the position of the service adjuster sleeve. Refer to the appropriate Light Truck Shop Manual, Section 14-21 for installation details. The new alignment adjusters are similiar to the current camber adjusters. The one exception is the rotational position of the adjuster sleeve to obtain the desired adjustment. ADJUSTER SLEEVE APPLICATION FOR RANGER BRONCO II, BRONCO, AND F-150 1. Measure and record the alignment readings. 2. Determine what alignment adjuster sleeves are on the truck. NOTE: IF AFTERMARKET ADJUSTER SLEEVES HAVE BEEN INSTALLED, IT WILL BE NECESSARY TO FIND OUT WHAT CASTER AND CAMBER SLEEVES WERE USED. If the adjuster sleeve is not marked or cannot be identified, install a 0 degree adjuster sleeve to use as a reference point. 3. Determine what adjuster sleeve change is required. Take your desired alignment (what you want to end up with) and compare it to the readings taken in Step 1 to determine the change. 4. Pick the adjuster sleeve that will get you the closest to the desired alignment. 5. Install and position the adjuster sleeve, Figure 1. Refer to the appropriate Light Truck Shop Manual, Section 14-21 for service details. See the following caster adjuster sleeve chart and camber adjuster sleeve chart for the correct service parts. CAMBER ADJUSTER SLEEVE APPLICATION CHART Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 892110 > Oct > 89 > Steering - Pull or Drift > Page 5549 SERVICE PART APPLICATION VALUE NUMBER F Series/Bronco - 0~ E0TZ-3B440-A 4x4 1/2~ E0TZ-3B440-B 1~ E0TZ-3B440-C 1-1/2~ E0TZ-3B440-D Ranger/ Bronco II - 0~ E3TZ-3B440-A 4x4 1/2~ E3TZ-3B440-B 1~ E3TZ-3B440-C 1-1/2~ E3TZ-3B440-D ADJUSTER ORIENTATION CHART CAMBER CASTER CAMBER CASTER POSITION LEFT LEFT RIGHT RIGHT OF SLOT SIDE SIDE SIDE SIDE 45~ +1~ -1~ -1~ -1~ 135~ -1~ -1~ + 1~ -1~ 225~ -1~ +1~ +1~ +1~ 315~ +1~ +1~ -1~ +1~ 6. Recheck the alignment to make sure you arrived at the desired values. CASTER WEDGE APPLICATION: F-250/350 4X4 The caster angle on the F-250 4x4 can be adjusted by inserting a wedge between the spring and the axle. Refer to the appropriate model year Light Truck Shop Manual, page 14-01-14 for installation details. See the following application chart for the correct service part. CASTER WEDGE APPLICATION CHART SERVICE PART APPLICATION VALUE NUMBER F-250/350 - 0~ E0TZ-5A313-A 4x4 1~ E0TZ-5A313-C 2~ E0TZ-5A313-B NOTE: F-350 4X4 TWIN TRACTION BEAM - CASTER AND CASTER SPLITS ARE ADJUSTABLE USING WEDGES. F-350 4X4 MONOBEAM - CASTER SPLITS ARE NOT ADJUSTABLE. A CASTER CHANGE FOR BOTH WHEELS IS ACCOMPLISHED USING WEDGES. PART NUMBER PART NAME CLASS E9TZ-3B440-F Caster Adjuster - B F-Series/Bronco E9TZ-3B440-G Caster Adjuster - B Ranger/Bronco II E0TZ-3B440-A Camber Adjuster - AM F-Series/Bronco E0TZ-3B440-B Camber Adjuster - AM Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 892110 > Oct > 89 > Steering - Pull or Drift > Page 5550 F-Series/Bronco E0TZ-3B440-C Camber Adjuster - AM F-Series/Bronco E0TZ-3B440-D Camber Adjuster - AM F-Series/Bronco E3TZ-3B440-A Camber Adjuster - BM Ranger/Bronco II E3TZ-3B440-B Camber Adjuster - AM Ranger/Bronco II E3TZ-3B440-C Camber Adjuster - AM Ranger/Bronco II E3TZ-3B440-D Camber Adjuster - AM Ranger/Bronco II E0TZ-5A313-A Caster Wedge C E0TZ-5A313-B Caster Wedge BM E0TZ-5A313-C Caster Wedge RM OTHER APPLICABLE ARTICLES: 87-4-16 SUPERSEDES: 89-19-13, date 9/20 89 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 3100, 3200, 3300 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 87416 > Feb > 87 > Steering - Pulling or Drifting Alignment: All Technical Service Bulletins Steering - Pulling or Drifting ^ STEERING - PULL OR DRIFT - CASTER Article No. ADJUSTMENT SERVICE KIT 87-4-16 ^ SUSPENSION - FRONT - CASTER ADJUSTMENT SERVICE KIT LIGHT TRUCK 1980-86 F-150 (4x4), BRONCO ISSUE: A steering drift or pull may be caused by excessive front wheel side-to-side caster angle differences. ACTION: If a front axle alignment check shows excessive (more than 3/4 degree split) side-to-side caster angle difference causing the vehicle to drift or pull, install a new caster adjustment kit (E0TZ-3K064-A) which allows the front axle side-to-side caster angles to be changed up to 2-1/2 degrees in 1/2 degree increments. New front axle to radius arm brackets must also be replaced when the caster kit is installed. Refer to the following service procedure for step-by-step instructions. NOTE THE FOLLOWING INFORMATION BEFORE DOING WORK ON THE VEHICLE. To correct caster side-to-side difference of up to 1- 1/2 degrees, install a caster adjuster plate on the radius arm that has the lower caster reading. Adjuster plates are identified R.H. and L.H. To correct caster side-to-side difference more than 1-1/2 degrees, install the caster plate on both radius arms. Installing both plates will allow a caster split change of 2-1/2 degrees (+1-1/2 degrees on the low caster side, -1 degree on the high caster side). 1. Remove radius arm from vehicle. Figure 14 - Article 87-4-16 2. Locate the template, included in the kit, on the bottom flange of radius arm over the existing holes, as shown in Figure 14. NOTE: Right arm adjustment is shown. One template is used to modify both right and left hand arms. When modifying right arm, position template with printed side down (printed side up for left arm). Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 87416 > Feb > 87 > Steering - Pulling or Drifting > Page 5555 Figure 14 - Article 87-4-16 Figure 15 - Article 87-4-16 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 87416 > Feb > 87 > Steering - Pulling or Drifting > Page 5556 Figure 16 - Article 87-4-16 3. With template secure, punch mark radius arm at the small hole in the template, as shown in Figures 14 and 15. Mark radius arm, and diegrind a slot at the axle attaching hole the same size as the slot in the template, see Figure 16. De-burr the surface; avoid rounding the edges of the slot. Figure 13 - Article 87-4-16 4. Use a No. 6 drill to make a .204 inch diameter through hole at the punch mark. Line up the caster adjuster plate on the radius arm to obtain the required change in caster, see Figure 13. Figure 17 - Article 87-4-16 NOTE: Each hole changes caster approximately 1/2 degree + or - from the "0" index hole. 5. Install the tap screw to 120 in.lbs. (13 N-m) torque. 6. Reinstall radius arm with a new bracket (front axle to radius arm). The new bracket has a larger "jaw" spacing to fit over caster adjuster plate. ^ For non-quad shock vehicles, install bracket E7TZ-3B446-A. ^ For quad shock vehicles, install bracket E7TZ-18112-A, R.H. or E7TZ-18113-A, L.H. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 87416 > Feb > 87 > Steering - Pulling or Drifting > Page 5557 Figure 18 - Article 87-4-16 7. Tighten upper stud/bolt to 240-260 ft.lbs. (325-352 N-m) torque, Figure 18. 8. Tighten lower bolt to 320-340 ft.lbs. (434-461 N-m) torque, Figure 18. 9. Tighten front axle radius arm bracket bolts to 20-26 ft.lbs. (27-35 N-m) torque, Figure 18. 10. Arc weld caster adjuster plate to radius arm with a 1/4 inch-long bead along two sides of the plate. 11. Reset toe to specification. PART NUMBER PART NAME CLASS E0TZ-3K064-A Caster Kit CG E7TZ-3B446-A Bracket - Radius Arm C E7TZ-18112-A Bracket - Radius Arm CG E7TZ-18113-A Bracket - Radius Arm CG OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual OPERATION: SP870416A - Caster kit one side TIME: 2.1 Hrs. OPERATION: SP870416B - Caster kit both sides TIME: 3.5 Hrs. DLR. CODING: Basic Part No. FRONT - Code: 07 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 862427 > Dec > 86 > Front Tires - Irregular Wear Pattern Alignment: All Technical Service Bulletins Front Tires - Irregular Wear Pattern Article No. 86-24-27 TIRE WEAR - FRONT - IRREGULAR PATTERN LIGHT TRUCK 1985-87 ALL LIGHT TRUCKS Vehicles may experience front tire wear with all season/all terrain tires described as irregular, heel and toe, or diagonal. The condition may be related to alignment settings, vehicle usage, and tire tread/ carcass/compound design. Tires with minimal wear conditions should be crossrotated to the rear and alignment checked and set to Shop Manual preferred settings for toe. In cases of severe wear, obtain the complete alignment readings and tire information. Contact both your Ford Representative and Tire Manufacturer's Representative for their assistance and participation in resolving the customer's concern. Contacting the "local" tire store may not obtain the assistance which may be available from the tire manufacturer. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 862428 > Dec > 86 > Tire Wear - Toe Set Prior Vehicle Service Alignment: All Technical Service Bulletins Tire Wear - Toe Set Prior Vehicle Service Article No. 86-24-28 TIRE WEAR - TOE SET PRIOR TO VEHICLE PLACEMENT INTO SERVICE VEHICLES WITH SNOWPLOW SCHOOL BUSES, AMBULANCES LIGHT TRUCK 1985-86 RANGER, F-SERIES, BRONCO, ECONOLINE Certain model vehicles have a significant weight change on the front axle between manufacture by Ford and placement into service. This occurs when incomplete vehicles are completed by a body company or when equipment is added to a complete vehicle (i.e., winches, plows, tool boxes, etc.). This weight change can affect toe setting so these vehicles require that toe be reset. Figure 25 The tag shown in Figure 25 is attached to the steering column of vehicles originally built with the intent to add additional equipment. These vehicles require toe reset. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 86622 > Mar > 86 > Steering - Vehicle Drifting/Pulling Alignment: All Technical Service Bulletins Steering - Vehicle Drifting/Pulling Article No. 86-6-22 STEERING - DRIFT/PULL - RUBBER BALL SOCKET LINKAGE WIND-UP LIGHT TRUCK 1985-86 E, F SERIES, BRONCO Complaints of drifts and pulls on certain 1985-86 E, F Series and Bronco models may be caused by the installation procedure of the steering linkage. BECAUSE THE RUBBER TENDS TO RETURN TO ITS INSTALLED POSITION, IT IS IMPERATIVE THAT THE INSTALLATION BE ACCOMPLISHED WITH THE FRONT WHEELS AND THE PITMAN ARM IN THE STRAIGHT AHEAD POSITION, AND THE STUD SEATED IN THE TAPERED HOLE PRIOR TO TIGHTENING THE NUTS. Care should be taken with the installation to prevent a drift condition. To diagnose if a preload in the rubber is causing the drift, the following procedure is recommended: 1. Loosen the studs in the tapered holes at the pitman arm and the left and right spindles (i.e., disengage the stud from the hole so that it is no longer seated). 2. Hand install the nuts so that the stud is free to turn inside the tapered hole. 3. INSTALL COTTER PINS IN ALL THE STUDS. 4. Drive the vehicle. If it no longer drifts, then it can be assumed that the rubber was causing the drift. If it continues to drift, the condition is NOT being caused by the rubber ball sockets. 5. In either case, do not replace the steering linkage. Reinstall the linkage as follows: F Series and Bronco 1. Ensure the pitman arm and wheels are in the straight ahead position. (The pitman arm is exactly straight ahead when the clear vision is at 0~.) 2. Lock the steering wheel straight ahead and loose assemble the steering linkage to the pitman arm and then to the spindles. 3. Being careful not to change the position of the pitman arm, torque the steering linkage nuts to 65 ft.lbs. (88.1 N-m) The recommended sequence for tightening is: 1) the pitman arm, 2) the right side spindle and 3) the left side spindle. 4. Install all the cotter pins by advancing the nut to the next castellation. 5. Adjust the toe-in if necessary. Econoline 1. Ensure that the wheels are in the straight ahead position. 2. Loose assemble the steering linkage to the spindles and the pitman arm. 3. Being careful not to move the wheels from the straight ahead position, torque the steering linkage nuts to 65 ft.lbs. The recommended tightening sequence is: 1) the right side spindle, 2) the pitman arm and 3) the left side spindle. 4. Install all the cotter pins by advancing the nut to the next castellation. 5. Adjust the toe-in and reset the clear vision if necessary. The above procedure will eliminate any of the drift being caused by the rubber ball sockets. If the vehicle still drifts, refer to Section 19 of the Light Truck Shop Manual for further diagnosis. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION: SP3008A86A - F Series and Bronco TIME: 1.4 Hrs. OPERATION: SP3008A86B - Econoline TIME: 1.5 Hrs. DLR. CODING: Basic Part No. 3304 - Code: 36 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 851915 > Sep > 85 > Steering - Drift/Pull Alignment: All Technical Service Bulletins Steering - Drift/Pull Article No. 85-19-15 STEERING - DRIFT/PULL CASTER SPLIT ADJUSTMENT LIGHT TRUCK 1980-86 F250-350 4x2; 1976-86 E100-350 A side-to-side front wheel caster difference greater than 3/4 degree can contribute to a vehicle drift or pull in the direction of the side with less caster. The service kit (E5TZ-3K064-A) can be used to increase the front wheel caster angle on either or both wheels to balance the caster split to correct a vehicle drift/pull concern. The kit contains complete parts and instructions needed to modify the front radius arm and mount a metal cam on the bottom flange of the radius arm. The kit can increase caster from 1/2 degree to 3 degrees, in 1/2 degree increments. It is not designed to decrease caster. To increase front wheel caster angle of subject vehicles and/or to balance a caster split, the following procedure is suggested: 1. Remove the radius arm from the vehicle as shown in Section 14-21 of the Reference Shop Manual and choose the appropriate paper template applicable to the vehicle model. Figure 8 - POSITIONING TEMPLATE TO LOWER FLANGE OF RADIUS ARM 2. Locate the template (3B474) on the bottom flange of the radius arm. Refer to Figure 8 for a typical arm modification for the right hand radius arm. One template per vehicle model is used to modify both the right and left hand radius arms. When modifying the right hand arm, position the Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 851915 > Sep > 85 > Steering - Drift/Pull > Page 5574 template with the printed side downward. The template locates off of one of two existing holes in the radius arm. The E100-350 template is shaped to match the contours of the radius arm. Figure 9 - HOLE DRILLING INSTRUCTIONS - CAM ATTACHMENT TO LOWER FLANGE RADIUS ARM 3. With template secure, make a punch mark at the center of the small hole inside the printed circle. Scribe the slot printed/cut-out on the template and die-grind out the slot at the axle-attaching hole the same size as the slot in the template and de-burr the surface avoiding rounding the edges of the slot. Refer to Figure 9. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 851915 > Sep > 85 > Steering - Drift/Pull > Page 5575 Figure 10 - ATTACHMENT OF ADJUSTING CAM TO RADIUS ARM 4. Drill a 0.228 inch diameter hole at the punch mark. Use this hole to mount the adjusting cam with the 1/4-20 self-tapping screw supplied. Refer to Figure 10. 5. Figure 10 shows a typical cam installation. Each hole in the cam represents a 1/2 degree caster increase. A caster increase of approximately 2 degrees for the E100-350, for example, will be obtained by mounting the cam with the selftapping screw in the No. 2 hole of the cam to the lower flange of the radius arm. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 851915 > Sep > 85 > Steering - Drift/Pull > Page 5576 Figure 11 - TYPICAL INSTALLATION - FRONT AND RADIUS ARM 6. Figure 11 shows a typical vehicle installation. TORQUE BOLT "A" AND NUT "B" TO 270-330 FT. LBS. When increasing caster 2 degrees or more, the ears of the radius arm should be bent upward slightly to help install and seat the axles. Do not use heat to bend. 7. Reset front wheel toe after installation is complete. AFTER THE DESIRED ALIGNMENT IS ASSURED THE CAM MUST BE WELDED TO THE ARM ARC WELD ONE INCH MINIMUM LENGTH ALONG TWO SIDES OF THE CAM. NOTE: The metal adjusting cam plate has a Ford logo stamped on it to identify it for E100- 150 and F250-350 4x2 vehicles only on vehicles with a front stabilizer bar. The bar mounting bracket may be reworked to provide clearance for the self-tapping screw. Do not use parts from kit E4TZ3K064-A on these vehicles. PART NUMBER PART NAME CLASS E5TZ-3K064-A Kit Caster Adjustment C OTHER APPLICABLE ARTICLES: 85-13-12 WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION: SP3360B85L TIME: Left - F Series: 2.4 Hrs. Econoline: 2.8 Hrs. OPERATION: SP3360B85R TIME: Right - F Series: 2.4 Hrs. Econoline: 2.8 Hrs. OPERATION: SP3360B85T TIME: Both - F Series: 3.8 Hrs. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 851915 > Sep > 85 > Steering - Drift/Pull > Page 5577 Econoline: 4.6 Hrs. OPERATION: 3001A TIME: 0.5 Hr. - Check caster camber and toe-in DLR. CODING: Basic Part No. 3A360 - Code: 36 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 862427 > Dec > 86 > Front Tires - Irregular Wear Pattern Alignment: All Technical Service Bulletins Front Tires - Irregular Wear Pattern Article No. 86-24-27 TIRE WEAR - FRONT - IRREGULAR PATTERN LIGHT TRUCK 1985-87 ALL LIGHT TRUCKS Vehicles may experience front tire wear with all season/all terrain tires described as irregular, heel and toe, or diagonal. The condition may be related to alignment settings, vehicle usage, and tire tread/ carcass/compound design. Tires with minimal wear conditions should be crossrotated to the rear and alignment checked and set to Shop Manual preferred settings for toe. In cases of severe wear, obtain the complete alignment readings and tire information. Contact both your Ford Representative and Tire Manufacturer's Representative for their assistance and participation in resolving the customer's concern. Contacting the "local" tire store may not obtain the assistance which may be available from the tire manufacturer. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 862428 > Dec > 86 > Tire Wear - Toe Set Prior Vehicle Service Alignment: All Technical Service Bulletins Tire Wear - Toe Set Prior Vehicle Service Article No. 86-24-28 TIRE WEAR - TOE SET PRIOR TO VEHICLE PLACEMENT INTO SERVICE VEHICLES WITH SNOWPLOW SCHOOL BUSES, AMBULANCES LIGHT TRUCK 1985-86 RANGER, F-SERIES, BRONCO, ECONOLINE Certain model vehicles have a significant weight change on the front axle between manufacture by Ford and placement into service. This occurs when incomplete vehicles are completed by a body company or when equipment is added to a complete vehicle (i.e., winches, plows, tool boxes, etc.). This weight change can affect toe setting so these vehicles require that toe be reset. Figure 25 The tag shown in Figure 25 is attached to the steering column of vehicles originally built with the intent to add additional equipment. These vehicles require toe reset. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 5587 Alignment: By Symptom Technical Service Bulletin # 892110 Date: 891018 Steering - Pull or Drift Article No. 89-21-10 ^ STEERING - PULL OR DRIFT - CASTER SPLIT - NEW SERVICE ADJUSTERS - 4X4 MODELS ^ SUSPENSION - FRONT - NEW SERVICE CASTER ADJUSTERS - 4X4 MODELS LIGHT TRUCK: 1980-89 BRONCO, F-150, F-250, F-350 1983-89 RANGER 1984-89 BRONCO II Figure 1 This TSB article is being republished in its entirety to correct the service parts for the Caster Adjusters. ISSUE: Two new alignment adjusters are now available for service. These new parts provide one degree of caster adjustment along with one degree of camber. Steering pull may be caused by caster split. The affected trucks are 4x4 Twin Traction Beam vehicles. ACTION: Use the following procedure to determine the position of the service adjuster sleeve. Refer to the appropriate Light Truck Shop Manual, Section 14-21 for installation details. The new alignment adjusters are similiar to the current camber adjusters. The one exception is the rotational position of the adjuster sleeve to obtain the desired adjustment. ADJUSTER SLEEVE APPLICATION FOR RANGER BRONCO II, BRONCO, AND F-150 1. Measure and record the alignment readings. 2. Determine what alignment adjuster sleeves are on the truck. NOTE: IF AFTERMARKET ADJUSTER SLEEVES HAVE BEEN INSTALLED, IT WILL BE NECESSARY TO FIND OUT WHAT CASTER AND CAMBER SLEEVES WERE USED. If the adjuster sleeve is not marked or cannot be identified, install a 0 degree adjuster sleeve to use as a reference point. 3. Determine what adjuster sleeve change is required. Take your desired alignment (what you want to end up with) and compare it to the readings taken in Step 1 to determine the change. 4. Pick the adjuster sleeve that will get you the closest to the desired alignment. 5. Install and position the adjuster sleeve, Figure 1. Refer to the appropriate Light Truck Shop Manual, Section 14-21 for service details. See the following caster adjuster sleeve chart and camber adjuster sleeve chart for the correct service parts. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 5588 CAMBER ADJUSTER SLEEVE APPLICATION CHART SERVICE PART APPLICATION VALUE NUMBER F Series/Bronco - 0~ E0TZ-3B440-A 4x4 1/2~ E0TZ-3B440-B 1~ E0TZ-3B440-C 1-1/2~ E0TZ-3B440-D Ranger/ Bronco II - 0~ E3TZ-3B440-A 4x4 1/2~ E3TZ-3B440-B 1~ E3TZ-3B440-C 1-1/2~ E3TZ-3B440-D ADJUSTER ORIENTATION CHART CAMBER CASTER CAMBER CASTER POSITION LEFT LEFT RIGHT RIGHT OF SLOT SIDE SIDE SIDE SIDE 45~ +1~ -1~ -1~ -1~ 135~ -1~ -1~ + 1~ -1~ 225~ -1~ +1~ +1~ +1~ 315~ +1~ +1~ -1~ +1~ 6. Recheck the alignment to make sure you arrived at the desired values. CASTER WEDGE APPLICATION: F-250/350 4X4 The caster angle on the F-250 4x4 can be adjusted by inserting a wedge between the spring and the axle. Refer to the appropriate model year Light Truck Shop Manual, page 14-01-14 for installation details. See the following application chart for the correct service part. CASTER WEDGE APPLICATION CHART SERVICE PART APPLICATION VALUE NUMBER F-250/350 - 0~ E0TZ-5A313-A 4x4 1~ E0TZ-5A313-C 2~ E0TZ-5A313-B NOTE: F-350 4X4 TWIN TRACTION BEAM - CASTER AND CASTER SPLITS ARE ADJUSTABLE USING WEDGES. F-350 4X4 MONOBEAM - CASTER SPLITS ARE NOT ADJUSTABLE. A CASTER CHANGE FOR BOTH WHEELS IS ACCOMPLISHED USING WEDGES. PART NUMBER PART NAME CLASS E9TZ-3B440-F Caster Adjuster - B F-Series/Bronco E9TZ-3B440-G Caster Adjuster - B Ranger/Bronco II E0TZ-3B440-A Camber Adjuster - AM Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 5589 F-Series/Bronco E0TZ-3B440-B Camber Adjuster - AM F-Series/Bronco E0TZ-3B440-C Camber Adjuster - AM F-Series/Bronco E0TZ-3B440-D Camber Adjuster - AM F-Series/Bronco E3TZ-3B440-A Camber Adjuster - BM Ranger/Bronco II E3TZ-3B440-B Camber Adjuster - AM Ranger/Bronco II E3TZ-3B440-C Camber Adjuster - AM Ranger/Bronco II E3TZ-3B440-D Camber Adjuster - AM Ranger/Bronco II E0TZ-5A313-A Caster Wedge C E0TZ-5A313-B Caster Wedge BM E0TZ-5A313-C Caster Wedge RM OTHER APPLICABLE ARTICLES: 87-4-16 SUPERSEDES: 89-19-13, date 9/20 89 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 3100, 3200, 3300 Technical Service Bulletin # 87416 Date: 870225 Steering - Pulling or Drifting ^ STEERING - PULL OR DRIFT - CASTER Article No. ADJUSTMENT SERVICE KIT 87-4-16 ^ SUSPENSION - FRONT - CASTER ADJUSTMENT SERVICE KIT LIGHT TRUCK 1980-86 F-150 (4x4), BRONCO ISSUE: A steering drift or pull may be caused by excessive front wheel side-to-side caster angle differences. ACTION: If a front axle alignment check shows excessive (more than 3/4 degree split) side-to-side caster angle difference causing the vehicle to drift or pull, install a new caster adjustment kit (E0TZ-3K064-A) which allows the front axle side-to-side caster angles to be changed up to 2-1/2 degrees in 1/2 degree increments. New front axle to radius arm brackets must also be replaced when the caster kit is installed. Refer to the following service procedure for step-by-step instructions. NOTE THE FOLLOWING INFORMATION BEFORE DOING WORK ON THE VEHICLE. To correct caster side-to-side difference of up to 1- 1/2 degrees, install a caster adjuster plate on the radius arm that has the lower caster reading. Adjuster plates are identified R.H. and L.H. To correct caster side-to-side difference more than 1-1/2 degrees, install the caster plate on both radius arms. Installing both plates will allow a caster split change of 2-1/2 degrees (+1-1/2 degrees on the low caster side, -1 degree on the high caster side). 1. Remove radius arm from vehicle. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 5590 Figure 14 - Article 87-4-16 2. Locate the template, included in the kit, on the bottom flange of radius arm over the existing holes, as shown in Figure 14. NOTE: Right arm adjustment is shown. One template is used to modify both right and left hand arms. When modifying right arm, position template with printed side down (printed side up for left arm). Figure 14 - Article 87-4-16 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 5591 Figure 15 - Article 87-4-16 Figure 16 - Article 87-4-16 3. With template secure, punch mark radius arm at the small hole in the template, as shown in Figures 14 and 15. Mark radius arm, and diegrind a slot at the axle attaching hole the same size as the slot in the template, see Figure 16. De-burr the surface; avoid rounding the edges of the slot. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 5592 Figure 13 - Article 87-4-16 4. Use a No. 6 drill to make a .204 inch diameter through hole at the punch mark. Line up the caster adjuster plate on the radius arm to obtain the required change in caster, see Figure 13. Figure 17 - Article 87-4-16 NOTE: Each hole changes caster approximately 1/2 degree + or - from the "0" index hole. 5. Install the tap screw to 120 in.lbs. (13 N-m) torque. 6. Reinstall radius arm with a new bracket (front axle to radius arm). The new bracket has a larger "jaw" spacing to fit over caster adjuster plate. ^ For non-quad shock vehicles, install bracket E7TZ-3B446-A. ^ For quad shock vehicles, install bracket E7TZ-18112-A, R.H. or E7TZ-18113-A, L.H. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 5593 Figure 18 - Article 87-4-16 7. Tighten upper stud/bolt to 240-260 ft.lbs. (325-352 N-m) torque, Figure 18. 8. Tighten lower bolt to 320-340 ft.lbs. (434-461 N-m) torque, Figure 18. 9. Tighten front axle radius arm bracket bolts to 20-26 ft.lbs. (27-35 N-m) torque, Figure 18. 10. Arc weld caster adjuster plate to radius arm with a 1/4 inch-long bead along two sides of the plate. 11. Reset toe to specification. PART NUMBER PART NAME CLASS E0TZ-3K064-A Caster Kit CG E7TZ-3B446-A Bracket - Radius Arm C E7TZ-18112-A Bracket - Radius Arm CG E7TZ-18113-A Bracket - Radius Arm CG OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual OPERATION: SP870416A - Caster kit one side TIME: 2.1 Hrs. OPERATION: SP870416B - Caster kit both sides TIME: 3.5 Hrs. DLR. CODING: Basic Part No. FRONT - Code: 07 Technical Service Bulletin # 86622 Date: 860326 Steering - Vehicle Drifting/Pulling Article No. 86-6-22 STEERING - DRIFT/PULL - RUBBER BALL SOCKET LINKAGE WIND-UP LIGHT TRUCK 1985-86 E, F SERIES, BRONCO Complaints of drifts and pulls on certain 1985-86 E, F Series and Bronco models may be caused by the installation procedure of the steering linkage. BECAUSE THE RUBBER TENDS TO RETURN TO ITS INSTALLED POSITION, IT IS IMPERATIVE THAT THE INSTALLATION BE ACCOMPLISHED WITH THE FRONT WHEELS AND THE PITMAN ARM IN THE STRAIGHT AHEAD POSITION, AND THE STUD SEATED IN THE TAPERED HOLE PRIOR TO TIGHTENING THE NUTS. Care should be taken with the installation to prevent a drift condition. To diagnose if a preload in the rubber is causing the drift, the following procedure is recommended: 1. Loosen the studs in the tapered holes at the pitman arm and the left and right spindles (i.e., disengage the stud from the hole so that it is no longer seated). 2. Hand install the nuts so that the stud is free to turn inside the tapered hole. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 5594 3. INSTALL COTTER PINS IN ALL THE STUDS. 4. Drive the vehicle. If it no longer drifts, then it can be assumed that the rubber was causing the drift. If it continues to drift, the condition is NOT being caused by the rubber ball sockets. 5. In either case, do not replace the steering linkage. Reinstall the linkage as follows: F Series and Bronco 1. Ensure the pitman arm and wheels are in the straight ahead position. (The pitman arm is exactly straight ahead when the clear vision is at 0~.) 2. Lock the steering wheel straight ahead and loose assemble the steering linkage to the pitman arm and then to the spindles. 3. Being careful not to change the position of the pitman arm, torque the steering linkage nuts to 65 ft.lbs. (88.1 N-m) The recommended sequence for tightening is: 1) the pitman arm, 2) the right side spindle and 3) the left side spindle. 4. Install all the cotter pins by advancing the nut to the next castellation. 5. Adjust the toe-in if necessary. Econoline 1. Ensure that the wheels are in the straight ahead position. 2. Loose assemble the steering linkage to the spindles and the pitman arm. 3. Being careful not to move the wheels from the straight ahead position, torque the steering linkage nuts to 65 ft.lbs. The recommended tightening sequence is: 1) the right side spindle, 2) the pitman arm and 3) the left side spindle. 4. Install all the cotter pins by advancing the nut to the next castellation. 5. Adjust the toe-in and reset the clear vision if necessary. The above procedure will eliminate any of the drift being caused by the rubber ball sockets. If the vehicle still drifts, refer to Section 19 of the Light Truck Shop Manual for further diagnosis. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION: SP3008A86A - F Series and Bronco TIME: 1.4 Hrs. OPERATION: SP3008A86B - Econoline TIME: 1.5 Hrs. DLR. CODING: Basic Part No. 3304 - Code: 36 Technical Service Bulletin # 851915 Date: 850926 Steering - Drift/Pull Article No. 85-19-15 STEERING - DRIFT/PULL CASTER SPLIT ADJUSTMENT LIGHT TRUCK 1980-86 F250-350 4x2; 1976-86 E100-350 A side-to-side front wheel caster difference greater than 3/4 degree can contribute to a vehicle drift or pull in the direction of the side with less caster. The service kit (E5TZ-3K064-A) can be used to increase the front wheel caster angle on either or both wheels to balance the caster split to correct a vehicle drift/pull concern. The kit contains complete parts and instructions needed to modify the front radius arm and mount a metal cam on the bottom flange of the radius arm. The kit can increase caster from 1/2 degree to 3 degrees, in 1/2 degree increments. It is not designed to decrease caster. To increase front wheel caster angle of subject vehicles and/or to balance a caster split, the following procedure is suggested: 1. Remove the radius arm from the vehicle as shown in Section 14-21 of the Reference Shop Manual and choose the appropriate paper template applicable to the vehicle model. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 5595 Figure 8 - POSITIONING TEMPLATE TO LOWER FLANGE OF RADIUS ARM 2. Locate the template (3B474) on the bottom flange of the radius arm. Refer to Figure 8 for a typical arm modification for the right hand radius arm. One template per vehicle model is used to modify both the right and left hand radius arms. When modifying the right hand arm, position the template with the printed side downward. The template locates off of one of two existing holes in the radius arm. The E100-350 template is shaped to match the contours of the radius arm. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 5596 Figure 9 - HOLE DRILLING INSTRUCTIONS - CAM ATTACHMENT TO LOWER FLANGE RADIUS ARM 3. With template secure, make a punch mark at the center of the small hole inside the printed circle. Scribe the slot printed/cut-out on the template and die-grind out the slot at the axle-attaching hole the same size as the slot in the template and de-burr the surface avoiding rounding the edges of the slot. Refer to Figure 9. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 5597 Figure 10 - ATTACHMENT OF ADJUSTING CAM TO RADIUS ARM 4. Drill a 0.228 inch diameter hole at the punch mark. Use this hole to mount the adjusting cam with the 1/4-20 self-tapping screw supplied. Refer to Figure 10. 5. Figure 10 shows a typical cam installation. Each hole in the cam represents a 1/2 degree caster increase. A caster increase of approximately 2 degrees for the E100-350, for example, will be obtained by mounting the cam with the selftapping screw in the No. 2 hole of the cam to the lower flange of the radius arm. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 5598 Figure 11 - TYPICAL INSTALLATION - FRONT AND RADIUS ARM 6. Figure 11 shows a typical vehicle installation. TORQUE BOLT "A" AND NUT "B" TO 270-330 FT. LBS. When increasing caster 2 degrees or more, the ears of the radius arm should be bent upward slightly to help install and seat the axles. Do not use heat to bend. 7. Reset front wheel toe after installation is complete. AFTER THE DESIRED ALIGNMENT IS ASSURED THE CAM MUST BE WELDED TO THE ARM ARC WELD ONE INCH MINIMUM LENGTH ALONG TWO SIDES OF THE CAM. NOTE: The metal adjusting cam plate has a Ford logo stamped on it to identify it for E100- 150 and F250-350 4x2 vehicles only on vehicles with a front stabilizer bar. The bar mounting bracket may be reworked to provide clearance for the self-tapping screw. Do not use parts from kit E4TZ3K064-A on these vehicles. PART NUMBER PART NAME CLASS E5TZ-3K064-A Kit Caster Adjustment C OTHER APPLICABLE ARTICLES: 85-13-12 WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION: SP3360B85L TIME: Left - F Series: 2.4 Hrs. Econoline: 2.8 Hrs. OPERATION: SP3360B85R TIME: Right - F Series: 2.4 Hrs. Econoline: 2.8 Hrs. OPERATION: SP3360B85T TIME: Both - F Series: 3.8 Hrs. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 5599 Econoline: 4.6 Hrs. OPERATION: 3001A TIME: 0.5 Hr. - Check caster camber and toe-in DLR. CODING: Basic Part No. 3A360 - Code: 36 Technical Service Bulletin # 851915 Date: 850926 Steering - Drift/Pull Article No. 85-19-15 STEERING - DRIFT/PULL CASTER SPLIT ADJUSTMENT LIGHT TRUCK 1980-86 F250-350 4x2; 1976-86 E100-350 A side-to-side front wheel caster difference greater than 3/4 degree can contribute to a vehicle drift or pull in the direction of the side with less caster. The service kit (E5TZ-3K064-A) can be used to increase the front wheel caster angle on either or both wheels to balance the caster split to correct a vehicle drift/pull concern. The kit contains complete parts and instructions needed to modify the front radius arm and mount a metal cam on the bottom flange of the radius arm. The kit can increase caster from 1/2 degree to 3 degrees, in 1/2 degree increments. It is not designed to decrease caster. To increase front wheel caster angle of subject vehicles and/or to balance a caster split, the following procedure is suggested: 1. Remove the radius arm from the vehicle as shown in Section 14-21 of the Reference Shop Manual and choose the appropriate paper template applicable to the vehicle model. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 5600 Figure 8 - POSITIONING TEMPLATE TO LOWER FLANGE OF RADIUS ARM 2. Locate the template (3B474) on the bottom flange of the radius arm. Refer to Figure 8 for a typical arm modification for the right hand radius arm. One template per vehicle model is used to modify both the right and left hand radius arms. When modifying the right hand arm, position the template with the printed side downward. The template locates off of one of two existing holes in the radius arm. The E100-350 template is shaped to match the contours of the radius arm. Figure 9 - HOLE DRILLING INSTRUCTIONS - CAM ATTACHMENT TO LOWER FLANGE RADIUS ARM 3. With template secure, make a punch mark at the center of the small hole inside the printed circle. Scribe the slot printed/cut-out on the template and die-grind out the slot at the axle-attaching hole the same size as the slot in the template and de-burr the surface avoiding rounding the edges of the slot. Refer to Figure 9. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 5601 Figure 10 - ATTACHMENT OF ADJUSTING CAM TO RADIUS ARM 4. Drill a 0.228 inch diameter hole at the punch mark. Use this hole to mount the adjusting cam with the 1/4-20 self-tapping screw supplied. Refer to Figure 10. 5. Figure 10 shows a typical cam installation. Each hole in the cam represents a 1/2 degree caster increase. A caster increase of approximately 2 degrees for the E100-350, for example, will be obtained by mounting the cam with the selftapping screw in the No. 2 hole of the cam to the lower flange of the radius arm. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 5602 Figure 11 - TYPICAL INSTALLATION - FRONT AND RADIUS ARM 6. Figure 11 shows a typical vehicle installation. TORQUE BOLT "A" AND NUT "B" TO 270-330 FT. LBS. When increasing caster 2 degrees or more, the ears of the radius arm should be bent upward slightly to help install and seat the axles. Do not use heat to bend. 7. Reset front wheel toe after installation is complete. AFTER THE DESIRED ALIGNMENT IS ASSURED THE CAM MUST BE WELDED TO THE ARM ARC WELD ONE INCH MINIMUM LENGTH ALONG TWO SIDES OF THE CAM. NOTE: The metal adjusting cam plate has a Ford logo stamped on it to identify it for E100- 150 and F250-350 4x2 vehicles only on vehicles with a front stabilizer bar. The bar mounting bracket may be reworked to provide clearance for the self-tapping screw. Do not use parts from kit E4TZ3K064-A on these vehicles. PART NUMBER PART NAME CLASS E5TZ-3K064-A Kit Caster Adjustment C OTHER APPLICABLE ARTICLES: 85-13-12 WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION: SP3360B85L TIME: Left - F Series: 2.4 Hrs. Econoline: 2.8 Hrs. OPERATION: SP3360B85R TIME: Right - F Series: 2.4 Hrs. Econoline: 2.8 Hrs. OPERATION: SP3360B85T TIME: Both - F Series: 3.8 Hrs. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 5603 Econoline: 4.6 Hrs. OPERATION: 3001A TIME: 0.5 Hr. - Check caster camber and toe-in DLR. CODING: Basic Part No. 3A360 - Code: 36 Technical Service Bulletin # 892110 Date: 891018 Steering - Pull or Drift Article No. 89-21-10 ^ STEERING - PULL OR DRIFT - CASTER SPLIT - NEW SERVICE ADJUSTERS - 4X4 MODELS ^ SUSPENSION - FRONT - NEW SERVICE CASTER ADJUSTERS - 4X4 MODELS LIGHT TRUCK: 1980-89 BRONCO, F-150, F-250, F-350 1983-89 RANGER 1984-89 BRONCO II Figure 1 This TSB article is being republished in its entirety to correct the service parts for the Caster Adjusters. ISSUE: Two new alignment adjusters are now available for service. These new parts provide one degree of caster adjustment along with one degree of camber. Steering pull may be caused by caster split. The affected trucks are 4x4 Twin Traction Beam vehicles. ACTION: Use the following procedure to determine the position of the service adjuster sleeve. Refer to the appropriate Light Truck Shop Manual, Section 14-21 for installation details. The new alignment adjusters are similiar to the current camber adjusters. The one exception is the rotational position of the adjuster sleeve to obtain the desired adjustment. ADJUSTER SLEEVE APPLICATION FOR RANGER BRONCO II, BRONCO, AND F-150 1. Measure and record the alignment readings. 2. Determine what alignment adjuster sleeves are on the truck. NOTE: IF AFTERMARKET ADJUSTER SLEEVES HAVE BEEN INSTALLED, IT WILL BE NECESSARY TO FIND OUT WHAT CASTER AND CAMBER SLEEVES WERE USED. If the adjuster sleeve is not marked or cannot be identified, install a 0 degree adjuster sleeve to use as a reference point. 3. Determine what adjuster sleeve change is required. Take your desired alignment (what you want to end up with) and compare it to the readings taken in Step 1 to determine the change. 4. Pick the adjuster sleeve that will get you the closest to the desired alignment. 5. Install and position the adjuster sleeve, Figure Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 5604 1. Refer to the appropriate Light Truck Shop Manual, Section 14-21 for service details. See the following caster adjuster sleeve chart and camber adjuster sleeve chart for the correct service parts. CAMBER ADJUSTER SLEEVE APPLICATION CHART SERVICE PART APPLICATION VALUE NUMBER F Series/Bronco - 0~ E0TZ-3B440-A 4x4 1/2~ E0TZ-3B440-B 1~ E0TZ-3B440-C 1-1/2~ E0TZ-3B440-D Ranger/ Bronco II - 0~ E3TZ-3B440-A 4x4 1/2~ E3TZ-3B440-B 1~ E3TZ-3B440-C 1-1/2~ E3TZ-3B440-D ADJUSTER ORIENTATION CHART CAMBER CASTER CAMBER CASTER POSITION LEFT LEFT RIGHT RIGHT OF SLOT SIDE SIDE SIDE SIDE 45~ +1~ -1~ -1~ -1~ 135~ -1~ -1~ + 1~ -1~ 225~ -1~ +1~ +1~ +1~ 315~ +1~ +1~ -1~ +1~ 6. Recheck the alignment to make sure you arrived at the desired values. CASTER WEDGE APPLICATION: F-250/350 4X4 The caster angle on the F-250 4x4 can be adjusted by inserting a wedge between the spring and the axle. Refer to the appropriate model year Light Truck Shop Manual, page 14-01-14 for installation details. See the following application chart for the correct service part. CASTER WEDGE APPLICATION CHART SERVICE PART APPLICATION VALUE NUMBER F-250/350 - 0~ E0TZ-5A313-A 4x4 1~ E0TZ-5A313-C 2~ E0TZ-5A313-B NOTE: F-350 4X4 TWIN TRACTION BEAM - CASTER AND CASTER SPLITS ARE ADJUSTABLE USING WEDGES. F-350 4X4 MONOBEAM - CASTER SPLITS ARE NOT ADJUSTABLE. A CASTER CHANGE FOR BOTH WHEELS IS ACCOMPLISHED USING WEDGES. PART NUMBER PART NAME CLASS E9TZ-3B440-F Caster Adjuster - B F-Series/Bronco E9TZ-3B440-G Caster Adjuster - B Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 5605 Ranger/Bronco II E0TZ-3B440-A Camber Adjuster - AM F-Series/Bronco E0TZ-3B440-B Camber Adjuster - AM F-Series/Bronco E0TZ-3B440-C Camber Adjuster - AM F-Series/Bronco E0TZ-3B440-D Camber Adjuster - AM F-Series/Bronco E3TZ-3B440-A Camber Adjuster - BM Ranger/Bronco II E3TZ-3B440-B Camber Adjuster - AM Ranger/Bronco II E3TZ-3B440-C Camber Adjuster - AM Ranger/Bronco II E3TZ-3B440-D Camber Adjuster - AM Ranger/Bronco II E0TZ-5A313-A Caster Wedge C E0TZ-5A313-B Caster Wedge BM E0TZ-5A313-C Caster Wedge RM OTHER APPLICABLE ARTICLES: 87-4-16 SUPERSEDES: 89-19-13, date 9/20 89 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 3100, 3200, 3300 Technical Service Bulletin # 87416 Date: 870225 Steering - Pulling or Drifting ^ STEERING - PULL OR DRIFT - CASTER Article No. ADJUSTMENT SERVICE KIT 87-4-16 ^ SUSPENSION - FRONT - CASTER ADJUSTMENT SERVICE KIT LIGHT TRUCK 1980-86 F-150 (4x4), BRONCO ISSUE: A steering drift or pull may be caused by excessive front wheel side-to-side caster angle differences. ACTION: If a front axle alignment check shows excessive (more than 3/4 degree split) side-to-side caster angle difference causing the vehicle to drift or pull, install a new caster adjustment kit (E0TZ-3K064-A) which allows the front axle side-to-side caster angles to be changed up to 2-1/2 degrees in 1/2 degree increments. New front axle to radius arm brackets must also be replaced when the caster kit is installed. Refer to the following service procedure for step-by-step instructions. NOTE THE FOLLOWING INFORMATION BEFORE DOING WORK ON THE VEHICLE. To correct caster side-to-side difference of up to 1- 1/2 degrees, install a caster adjuster plate on the radius arm that has the lower caster reading. Adjuster plates are identified R.H. and L.H. To correct caster side-to-side difference more than 1-1/2 degrees, install the caster plate on both radius arms. Installing both plates will allow a caster split change of 2-1/2 degrees (+1-1/2 degrees on the low caster side, -1 degree on the high caster side). 1. Remove radius arm from vehicle. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 5606 Figure 14 - Article 87-4-16 2. Locate the template, included in the kit, on the bottom flange of radius arm over the existing holes, as shown in Figure 14. NOTE: Right arm adjustment is shown. One template is used to modify both right and left hand arms. When modifying right arm, position template with printed side down (printed side up for left arm). Figure 14 - Article 87-4-16 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 5607 Figure 15 - Article 87-4-16 Figure 16 - Article 87-4-16 3. With template secure, punch mark radius arm at the small hole in the template, as shown in Figures 14 and 15. Mark radius arm, and diegrind a slot at the axle attaching hole the same size as the slot in the template, see Figure 16. De-burr the surface; avoid rounding the edges of the slot. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 5608 Figure 13 - Article 87-4-16 4. Use a No. 6 drill to make a .204 inch diameter through hole at the punch mark. Line up the caster adjuster plate on the radius arm to obtain the required change in caster, see Figure 13. Figure 17 - Article 87-4-16 NOTE: Each hole changes caster approximately 1/2 degree + or - from the "0" index hole. 5. Install the tap screw to 120 in.lbs. (13 N-m) torque. 6. Reinstall radius arm with a new bracket (front axle to radius arm). The new bracket has a larger "jaw" spacing to fit over caster adjuster plate. ^ For non-quad shock vehicles, install bracket E7TZ-3B446-A. ^ For quad shock vehicles, install bracket E7TZ-18112-A, R.H. or E7TZ-18113-A, L.H. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 5609 Figure 18 - Article 87-4-16 7. Tighten upper stud/bolt to 240-260 ft.lbs. (325-352 N-m) torque, Figure 18. 8. Tighten lower bolt to 320-340 ft.lbs. (434-461 N-m) torque, Figure 18. 9. Tighten front axle radius arm bracket bolts to 20-26 ft.lbs. (27-35 N-m) torque, Figure 18. 10. Arc weld caster adjuster plate to radius arm with a 1/4 inch-long bead along two sides of the plate. 11. Reset toe to specification. PART NUMBER PART NAME CLASS E0TZ-3K064-A Caster Kit CG E7TZ-3B446-A Bracket - Radius Arm C E7TZ-18112-A Bracket - Radius Arm CG E7TZ-18113-A Bracket - Radius Arm CG OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual OPERATION: SP870416A - Caster kit one side TIME: 2.1 Hrs. OPERATION: SP870416B - Caster kit both sides TIME: 3.5 Hrs. DLR. CODING: Basic Part No. FRONT - Code: 07 Technical Service Bulletin # 86622 Date: 860326 Steering - Vehicle Drifting/Pulling Article No. 86-6-22 STEERING - DRIFT/PULL - RUBBER BALL SOCKET LINKAGE WIND-UP LIGHT TRUCK 1985-86 E, F SERIES, BRONCO Complaints of drifts and pulls on certain 1985-86 E, F Series and Bronco models may be caused by the installation procedure of the steering linkage. BECAUSE THE RUBBER TENDS TO RETURN TO ITS INSTALLED POSITION, IT IS IMPERATIVE THAT THE INSTALLATION BE ACCOMPLISHED WITH THE FRONT WHEELS AND THE PITMAN ARM IN THE STRAIGHT AHEAD POSITION, AND THE STUD SEATED IN THE TAPERED HOLE PRIOR TO TIGHTENING THE NUTS. Care should be taken with the installation to prevent a drift condition. To diagnose if a preload in the rubber is causing the drift, the following procedure is recommended: 1. Loosen the studs in the tapered holes at the pitman arm and the left and right spindles (i.e., disengage the stud from the hole so that it is no longer seated). 2. Hand install the nuts so that the stud is free to turn inside the tapered hole. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 5610 3. INSTALL COTTER PINS IN ALL THE STUDS. 4. Drive the vehicle. If it no longer drifts, then it can be assumed that the rubber was causing the drift. If it continues to drift, the condition is NOT being caused by the rubber ball sockets. 5. In either case, do not replace the steering linkage. Reinstall the linkage as follows: F Series and Bronco 1. Ensure the pitman arm and wheels are in the straight ahead position. (The pitman arm is exactly straight ahead when the clear vision is at 0~.) 2. Lock the steering wheel straight ahead and loose assemble the steering linkage to the pitman arm and then to the spindles. 3. Being careful not to change the position of the pitman arm, torque the steering linkage nuts to 65 ft.lbs. (88.1 N-m) The recommended sequence for tightening is: 1) the pitman arm, 2) the right side spindle and 3) the left side spindle. 4. Install all the cotter pins by advancing the nut to the next castellation. 5. Adjust the toe-in if necessary. Econoline 1. Ensure that the wheels are in the straight ahead position. 2. Loose assemble the steering linkage to the spindles and the pitman arm. 3. Being careful not to move the wheels from the straight ahead position, torque the steering linkage nuts to 65 ft.lbs. The recommended tightening sequence is: 1) the right side spindle, 2) the pitman arm and 3) the left side spindle. 4. Install all the cotter pins by advancing the nut to the next castellation. 5. Adjust the toe-in and reset the clear vision if necessary. The above procedure will eliminate any of the drift being caused by the rubber ball sockets. If the vehicle still drifts, refer to Section 19 of the Light Truck Shop Manual for further diagnosis. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION: SP3008A86A - F Series and Bronco TIME: 1.4 Hrs. OPERATION: SP3008A86B - Econoline TIME: 1.5 Hrs. DLR. CODING: Basic Part No. 3304 - Code: 36 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Camber Alignment: Specifications Camber Note: Side to side camber readings must be within 7 (degrees), when truck frame to axle riding height is such that right-hand side is from 0-.4 inch less than left-hand side. Ride Height 3-3.2 in -1 to +1/4 deg 3.2-3.4 in -3/4 to +3/4 deg 3.4-3.6 in -1/4 to +1 1/4 deg 3.6-3.8 in +1/4 to + 1 3/4 deg 3.8-4 in +3/4 to +2 deg 4-4.2 in +1 to +2 1/2 deg 4.2-4.74 in +1 1/2 to +3 deg 4.4-4.6 in +2 to +3 1/2 1/4 deg 4.6-4.8 in +2 1/2 to +4 deg Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Camber > Page 5613 Alignment: Specifications Caster Note: Side to side caster readings must be wintin 1 1/2 (degrees), when truck frame to axle riding height is such that right hand side is from 0 to .4 inch than left hand side. Ride Height 3-3.2 in +5 1/4 to 7 1/4 deg 3.2-3.4 in +5 to 7 deg 3.4-3.6 in 4 1/2 to 6 1/2 deg 3.6-3.8 in +4 1/4 to 6 1/4 deg 3.8-4.0 in +3 3/4 to 5 3/4 deg 4.0-4.2 in +3 1/4 to 5 1/4 deg 4.2-4.4 in +2 3/4 to 4 3/4 deg 4.4-4.6 in +2 1/2 to 4 1/2 deg 4.6-4.8 in +2 to 4 deg 4.8-5.0 in +1 1/2 to 3 1/2 deg Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Page 5614 Alignment: Service and Repair Fig. 1 Measuring Ride Height Fig. 7 Measuring riding height. 1980---85 F-100---350 & Bronco Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Page 5615 Fig. 8 Measuring Riding Height Prior to checking caster and camber, ensure vehicle front ride height is within {1/8} inch side to side 1980-87 E-100-350. On 1980-87 F-100-350 models, the left side ride height should be within 0-{3/8} inch higher than the right side ride height. On 1980-87 F-150-350 (4x4) and Bronco, the front ride heights should be within {3/16} inch side to side. Refer to Figs. 6, 7 and 8. If the vehicle ride heights are not within specifications, redistribute load on loaded vehicles or slightly load empty vehicles on one side. If the ride heights cannot be brought within specifications, verify correct spring installation. The ride height variations stated, are for checking purposes only. The vehicle does not have to operate within these specifications. Check and correct as necessary all tire inflation pressures, then check front tires for the same size, ply rating and load range. Check front wheel bearings and adjust as necessary. If all the above checks have been made, check wheel alignment with suitable alignment equipment. Using the ride heights obtained earlier, compare caster and camber readings to those listed in the ``Wheel Alignment Specifications Chart''. If the caster and camber angles exceed the specifications, inspect front end for damaged suspension components. Replace as necessary. Alignment equipment indicates a true reading only when the vehicle's frame is horizontal. Therefore, if the frame is not level (due to tire, spring or load differences), the caster angle reading must be modified to compensate for the frame angles. If the front is higher than the rear, subtract the amount of angle from the reading. If the front is lower than the rear, add the angle. To check frame angle, use a spirit protractor, and take the frame angle measurement on the lower frame flange at the flat area immediately adjacent to the rear spring front hanger. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Page 5616 Fig. 3 Camber Adjustment Fig. 4 Removing Caster/Camber Adjustment Sleeve Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Page 5617 Fig. 5 Caster/Camber Adjustment 1980-87 F-150-350 4 X 4 & BRONCO, 1982-87 F-100-350 4 X 2 W/BALL JOINTS The caster angle on 1981-87 F-250-350 4 x 4 models with leaf spring front suspension can be adjusted by inserting a shim between the spring and axle. Shims are available in increments of 0°, 1° and 2°. The 0° shim is used to adjust side to side ride height when an angled shim is installed on the opposite side of the axle. On all other models, the caster angle is designed into the axle and is not adjustable. The camber angle may be adjusted by means of mounting sleeves placed on the upper ball joint, Figs. 9, 10 and 11. Four sleeves are available in {1/2}° camber increments to allow a 3° range of adjustment from - 1 {1/2}° to +1 {1/2}°. TOE-IN, ADJUST Check the steering wheel spoke position when the front wheels are in the straight ahead position. If the spokes are not in the normal position, they can be adjusted while toe-in is being adjusted. 1. Loosen clamp bolts on each tie rod end sleeve. 2. Adjust toe-in. If steering wheel spokes are in their normal position, lengthen or shorten both rods equally to obtain correct toe-in. If spokes are not in normal position, make necessary rod adjustments to obtain correct toe-in and steering wheel spoke alignment. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Locations Power Steering Pressure Switch: Locations In Power Steering Hose, Near Steering Gear Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Locations > Page 5623 Power Steering Pressure Switch: Testing and Inspection Ford provides trouble code/symptom driven diagnostics for this component. For complete diagnosis and pinpoint testing, refer to Computers and Control Systems, Testing and Inspection. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Service and Repair Front Steering Knuckle: Service and Repair Spindle REMOVE 1. Raise the front of the vehicle and install safety stands. 2. Remove the wheel and tire assembly. 3. Remove the caliper assembly from the rotor and hold it out of the way with wire. 4. Remove the dust cap, cotter pin, nut retainer, nut, washer, and outer bearing, and remove the rotor from the spindle. 5. Remove inner bearing cone and seal. Discard the seal. 6. Remove brake dust shield. 7. Disconnect the steering linkage from the integral spindle and spindle arm by removing the cotter pin and nut and then removing the tie rod end from the spindle arm with TOOL 3290-C. 8. Remove the cotter pin from the upper and lower ball joint studs. Remove the nut from the upper ball joint stud. Loosen the lower nut to the end of the lower stud. 9. Strike the inside area of the spindle to pop the ball joints loose from the spindle. CAUTION: Do not use a pickle fork to separate the ball joint from the spindle as this will damage the seal and the ball joint socket. 10. Remove the spindle. INSTALL 1. Prior to assembly, make sure the upper and lower ball joint seals are in place. 2. Place the spindle over the ball joints. 3. Install the nut on the lower ball joint stud and partially tighten to 41 Nm (30 ft lb). 4. Install the camber adapter in the upper spindle over the upper ball joint stud. Be sure the adapter is aligned properly. If camber adjustment is necessary, special adaptors must be installed. 5. Install the nut on the upper ball joint stud. Hold the camber adaptor with a wrench to keep the ball stud from turning. If the ball stud turns, tap the adaptor lightly into the spindle. Tighten the nut to 116-136 Nm (85-101 ft lbs) and continue tightening the castellated nut until it lines up with the hole in the stud. Install the cotter pin. 6. Retighten lower nut to 190-244 Nm (140-180 ft lb). 7. Install the dust shield. 8. Pack the inner and outer bearing cone with a lithium-base grease, Multi-Purpose Long-Life Lubricant, C1AZ-19590-B (ESA-M1C75-B) or equivalent. Use a bearing packer. If a bearing packer is unavailable, pack the bearing cone by hand working the grease through the cage behind the rollers. 9. Install the inner bearing cone and seal. Install the hub and rotor on the spindle. 10. Install the outer bearing cone, washer, and nut. Adjust bearing end play and install the nut retainer, cotter pin and dust cap. 11. Install the caliper. 12. Connect the steering linkage to the spindle. Tighten the nut to 94-135 Nm (70-100 ft lbs) and advance the nut as required for installation of the cotter pin. 13. Install the wheel and tire assembly. 14. Lower the vehicle. 15. Check and, if necessary adjust the toe setting. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Bleeding > System Information > Service and Repair Power Steering Bleeding: Service and Repair Four factors affect power operation of the steering system: fluid level and condition, drive belt tension, pump pressure and steering gear adjustment. These should always be checked before any major service operations are performed. Conditions such as, hard or loose steering, road shock or vibrations are not always due to steering gear or pump, but are often related instead to such factors as low tire pressure and front end alignment. These factors should be checked and corrected before any adjustment of the steering gear is made. CHECKING FLUID LEVEL 1. Run engine to normal operating temperature, then shut it off. Remove reservoir filler cap and check oil level on dipstick. Level should be up to ``Full'' mark on dipstick. 2. If level is low, add power steering fluid to proper level on dipstick and replace filler cap. When adding less than one pint of fluid, it is permissible to use automatic transmission fluid. When adding larger quantities or when making a complete fluid change, it is recommended that special power steering fluid be used. 3. When checking fluid level after system has been serviced, air must be bled from the system as outlined under ``Bleeding System.'' BLEEDING SYSTEM 1. With wheels turned all the way to the left, add the recommended fluid to the ``Add'' mark on dipstick. 2. Start engine. While running at fast idle, recheck fluid level and, if necessary, add fluid to the ``Add'' mark on dipstick. 3. Bleed system by turning wheels from side to side without hitting stops. Maintain fluid level just above internal pump casting. Fluid with air in it will have a light tan appearance. This air must be eliminated from fluid before normal steering action can be obtained. 4. Return wheels to center position and continue to run engine for two or three minutes, then shut it off. 5. Road test vehicle to make sure steering functions normally and is free from noise. 6. Recheck fluid level, making sure level is at the ``Full'' mark. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Removal and Installation Power Steering Pump: Service and Repair Removal and Installation F-100---350 & BRONCO 1. Disconnect return hose from pump reservoir and drain steering pump fluid into a suitable container. 2. Remove pressure hose from pump. 3. Remove pump drive belt, then unfasten pump and adjusting bracket from support bracket. Remove pump pulley, then the pump attaching bolts and pump. 4. Reverse procedure to install. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Removal and Installation > Page 5636 Power Steering Pump: Service and Repair Disassembly Fig. 1 Exploded view of Ford Model CII power steering pump Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Removal and Installation > Page 5637 Fig. 2 Positioning Pump In C-Clamp Fig. 2 Positioning Pump In C-Clamp 1. Remove pulley from pump. 2. Remove outlet fitting, flow control valve and flow control valve spring from pump, then remove reservoir, Fig. 1. 3. Place a suitable C-clamp in a vise. 4. Position lower support plate T78P-3733-A2 over pump rotor shaft. 5. Install upper compressor plate T78P-3733-A1 into upper portion of C-clamp. 6. While holding compressor tool, place pump assembly into C-clamp with rotor shaft facing downward, Fig. 2. 7. Tighten C-clamp until a slight bottoming of valve cover is observed. 8. Through small hole located on side of pump housing, insert a suitable drift and push inward on valve cover snap ring. While pushing inward on snap ring, place a screwdriver under snap ring edge and remove ring from housing, Fig. 3. 9. Loosen C-clamp and remove upper compressor plate T78P-3733-A2, then remove pump assembly. 10. Remove pump valve cover and O-ring. 11. Remove rotor shaft, upper plate, cam and rotor assembly and two dowel pins. 12. Remove lower plate and spring, by tapping housing on a flat surface. 13. Using a suitable screwdriver, remove rotor shaft seal. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Removal and Installation > Page 5638 Power Steering Pump: Service and Repair Assembly Fig. 1 Exploded view of Ford Model CII power steering pump Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Removal and Installation > Page 5639 Fig. 4 Installing Slipper Springs Fig. 5 Installing Slippers 1. Position rotor on rotor shaft splines with triangle detent on rotor counter bore facing upward. 2. Install snap ring into groove on end of rotor shaft, Fig. 1. 3. Position insert cam over rotor. Ensure recessed notch on insert cam is facing upward. 4. With rotor extended upward approximately half out of cam, insert spring into rotor picket, Fig. 4. 5. Use a slipper to compress spring, then install slipper with groove facing cam, Fig. 5. 6. Perform steps 4 and 5 on slipper cavity beneath opposite inlet recess. 7. While holding cam stationary, index rotor left or right one space and install another spring and slipper until all ten rotor cavities have been filled. Ensure rotor springs and slippers remain in position while turning. 8. Apply Loctite No. 242 or 271 adhesive or equivalent to outside diameter of seal and Lockquick NF or T primer or equivalent to seal bore in housing. Install rotor shaft seal using tool No. T78P-3733-A3. Using a plastic mallet, drive seal into bore until properly seated. 9. Position pump plate on flat surface with pulley side facing downward. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Removal and Installation > Page 5640 10. Install two dowel pins and spring into housing. Spring must be inserted with dished surface facing upward. 11. Lubricate inner and outer O-ring seals with power steering fluid, then install seals on lower pressure plate. 12. Install lower pressure plate into housing and over dowel pin with O-ring seals facing toward front of pump. Position assembly on C-clamp. Place tool No. T78P-3733-A3 into rotor shaft hole and press on lower plate lightly until it bottoms in pump housing. This will seat the outer O-ring seal. Upper Pressure Plate Installation Fig. 8 Installing Valve Cover Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Removal and Installation > Page 5641 Fig. 6 Assembling Cam, Slippers And Rotor 13. Install cam, rotor, rotor and slippers and rotor shaft assembly into pump housing over dowel pins. When installing assembly into pump housing,stepped holes must be used for dowel pins and notch in cam insert must be toward reservoir and approximately 180 degrees opposite square mounting lug on housing, Fig. 6. 14. Position upper pressure plate over dowel pins with recess directly over recessed notch on cam insert and approximately 180 degrees opposite square mounting lug, Fig. 7. 15. Lubricate O-ring seal with power steering fluid. Then, position O-ring on valve cover. Ensure plastic baffle is securely in position on valve cover. A coat of petroleum jelly may be used to hold baffle in position. 16. Insert valve cover over dowel pins. Ensure outlet fitting hole in valve cover is aligned with square mounting lug on housing, Fig. 8. 17. Place assembly in C-clamp and compress valve cover into pump housing until snap ring groove on housing is exposed. 18. Install valve cover snap ring in pump housing. Ensure snap ring ends are near access hole in pump housing. 19. Remove pump assembly from C-clamp. 20. Lubricate O-ring seal with power steering fluid, then place seal on pump housing. 21. Install reservoir on pump housing. 22. Install flow control valve and spring into valve cover. 23. Lubricate O-ring seals with power steering fluid, then place seals on outlet fitting. 24. Install outlet fitting on valve cover. Torque outlet fitting to 25---34 ft. lbs. Use care not to cock flow control valve when installing. Do not force valve forward otherwise damage to housing may result. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Removal and Installation > Page 5642 Power Steering Pump: Service and Repair Vane Type Pump W/ Integral Reservoir Disassembly Fig. 1 Vane type power steering pump w/integral reservoir disassembled (typical) Fig. 2 Removing end plate retaining ring Fig. 3 Removing flow control valve & spring Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Removal and Installation > Page 5643 Fig. 4 Thrust plate & rotor installed on driveshaft 1. Referring to Fig. 1, carefully mount pump in vise with soft jaws and remove reservoir cap. When clamping pump in vise, do not exert excessive force on front hub as this may distort drive shaft bushing in housing. 2. Remove rear pump mounting stud and O-ring seal, pressure union and O-ring seal. 3. Remove reservoir, and second pressure union O-ring seal. 4. Using a small punch, depress end plate retaining ring enough to allow removal from groove. Use the {1/8} inch diameter hole in housing, Fig. 2. Then remove retaining ring with screwdriver. 5. Remove end plate which is spring loaded and usually sits above housing level. If end plate sticks, a slight rocking action should free it. If rocking action fails to free plate, use a magnet. 6. Remove two pressure springs from pump housing. 7. Remove flow control valve and spring by inverting housing. Do not disassemble flow control valve as it is serviced as a unit and pre-set at the factory, Fig. 3. 8. Remove drive shaft key from slot in shaft. Then with end of shaft pointed downward, press down until shaft is free. 9. Turn assembly over and remove drive shaft and rotary group. 10. Remove rotor retaining ring from groove in drive shaft. Remove rotor and thrust plate from shaft, Fig. 4. 11. Remove and discard O-ring seals from pump housing. Remove driveshaft oil seal only if inspection shows necessity for replacement. Inspection 1. Clean all parts except the drive shaft oil seal in cleaning fluid. The seal will be damaged if immersed in cleaning fluid. 2. Check fit of vanes in slots of rotor for tightness or excessive looseness. Vanes must fit snugly but slide freely in slots in rotor. Tight fit of vanes in rotor can usually be corrected by thorough cleaning. Replace rotor if excessive looseness exists between rotor and vanes. Replace vanes if worn or scored. 3. Examine machined surfaces of pump ring for roughness or wear. Replace ring if roughness cannot be corrected with crocus cloth. 4. Inspect thrust plate, pressure plate and end plate for wear, scores or other damage. 5. Inspect pump housing for cracks or damage. Check housing for evidence of wear or scoring. 6. Check all springs for free length, distortion or collapsed coils. 7. Inspect located dowel pins for distortion. 8. Examine outer diameter of flow control valve for scoring or roughness. Slight damage may be cleaned up with crocus cloth. Check valve assembly for freedom of movement in bore of pump housing. 9. Check all oil passages in pump parts for obstruction. Use a piece of tag wire to clean out holes. 10. Check bushing in pump housing for wear or damage. Assembly Fig. 4 Thrust plate & rotor installed on driveshaft Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Removal and Installation > Page 5644 Fig. 5 Installing driveshaft assembly Fig. 6 Installing pump ring Fig. 7 Installing rotor vanes 1. Lubricate new O-ring seals with Vaseline and place in pump housing. 2. If drive shaft oil seal was removed during disassembly, lubricate new seal with Vaseline. Then install seal in pump body front hub, using a suitable seal driver. 3. Position thrust plate and rotor on drive shaft. Then install rotor retaining ring in groove of drive shaft, Fig. 4. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Removal and Installation > Page 5645 4. Place pump housing on work bench as shown in Fig. 5 and install two pump ring dowel pins in bore of housing. 5. Install drive shaft in housing, making sure shaft seats properly. 6. Install pump ring in housing over two dowel pins with rotation arrow on ring to rear of pump housing, Fig. 6.Arrow on outer edge of pump ring points in direction of pump rotation (counterclockwise when viewed from rear of pump). 7. Install rotor vanes in slots of pump rotor, with radius edge of vanes toward outside of rotor, Fig. 7. Fig. 8 Installing pressure plate Fig. 9 Installing pressure plate springs 8. Position pump housing on two wood blocks and push parts down into place as shown in Fig. 8. 9. Lubricate outside diameter and chamfer of pressure plate with Vaseline to insure against damage to O-ring seals in housing. Then install pressure plate in housing over dowel pins.Ported face of pressure plate goes toward pump ring, Fig. 8. 10. Using a 2{3/4} inch diameter sleeve to apply pressure to outer edge of pressure plate only, press pressure plate into seat. Pressure plate will travel about {1/16} inch to seat. Do not press or hammer on center of pressure plate as to do so will cause permanent distortion resulting in pump failure. 11. Install two pressure plate springs, one over each dowel pin in pump housing, Fig. 9. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Removal and Installation > Page 5646 Fig. 10 Installing end plate & retaining ring Fig. 11 Installing flow control valve & spring Fig. 12 Installing pressure union O-ring seal 12. Lubricate outside diameter and chamfer of end plate with Vaseline to insure against damage to O-ring seal in housing. Then press end plate into housing. While holding end plate down in housing, install end plate retaining ring. Be sure end plate is completely and solidly seated in groove of housing, Fig. 10. 13. Remove assembly from press and place on work bench. Install flow control spring and valve in bore of housing. Make sure hex head screw goes into housing bore, Fig. 11. 14. Position pressure union O-ring seal in bore of housing over flow control valve, Fig. 12. 15. Mount pump housing in vise with soft jaws and install reservoir. 16. Install pressure union and new O-ring seal in reservoir. Tighten union. 17. Install mounting stud and new O-ring seal in reservoir. Tighten stud. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Removal and Installation > Page 5647 18. Install drive shaft key in slot in shaft. Support shaft on opposite side while installing key. Install reservoir cap. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Removal and Installation > Page 5648 Power Steering Pump: Service and Repair Vane Type Pump, Less Integral Reservoir Fig. 1 Vane type power steering pump, less integral reservoir disassembled Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Removal and Installation > Page 5649 Fig. 2 Removal & installation of return tube, control valve, driveshaft, ball bearing assembly & driveshaft seal Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Removal and Installation > Page 5650 Fig. 3 Removal & installation of rotating group Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Removal and Installation > Page 5651 Fig. 4 Removal & installation of sleeve assembly Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Locations Power Steering Pressure Switch: Locations In Power Steering Hose, Near Steering Gear Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Locations > Page 5656 Power Steering Pressure Switch: Testing and Inspection Ford provides trouble code/symptom driven diagnostics for this component. For complete diagnosis and pinpoint testing, refer to Computers and Control Systems, Testing and Inspection. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Component Information > Service Precautions Steering Column: Service Precautions When the steering column is installed in the vehicle it is not susceptible to damage through ordinary use; however, when it is removed, care must be taken during handling. Such actions as a sharp blow on the end of the steering shaft or shift levers, leaning on the column assembly or dropping of the assembly could loosen or shear the plastic shear joints or rivets used to maintain column rigidity. Hammering, jolting or bumping on the steering shaft and gearshift tube must be avoided during all service operations. If the shear pins are broken, the controlled length of the telescoping design will be altered making these components unfit for further service. When removing the steering wheel, only a steering wheel puller designed for this purpose must be used. It is important that only the specified screws, bolts and nuts be used during the assembly procedure and torqued to specifications to insure proper breakaway action of the column under impact. Avoid using excessively long bolts or fasteners as they may prevent a portion of the steering column from collapsing. When replacing fasteners, replace with ones of the same part number or equivalent. When removing or installing the steering wheel, ignition switch, lock cylinder, turn signal switch, neutral start switch, back-up light switch or adjusting column shift manual transmission linkage refer to the appropriate vehicle chapter. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Component Information > Service Precautions > Page 5660 Steering Column: Description and Operation ENERGY ABSORBING STEERING COLUMNS The energy absorbing function of the steering column allows the column to collapse at a controlled rate during a severe collision. The collapsing action reduces the possibility of the steering wheel being driven rearward towards the driver. If the driver is thrown forward into the steering wheel, the column can collapse even further at the same controlled rate, thereby reducing the force of impact. Several designs of steering column jackets are used. There is the slip-tube design which is held together with plastic inserts or rivets that shear upon impact and allow the column to collapse. And there is the slotted or corrugated mesh design and bellows type design which shorten in length during impact. The shift tube is a two piece design which is held together by injections of plastic that form the interconnecting inserts and shear pins. Under impact, there is a gradual paring away of the inserts by the knife-like edge in the adjoining tube section. The steering shaft is a two piece assembly. The upper piece is solid and has a double flattened lower end. The lower piece is hollow and formed to fit over the double flattened section of the upper piece. The purpose of the double flattened section is to provide continued steering action even though the shaft is completely collapsed. Upon impact, the shear pins break off and the shaft gradually telescopes against resistance provided by the plastic injections. The steering column mounting bracket prevents the column from being shifted towards the driver during impact. It uses two ``breakaway capsules'' that allow the mounting bracket to slip off its attaching points, allowing the steering column to compress or yield in a forward direction under a severe impact from the driver's end. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Component Information > Service and Repair > Removal and Installation Steering Column: Service and Repair Removal and Installation 1980-87 BRONCO & F100-350 SERIES Removal 1. Apply parking brake and disconnect battery ground cable. 2. Remove bolt and nut attaching intermediate shaft to steering column. 3. Disconnect shift linkage rod(s) from column. 4. Remove screws from underneath steering wheel, then lift horn switch assembly from steering wheel. 5. Disconnect horn switch wires by pulling spade terminal from blade connectors, then squeeze J-clip ground wire terminal and pull it out of hole in steering wheel. 6. Remove horn switch assembly, then the steering wheel retaining nut. 7. Using suitable puller, remove steering wheel from shaft. When servicing a tilt steering column, the steering wheel must be in the full ``UP'' position when removed. 8. Remove steering column floor opening cover plate screws. 9. Remove shroud by loosening screw at bottom, selecting position ``1'' on manual 3 speeds and automatics and spreading shroud open, and withdrawing out of instrument panel opening while pulling up and away from column. 10. On vehicles with automatic transmission, remove shift lever cable. 11. Remove instrument panel column opening cover. 12. Remove column support bracket to pedal support bracket attaching bolts. 13. Disconnect turn signal/hazard warning and ignition switch wiring harnesses. 14. Remove column from vehicle, then the column support bracket from column. Installation 1. Attach steering column support bracket, ensuring that turn signal/hazard warning wiring is on outboard side of column, torquing nuts to 13-38 ft. lbs. 2. Hand start floor opening cover plate clamp bolt and press plate until clamp flats abut stops on column outer tube. 3. Load column into vehicle through opening in floor. 4. Connect turn signal/hazard warning and ignition switch wiring harnesses. 5. Raise column to pedal support bracket and hand start two bolts. 6. Fasten floor opening cover plate to floor, torquing screws to 6-10 ft. lbs. 7. Torque two support bracket bolts to 19-27 ft. lbs. and the cover plate clamp bolt to 8-18 ft. lbs. 8. On vehicles with automatic transmission, install and adjust shift lever cable. 9. Install instrument panel steering column opening cover. 10. Mount shroud by selecting position ``1'' on 3 speed manuals and automatics, spreading shroud around steering column and through opening in instrument panel. Post on interior will index shroud when properly positioned. 11. Torque screw at bottom of shroud to 10-15 inch lbs. 12. Attach shift linkage rod(s) to column. 13. Connect intermediate shaft to steering column, torquing bolts to 45-59 ft. lbs. on 1980-85 models and 35-50 ft. lbs. on 1986-87 models 14. Position steering wheel into place with retaining nut, then torque nut to 30-40 ft. lbs. 15. Connect spade terminal of horn switch wire to blade connector and press J-clip ground terminal fully into threaded hole. 16. Center horn switch on steering wheel and install attaching screws. 17. Connect battery ground cable. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Component Information > Service and Repair > Removal and Installation > Page 5663 Steering Column: Service and Repair Disassembly Non-Tilt Column Fig. 1 Exploded view of non-tilt steering column. 1980---87 Bronco & F100-350 Series w/3 speed man. trans. Fig. 2 Exploded view of non-tilt steering column. 1980---87 Bronco & F100-350 Series w/4 speed man. trans. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Component Information > Service and Repair > Removal and Installation > Page 5664 Fig. 3 Exploded view of non-tilt steering column. 1980---87 Bronco & F100-350 Series w/auto. trans. 1. Remove turn signal lever. 2. On vehicles equipped with 3 speed manual or automatic transmission, drive out pivot pin and remove hand shift lever. 3. Partially withdraw turn signal/hazard warning switch, and key warning buzzer terminal if equipped, from upper flange, Figs. 1, 2 and 3. 4. Remove snap ring from upper steering shaft. 5. Remove lower bearing retainer from bottom of steering column. 6. Using suitable tool, gently tap steering shaft out of bottom of steering column. Harsh impacts at either end of shaft may alter shaft in overall length, adversely affecting assembly. 7. On 1982 vehicles equipped with automatic transmission, remove shift tube retaining screw from bottom of shift socket. 8. On 1983-87 vehicles equipped with automatic transmission, drill out shift tube retaining rivet from bottom of shift socket. 9. On vehicles equipped with 3 speed manual or automatic transmission, withdraw shift tube assembly from bottom of column. 10. On all vehicles, clip ignition switch in lock position and remove ignition switch and actuator rod. 11. On E100-350 equipped with automatic transmission, remove PRNDL21 hood and lens assembly. 12. On all vehicles, loosen upper flange retaining nuts until only 1 or 2 threads remain engaged, then pinch nuts toward each other and withdraw upper flange from outer tube. 13. On vehicles equipped with 3 speed manual or automatic transmission, remove shift socket from outer tube. 14. On vehicles equipped with 4 speed manual transmission, remove flange extension from outer tube. 15. Remove upper bearing and insulator cover from upper flange by gently tapping from opposite side. 16. Remove flange retaining bolts and nuts. 17. On vehicles with manual transmission, remove snap ring from lock release lever assembly. 18. On vehicles equipped with manual transmission, remove lock release lever assembly through hole on front of flange and remove spring from assembly. 19. On vehicles equipped with automatic transmission, remove PRNDL21 insert from front of flange. 20. On all vehicles, place lock cylinder in ``Run'' position and remove retaining pin, then remove lock cylinder from flange. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Component Information > Service and Repair > Removal and Installation > Page 5665 Fig. 11 Lower Bearing Retainer 21. Remove lock bearing snap ring, then the lock bearing. 22. Remove lock drive gear through lock cylinder opening, then the lock actuator assembly and lock actuator insert. 23. On E100-350, disassemble steering column lower bearing retainer subassembly as follows: a. Remove steering column lower bayonet flange and leaf spring, Fig. 10. Do not loosen leaf spring. b. Remove lower bearing shaft clamp, bolt, and nut. c. Remove 3 screws and the lower bearing assembly. d. Remove split retainer sleeve from lower bearing retainer assembly. 24. On vehicles equipped with 3 speed manual transmission, disassemble shift tube subassembly as follows: a. Hold shift tube above spring and push up and rotate lower shift arm until loading slot in arm aligns with lower key. b. Remove lower arm and lower spacer. c. Rotate upper shift arm until loading slot in arm aligns with lower key,then remove upper arm and upper spacer. d. Remove and discard shift arm grommets. Tilt Column Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Component Information > Service and Repair > Removal and Installation > Page 5666 Fig. 6 Exploded view of tilt steering column (typical). 1980---87 exc. Aerostar, Bronco II & 1983---87 Ranger Fig. 7 Removing wire bale & tilt locking lever Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Component Information > Service and Repair > Removal and Installation > Page 5667 Fig. 8 Removing flange assembly pivot pins 1. Remove steering wheel and steering column, Fig. 6, from vehicle. 2. Remove turn signal actuator lever. 3. On models equipped with automatic transmission, drive out pivot pin and remove shift lever. 4. On 1980-S81 E100-S350 models, remove steering shaft lower flange and retaining clamp. 5. On all models, remove lower bearing retainer. 6. On models equipped with automatic transmission, remove shift tube retaining screw from bottom of shift socket, then slide shift tube out of bottom of column. 7. On all models, remove lock drive gear. 8. Remove turn signal switch attaching screws, then the wiring harness-to-steering column tube clips, if necessary. 9. Remove turn signal switch and harness from steering column. 10. Remove cover casting screws, then the casting from column. 11. Unhook and remove upper actuator from lower actuator. 12. Remove and discard lower flange-to-outer tube attaching screws. 13. Loosen ignition switch nut and washer assemblies and remove ignition rod from switch end. 14. Remove tilt mechanism, steering shaft and ignition actuation rod from steering column upper end. 15. On models equipped with automatic transmission, remove shift socket, then the shift lever indicator ring. 16. On models equipped with manual transmission, remove flange extension, then the key release lever mechanism from tilt mechanism. 17. On all models, remove spring clips holding wire bale, then the bale, Fig. 7. 18. Drive out pin holding locking lever, then remove the lever and spring. 19. Remove column upper shaft snap ring. 20. Remove two pivot pins from side of casting assembly, then separate upper and lower flange castings, Fig. 8. If pivot pins fit loosely in the lower flange, the pins must be discarded. 21. Position flange casting on suitable workbench with smaller bearing facing down. 22. Lightly tap on outer race of small bearing at each slot, using a small drift, and remove race and bearing. 23. Invert flange casting and repeat step 22 on large bearing. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Component Information > Service and Repair > Removal and Installation > Page 5668 Steering Column: Service and Repair Assembly Non-Tilt Column 1. On vehicles equipped with 3 speed manual transmission, place bushing in socket retainer in outer tube. 2. On vehicles equipped with 3 speed manual transmission, place bushing on upper hub and wave washer on lower hub of shift socket. 3. On vehicles equipped with 3 speed manual or automatic transmission, install shift socket in outer tube. 4. On vehicles equipped with 4 speed manual transmission, install flange extension on outer tube. 5. Install lock actuator insert in rear of flange and torque screw to 15---25 inch lbs. 6. Insert lock actuator assembly through opening in front of flange until it bottoms against insert. 7. Install lock drive gear through lock cylinder opening so that last gear tooth aligns with last tooth on actuator assembly when actuator is fully rearward. 8. Install lock bearing, then the lock bearing snap ring. 9. Place lock cylinder in ``ON'' position and depress retaining pin, then insert lock cylinder into flange. 10. On vehicles equipped with automatic transmission, attach PRNDL21 insert to front of flange. 11. On vehicles equipped with manual transmission, position spring on lock release lever assembly and position lever assembly through hole in front of flange, then tighten spring until lever assembly drops into place. 12. On vehicles equipped with manual transmission, install snap ring on lock release lever assembly. 13. On all vehicles, install flange retaining bolts through holes in flange and hand start nuts 1 to 2 threads. 14. On vehicles equipped with automatic transmission, place wave washer in flange hub. 15. Install subassembled flange onto outer tube by pinching nuts toward each other and pressing flange in place, then torque nuts to 60---75 inch lbs. 16. On vehicles equipped with 3 speed manual transmission, assemble shift tube assembly as follows: a. Install grommets in shift tube, small end facing up. b. Stack upper spacer, upper arm, lower spacer, and lower arm concentrically in order so that loading slots align. c. Press entire stack through common loading slot on shift tube, then rotate stack components individually until arms are aligned with their keyways on shift key and spacers allow shift key to pass freely through operating slots. 17. On vehicles with 3 speed manual transmission, load shift tube assembly through lower opening of column. 18. On vehicles equipped with automatic transmission, install shift tube retaining rivet through bottom of shift socket. 19. On all vehicles, install steering shaft clip below knurl for upper bearing. 20. On Bronco and F100-350, ensure that shaft assembly length is 35.6 inches, adjusting as necessary by tapping gently in appropriate direction. 21. Load shaft through bottom of column, being careful not to collapse steering shaft on Bronco and F100-350. 22. Place cover insulator onto upper bearing and press onto knurl of steering shaft until snap ring groove is visible above bearing. 23. Install snap ring on steering shaft in groove above bearing. 24. Install turn signal/hazard warning switch, torquing screws to 15---25 inch lbs. 25. On E100-350, subassemble lower bearing retainer assembly as follows: a. Install split retainer sleeve into lower bearing retainer assembly with sleeve shoulder against bearing. b. Loosely assemble clamp, bolt, and nut to lower bearing retainer assembly, ensuring that bolt aligns with round groove in split retainer sleeve. c. Push split retainer sleeve shoulder down and push clamp toward bearing, and torque clamp nut to 9-18 ft. lbs. 26. On Bronco and F100-350, install lower bearing retainer, ensuring that centerline of coupling shaft attachment hole extends .8 inch below lower face of retainer, and torque screws to 12-20 inch lbs. 27. On E100-350, install lower bearing retainer and telescope steering column lower bayonet shaft fully toward lower end of column. 28. Install ignition switch actuator rod. 29. Install ignition switch and hand start retaining nuts with lock cylinder in lock position. 30. Torque switch retaining nuts to 40-65 inch lbs. and remove clip. 31. Install hand shift lever and secure by driving in pivot pin. 32. Install turn signal switch lever, torquing screws to 30---45 inch lbs. AEROSTAR, BRONCO II & 1983-87 RANGER Tilt Column Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Component Information > Service and Repair > Removal and Installation > Page 5669 Fig. 6 Installing Flange Assembly Pivot Pins 1. Position flange casting on suitable work bench with large bearing seat facing up. 2. Place large upper bearing over seat with open side facing inward. Position a suitable socket on bearing outer race and lightly tap socket until bearing is seated. Use care to avoid contacting bearing inner race as damage will result. 3. Invert flange casting and repeat step 2 on small bearing. 4. Install lower actuator with ignition switch rod attached. 5. Install upper and lower flanges with pivot pins. Ensure column position spring is seated properly between upper and lower flange and wavy thrust washer is properly positioned between lower flange and socket. 6. Install column upper shaft snap ring. 7. Install locking lever, spring and lever pin. 8. Position wire bale on upper casting and install spring clips, Fig. 9. 9. On models equipped with automatic transmission, install shift lever indicator ring on tilt mechanism. Torque attaching screws to 10-20 inch lbs., then install shift socket. 10. On models equipped with manual transmission, attach key release mechanism to tilt mechanism, then install flange extension and torque attaching screws to 10-20 inch lbs. 11. On all models, install tilt mechanism. Feed steering shaft down center of column and ignition actuation rod through shift socket/flange extension along top of column outer tube. 12. Install flange retainer assemblies. Use new screws and torque to 50-68 inch lbs. 13. Install lower bearing retainer, then loosely attach ignition switch to outer tube. 14. Connect upper and lower actuators, then install column cover. Torque cover attaching screws to 40-50 inch lbs. 15. Position turn signal switch and wiring harness in steering column. Attach wiring harness to steering column tube clips, if necessary. 16. Install turn signal switch attaching screws and torque to 20-30 inch lbs. 17. Install turn signal lever, then the lock drive gear. 18. Install lock cylinder with key in ``On'' position. Ensure retaining pin is flush with cylinder. 19. On models equipped with automatic transmission, install shift lever and pivot pin. 20. On all models, install steering column. 1982-87 BRONCO, E100-350 & F100-350 SERIES, NON-TILT STEERING COLUMN Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Sector Shaft > Component Information > Adjustments Sector Shaft: Adjustments PITMAN SHAFT OVERCENTER PRELOAD 1. Perform steps 1 through 3 of ``Worm Bearing Preload, Adjust'' procedure. 2. Rotate worm shaft from one extreme to the other while counting total number of turns. Turn worm shaft back halfway to center gear. 3. Using inch pound torque wrench, rotate worm shaft approximately 90 degrees across center. Highest reading should be within specifications listed at end of section. Turn sector shaft adjusting screw until proper specification is obtained. 4. Hold sector shaft adjusting screw and tighten locknut to 25 ft. lbs. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Technical Service Bulletins > Customer Interest for Tie Rod End: > 86622 > Mar > 86 > Steering - Vehicle Drifting/Pulling Tie Rod End: Customer Interest Steering - Vehicle Drifting/Pulling Article No. 86-6-22 STEERING - DRIFT/PULL - RUBBER BALL SOCKET LINKAGE WIND-UP LIGHT TRUCK 1985-86 E, F SERIES, BRONCO Complaints of drifts and pulls on certain 1985-86 E, F Series and Bronco models may be caused by the installation procedure of the steering linkage. BECAUSE THE RUBBER TENDS TO RETURN TO ITS INSTALLED POSITION, IT IS IMPERATIVE THAT THE INSTALLATION BE ACCOMPLISHED WITH THE FRONT WHEELS AND THE PITMAN ARM IN THE STRAIGHT AHEAD POSITION, AND THE STUD SEATED IN THE TAPERED HOLE PRIOR TO TIGHTENING THE NUTS. Care should be taken with the installation to prevent a drift condition. To diagnose if a preload in the rubber is causing the drift, the following procedure is recommended: 1. Loosen the studs in the tapered holes at the pitman arm and the left and right spindles (i.e., disengage the stud from the hole so that it is no longer seated). 2. Hand install the nuts so that the stud is free to turn inside the tapered hole. 3. INSTALL COTTER PINS IN ALL THE STUDS. 4. Drive the vehicle. If it no longer drifts, then it can be assumed that the rubber was causing the drift. If it continues to drift, the condition is NOT being caused by the rubber ball sockets. 5. In either case, do not replace the steering linkage. Reinstall the linkage as follows: F Series and Bronco 1. Ensure the pitman arm and wheels are in the straight ahead position. (The pitman arm is exactly straight ahead when the clear vision is at 0~.) 2. Lock the steering wheel straight ahead and loose assemble the steering linkage to the pitman arm and then to the spindles. 3. Being careful not to change the position of the pitman arm, torque the steering linkage nuts to 65 ft.lbs. (88.1 N-m) The recommended sequence for tightening is: 1) the pitman arm, 2) the right side spindle and 3) the left side spindle. 4. Install all the cotter pins by advancing the nut to the next castellation. 5. Adjust the toe-in if necessary. Econoline 1. Ensure that the wheels are in the straight ahead position. 2. Loose assemble the steering linkage to the spindles and the pitman arm. 3. Being careful not to move the wheels from the straight ahead position, torque the steering linkage nuts to 65 ft.lbs. The recommended tightening sequence is: 1) the right side spindle, 2) the pitman arm and 3) the left side spindle. 4. Install all the cotter pins by advancing the nut to the next castellation. 5. Adjust the toe-in and reset the clear vision if necessary. The above procedure will eliminate any of the drift being caused by the rubber ball sockets. If the vehicle still drifts, refer to Section 19 of the Light Truck Shop Manual for further diagnosis. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION: SP3008A86A - F Series and Bronco TIME: 1.4 Hrs. OPERATION: SP3008A86B - Econoline TIME: 1.5 Hrs. DLR. CODING: Basic Part No. 3304 - Code: 36 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tie Rod End: > 86622 > Mar > 86 > Steering - Vehicle Drifting/Pulling Tie Rod End: All Technical Service Bulletins Steering - Vehicle Drifting/Pulling Article No. 86-6-22 STEERING - DRIFT/PULL - RUBBER BALL SOCKET LINKAGE WIND-UP LIGHT TRUCK 1985-86 E, F SERIES, BRONCO Complaints of drifts and pulls on certain 1985-86 E, F Series and Bronco models may be caused by the installation procedure of the steering linkage. BECAUSE THE RUBBER TENDS TO RETURN TO ITS INSTALLED POSITION, IT IS IMPERATIVE THAT THE INSTALLATION BE ACCOMPLISHED WITH THE FRONT WHEELS AND THE PITMAN ARM IN THE STRAIGHT AHEAD POSITION, AND THE STUD SEATED IN THE TAPERED HOLE PRIOR TO TIGHTENING THE NUTS. Care should be taken with the installation to prevent a drift condition. To diagnose if a preload in the rubber is causing the drift, the following procedure is recommended: 1. Loosen the studs in the tapered holes at the pitman arm and the left and right spindles (i.e., disengage the stud from the hole so that it is no longer seated). 2. Hand install the nuts so that the stud is free to turn inside the tapered hole. 3. INSTALL COTTER PINS IN ALL THE STUDS. 4. Drive the vehicle. If it no longer drifts, then it can be assumed that the rubber was causing the drift. If it continues to drift, the condition is NOT being caused by the rubber ball sockets. 5. In either case, do not replace the steering linkage. Reinstall the linkage as follows: F Series and Bronco 1. Ensure the pitman arm and wheels are in the straight ahead position. (The pitman arm is exactly straight ahead when the clear vision is at 0~.) 2. Lock the steering wheel straight ahead and loose assemble the steering linkage to the pitman arm and then to the spindles. 3. Being careful not to change the position of the pitman arm, torque the steering linkage nuts to 65 ft.lbs. (88.1 N-m) The recommended sequence for tightening is: 1) the pitman arm, 2) the right side spindle and 3) the left side spindle. 4. Install all the cotter pins by advancing the nut to the next castellation. 5. Adjust the toe-in if necessary. Econoline 1. Ensure that the wheels are in the straight ahead position. 2. Loose assemble the steering linkage to the spindles and the pitman arm. 3. Being careful not to move the wheels from the straight ahead position, torque the steering linkage nuts to 65 ft.lbs. The recommended tightening sequence is: 1) the right side spindle, 2) the pitman arm and 3) the left side spindle. 4. Install all the cotter pins by advancing the nut to the next castellation. 5. Adjust the toe-in and reset the clear vision if necessary. The above procedure will eliminate any of the drift being caused by the rubber ball sockets. If the vehicle still drifts, refer to Section 19 of the Light Truck Shop Manual for further diagnosis. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION: SP3008A86A - F Series and Bronco TIME: 1.4 Hrs. OPERATION: SP3008A86B - Econoline TIME: 1.5 Hrs. DLR. CODING: Basic Part No. 3304 - Code: 36 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Steering and Suspension > Suspension > Axle Beam > Component Information > Description and Operation Axle Beam: Description and Operation Fig. 1 Twin I-Beam front axle Fig. 2 Spindle used with twin I Beam front axle. Typical EXC. 4 WHEEL DRIVE MODELS Twin I-Beam Axle As illustrated in Fig. 1 there are two I-beam axles, one for each front wheel. One end of each axle is attached to the spindle and a radius arm and the other end is attached to a frame bracket on the opposite side of the vehicle. Each spindle is held in place on the axle by ball joints or a spindle bolt which pivots in bushings pressed in the upper and lower ends of the spindle, Fig. 2. On models equipped with spindle bolts, a thrust bearing is installed between the lower end of the axle and the spindle to support the load on the axle. On all models, a spindle arm is installed on each spindle for attachment to the steering linkage. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Steering and Suspension > Suspension > Axle Beam > Component Information > Description and Operation > Page 5692 Fig. 3 Independent front suspension. Bronco & F-150 Four Wheel Drive. 1981---87 shown (similar to 1980) 4 WHEEL DRIVE MODELS Bronco & F-150 The independent front suspension on these vehicles is composed of a two piece front driving axle assembly, two coil springs and two radius arms, Fig. 3. The front driving axle consists of two independent yoke and tube assemblies. One end of yoke and tube assembly is anchored to the frame. The other end of each yoke and tube assembly is supported by the coil spring and radius arm. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Steering and Suspension > Suspension > Axle Beam > Component Information > Description and Operation > Page 5693 Fig. 4 Independent front suspension. F-250 & F-350 Four Wheel Drive.1980---82 shown (similar to 1983---87 exc. 1986---87 F-350 w/Dana 60 Monobeam front drive axle) 1980---87 F-250 & F-350 EXC. F-350 W/DANA 60 MONOBEAM FRONT DRIVE AXLE The independent front suspension on these vehicles has a two piece driving axle attached to the frame with two semi-elliptic leaf springs, Fig. 4. Each spring is clamped to the axle yoke with two U-bolts. The rear tube assembly of the spring rests in a rear hanger bracket. The front of the spring is attached to a shackle bracket. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Steering and Suspension > Suspension > Axle Beam > Component Information > Description and Operation > Page 5694 Fig. 5 Independent front suspension. 1986---87 F-350 w/Dana 60 Monobeam front drive axle 1986---87 F-350 W/Dana 60 Monobeam Front Drive Axle The front suspension used on these models has a one piece driving axle attached to the frame with two semi-elliptic leaf springs, Fig. 5.Each spring is clamped to the axle assembly with two U-bolts. The rear eye of the spring is attached to the hanger bracket. The front of the spring is attached to a shackle bracket. On the right spring cap, a tracking bar is attached with the opposite end mounted on the crossmember. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Technical Service Bulletins > Customer Interest for Ball Joint: > 962315 > Nov > 96 > Ball Joint - Clunk Noise From Front End Ball Joint: Customer Interest Ball Joint - Clunk Noise From Front End Article No. 96-23-15 11/04/96 ^ SUSPENSION - EARLY BALL JOINT WEAR - "CLUNK" FROM FRONT END ^ NOISE - "CLUNKING" NOISE FROM BALL JOINTS - EARLY BALL JOINT WEAR LIGHT TRUCK: 1973-83 F-100 1973-96 BRONCO 1980-96 F-150-350 SERIES This TSB article is being republished in its entirety to include the latest level parts and to revise the model years. ISSUE: A "clunking" noise may be heard from the upper and lower ball joints on some vehicles. This may be due to early wear of the joints caused by entry of water and contamination into the ball area. ACTION: Replace the ball joints with a new integral seal design ball joint. Refer to the Application Chart for correct part usage. The new ball joint should reduce the possibility of moisture and contamination into the ball joint. Refer to the appropriate Service Manual for removal and installation procedures. PART NUMBER PART NAME F5UZ-3049-A Ball Joint F6TZ-3049-AA Ball Joint F6TZ-3050-AB Ball Joint F6TZ-3050-CA Ball Joint F6TZ-3050-FB Ball Joint F6TZ-3050-GA Ball Joint F6TZ-3050-HA Ball Joint OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 96-11-5 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Technical Service Bulletins > Customer Interest for Ball Joint: > 962315 > Nov > 96 > Ball Joint - Clunk Noise From Front End > Page 5703 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 962315AA Replace One (1) Lower 2.5 Hrs. Ball Joint - 4X2 962315AB Replace Upper Or Both 3.5 Hrs. Ball Joints On One Side And One (1) Lower Ball Joint On The Other Side - 4X2 962315AE Replace One (1) Lower 3.4 Hrs. Ball Joint - Each Side - 4X2 962315ATA Replace One (1) Upper 2.7 Hrs. Ball Joint Or Both Ball Joints On One Side - 4X2 962315AT Replace Both Ball Joints 3.7 Hrs. On Both Sides - 4X2 962315BB Replace Both Ball Joints 4.5 Hrs. On One Side And One (1) Lower Ball Joint On The Other Side - 4X4 962315BE Replace One (1) Lower 4.4 Hrs. Ball Joint - Each Side - 4X4 962315BTA Replace One (1) Upper 3.2 Hrs. Ball Joint Or Both Ball Joints On One Side - 4X4 962315BT Replace Upper Or Both 4.7 Hrs. Ball Joints On Both Sides - 4X4 962315B Replace One (1) Lower 3.1 Hrs. Ball Joint - 4X4 DEALER CODING CONDITION BASIC PART NO. CODE 3050 56 OASIS CODES: 303000, 304000, 702000, 702100 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ball Joint: > 962315 > Nov > 96 > Ball Joint - Clunk Noise From Front End Ball Joint: All Technical Service Bulletins Ball Joint - Clunk Noise From Front End Article No. 96-23-15 11/04/96 ^ SUSPENSION - EARLY BALL JOINT WEAR - "CLUNK" FROM FRONT END ^ NOISE - "CLUNKING" NOISE FROM BALL JOINTS - EARLY BALL JOINT WEAR LIGHT TRUCK: 1973-83 F-100 1973-96 BRONCO 1980-96 F-150-350 SERIES This TSB article is being republished in its entirety to include the latest level parts and to revise the model years. ISSUE: A "clunking" noise may be heard from the upper and lower ball joints on some vehicles. This may be due to early wear of the joints caused by entry of water and contamination into the ball area. ACTION: Replace the ball joints with a new integral seal design ball joint. Refer to the Application Chart for correct part usage. The new ball joint should reduce the possibility of moisture and contamination into the ball joint. Refer to the appropriate Service Manual for removal and installation procedures. PART NUMBER PART NAME F5UZ-3049-A Ball Joint F6TZ-3049-AA Ball Joint F6TZ-3050-AB Ball Joint F6TZ-3050-CA Ball Joint F6TZ-3050-FB Ball Joint F6TZ-3050-GA Ball Joint F6TZ-3050-HA Ball Joint OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 96-11-5 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ball Joint: > 962315 > Nov > 96 > Ball Joint - Clunk Noise From Front End > Page 5709 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 962315AA Replace One (1) Lower 2.5 Hrs. Ball Joint - 4X2 962315AB Replace Upper Or Both 3.5 Hrs. Ball Joints On One Side And One (1) Lower Ball Joint On The Other Side - 4X2 962315AE Replace One (1) Lower 3.4 Hrs. Ball Joint - Each Side - 4X2 962315ATA Replace One (1) Upper 2.7 Hrs. Ball Joint Or Both Ball Joints On One Side - 4X2 962315AT Replace Both Ball Joints 3.7 Hrs. On Both Sides - 4X2 962315BB Replace Both Ball Joints 4.5 Hrs. On One Side And One (1) Lower Ball Joint On The Other Side - 4X4 962315BE Replace One (1) Lower 4.4 Hrs. Ball Joint - Each Side - 4X4 962315BTA Replace One (1) Upper 3.2 Hrs. Ball Joint Or Both Ball Joints On One Side - 4X4 962315BT Replace Upper Or Both 4.7 Hrs. Ball Joints On Both Sides - 4X4 962315B Replace One (1) Lower 3.1 Hrs. Ball Joint - 4X4 DEALER CODING CONDITION BASIC PART NO. CODE 3050 56 OASIS CODES: 303000, 304000, 702000, 702100 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Testing and Inspection > Ball Joint, Lower Ball Joint: Testing and Inspection Ball Joint, Lower Fig. 13 Checking Lower Ball Joint For Ware 1981---83 F-100---350 & 1984---87 F-150 W/STAMPED FRONT AXLE 1. Adjust front wheel bearings as described under ``Wheel Bearings, Adjust''. 2. Check lower ball joint by grasping lower edge of tire and moving wheel in and out while observing lower spindle arm and lower portion of axle jaw. If movement exceeds {1/32} inch, Fig. 18, the lower ball joint must be replaced. 3. Check upper ball joint by grasping upper edge of tire and moving wheel in and out. If movement exceeds {1/32} inch, the upper ball joint must be replaced. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Testing and Inspection > Ball Joint, Lower > Page 5712 Ball Joint: Testing and Inspection Ball Joint, Upper Fig. 13 Checking Lower Ball Joint For Ware 1981---83 F-100---350 & 1984---87 F-150 W/STAMPED FRONT AXLE 1. Adjust front wheel bearings as described under ``Wheel Bearings, Adjust''. 2. Check lower ball joint by grasping lower edge of tire and moving wheel in and out while observing lower spindle arm and lower portion of axle jaw. If movement exceeds {1/32} inch, Fig. 18, the lower ball joint must be replaced. 3. Check upper ball joint by grasping upper edge of tire and moving wheel in and out. If movement exceeds {1/32} inch, the upper ball joint must be replaced. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Service and Repair > Ball Joint, Lower Ball Joint: Service and Repair Ball Joint, Lower Fig. 13 Upper ball joint removal. 1982---83 F-100---350 & 1984---87 F-150 w/stamped front axle Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Service and Repair > Ball Joint, Lower > Page 5715 Fig. 14 Lower ball joint removal. 1982---83 F-100---350 & 1984---87 F-150 w/stamped front axle REMOVE 1. Raise and support front of vehicle and remove front wheels. 2. Remove brake caliper and position aside, leaving brake lines attached. Do not allow weight of caliper to hang on brake lines. 3. Remove dust cap, cotter pin, nut retainer, nut washer and outer bearing, then the rotor from wheel spindle. 4. Remove inner bearing and seal, then the brake dust shield. Discard bearing seal. 5. Disconnect steering linkage from spindle and spindle arm by removing cotter pin and nut. 6. Remove the cotter pin from the upper and lower ball joint studs. Remove the nut from the upper ball joint stud. Loosen the lower nut to the end of the lower stud. 7. Strike the inside area of the spindle to pop the ball joints loose from the spindle 8. Remove ball joint snap ring. 9. Remove ball joints using tools shown in Figs. 13 and 14. Fig. 16 Upper ball joint installation. 1982---83 F-100---350 & 1984---87 F-150 w/stamped front axle Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Service and Repair > Ball Joint, Lower > Page 5716 Fig. 17 Lower ball joint installation. 1982---83 F-100---350 & 1984---87 F-150 w/stamped front axle INSTALL 1. Reverse procedure to install, using tools shown in Figs. 16 and 17. Remove upper ball joint first and install last. Do not heat ball joint or axle to aid in removal or installation. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Service and Repair > Ball Joint, Lower > Page 5717 Ball Joint: Service and Repair Ball Joint, Upper Fig. 13 Upper ball joint removal. 1982---83 F-100---350 & 1984---87 F-150 w/stamped front axle Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Service and Repair > Ball Joint, Lower > Page 5718 Fig. 14 Lower ball joint removal. 1982---83 F-100---350 & 1984---87 F-150 w/stamped front axle REMOVE 1. Raise and support front of vehicle and remove front wheels. 2. Remove brake caliper and position aside, leaving brake lines attached. Do not allow weight of caliper to hang on brake lines. 3. Remove dust cap, cotter pin, nut retainer, nut washer and outer bearing, then the rotor from wheel spindle. 4. Remove inner bearing and seal, then the brake dust shield. Discard bearing seal. 5. Disconnect steering linkage from spindle and spindle arm by removing cotter pin and nut. 6. Remove the cotter pin from the upper and lower ball joint studs. Remove the nut from the upper ball joint stud. Loosen the lower nut to the end of the lower stud. 7. Strike the inside area of the spindle to pop the ball joints loose from the spindle 8. Remove ball joint snap ring. 9. Remove ball joints using tools shown in Figs. 13 and 14. Fig. 16 Upper ball joint installation. 1982---83 F-100---350 & 1984---87 F-150 w/stamped front axle Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Service and Repair > Ball Joint, Lower > Page 5719 Fig. 17 Lower ball joint installation. 1982---83 F-100---350 & 1984---87 F-150 w/stamped front axle INSTALL 1. Reverse procedure to install, using tools shown in Figs. 16 and 17. Remove upper ball joint first and install last. Do not heat ball joint or axle to aid in removal or installation. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Component Information > Technical Service Bulletins > Customer Interest for Cross-Member: > 94813 > Apr > 94 > Frame/Crossmember - Snapping/Popping Noise Cross-Member: Customer Interest Frame/Crossmember - Snapping/Popping Noise Article No. 94-8-13 ^ FRAME - # 1 CROSSMEMBER - RIVET REPLACEMENT ^ NOISE - "POPPING/CREAKING" SOUNDS - FRAME # 1 CROSSMEMBER LIGHT TRUCK: 1980-94 BRONCO, F-150-350 SERIES 1988-94 F SUPER DUTY, F-47 This TSB article is being republished in its entirety to add certain 1992/94 model year vehicles, to revise the nut specified in the article and its torque specification, and to expand the diagnostic and repair procedures contained in the article. ISSUE: A "popping/creaking" sound may come from the area of the # 1 crossmember attachment to the left frame rail. This occurs because of a slip/stick motion at a loose rivet in the lower flange of the frame near the steering gear. The rivet could be either a standard cold head rivet in light duty applications or a "huck" rivet, which has the appearance of a large "pop" Civet. ACTION: Use the following diagnostic procedure to determine if the noise is originating in this rivet area. If so, replace the rivet with a nut, bolt and washer assembly. The revised parts increase the clamp load at the joint, minimizing the motion that causes the noise. Refer to the following procedure for service details. SOURCES OF VARIOUS FRONT UNDERBODY NOISES: Various front underbody noises may originate from several different sources. Several noises have been misdiagnosed as # 1 crossmember rivet "pop/creak" because the noise tends to propagate to the shock tower area and the shock tower area acts as an amplifier such that the noises all appear to be coming from that area. Other underbody areas that produce similar noises include: ^ loose or improperly seated shock tower rivets ^ loose or misaligned transmission crossmembers ^ loose radius arm brackets ^ loose axle pivot brackets Other service bulletins have been published to address the proper repair of these concerns. DESCRIPTION OF # 1 CROSSMEMBER NOISES: "Pop/creak" - A metal-to-metal rubbing motion which slip/sticks when a twist is induced into the frame. DIAGNOSTIC PROCEDURE: 1. INTERVIEW THE CUSTOMER: a. Understand the customer's description of the noise and of the conditions under which it is heard. b. Road test the vehicle with the customer to fully understand where, how and when the noise occurs. 2. DUPLICATE THE NOISE CONCERN: a. Drive the vehicle around for at least 15 minutes to warm-up and stress the frame joints, so that any frame noise is more likely to be repeatable in the garage. b. Test the following situations: ^ Can the noise be duplicated while stationary and on dry pavement by repeatedly turning the steering wheel from steering stop to steering stop? Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Component Information > Technical Service Bulletins > Customer Interest for Cross-Member: > 94813 > Apr > 94 > Frame/Crossmember - Snapping/Popping Noise > Page 5728 ^ Can the noise be repeated while on the hoist without the suspension loaded by repeatedly turning the steering wheel from steering stop to steering stop? Typically, the twist in the frame can be induced by turning the steering wheel back and forth from steering stop to steering stop to duplicate the noise at the # 1 crossmember attachment. IF THE NOISE IS NOT DUPLICATED UNDER ONE OF THESE SITUATIONS, INVESTIGATE OTHER AREAS FOR THE NOISE BEFORE PROCEEDING TO REPAIR THE # 1 CROSSMEMBER RIVET. 3. INSPECT FRAME BOLTS FOR PROPER INSTALLATION TORQUE: a. Inspect and tighten all front end components which bolt to the frame to confirm they are at the proper torque. This includes, but is not limited to: ^ Radius arm bracket bolts - 135 +/- 20 N-m (100 +/- 15 lb.ft.) ^ Axle pivot bracket bolts (torques vary by model - refer to the appropriate light truck Service Manual for proper torque specifications) ^ Bumper bracket bolts - (refer to the appropriate light truck Service Manual for proper torque specifications) b. Inspect the transmission crossmember for proper alignment and bolt torques. If misaligned: ^ Loosen all transmission crossmember fasteners (including to the transmission). ^ Lift the transmission to remove any load on the crossmember. ^ Lift and reposition the transmission crossmember to be centered on the frame attachment holes. ^ Tighten all frame fasteners to the 63 +/- 9 N-m (46 +/- 7 lb.ft.). ^ Lower the transmission and tighten fasteners to 95 +/- 15 N-m (70 +/- 11 lb.ft.). 4. TEST DRIVE THE VEHICLE Road test the vehicle again to duplicate the concern. If the noise is still present, continue. 5. INSPECT THE FRAME RIVETS a. Repeat Step 2 to duplicate the noise in the garage. b. Use a stethoscope or chassis ears to isolate the area of the chassis that the noise appears to be originating from. Areas to check include the shock tower rivets and all # 1 crossmember rivets. 6. SERVICE THE VEHICLE a. If the noise appears to be from the lower left-front # 1 crossmember fastener, follow the procedure outlined below. b. If the noise appears to be coming from another rivet (other than the lower left front # 1 crossmember rivet), refer to TSB 93-6-10 for the proper rivet repair procedure. LOWER LEFT FRONT # 1 CROSSMEMBER RIVET REPLACEMENT: NOTE: THIS SERVICE PROCEDURE DOES NOT APPLY TO STEERING GEAR LINER REPLACEMENT. REFER TO TSB 90-11-10 FOR STEERING GEAR LINER REPAIR PROCEDURE. 1. Remove damaged or loose COLD HEAD RIVETS: a. Drill a 1/8" (3.175 mm) hole through the rivet. b. Redrill the same hole through the shank of the rivet with a 3/8" (9.525 mm) drill. c. Remove the rivet head with an air chisel. d. Drive out the rivet with a punch and hammer. 2. Remove damaged or loose "HUCK" RIVETS: Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Component Information > Technical Service Bulletins > Customer Interest for Cross-Member: > 94813 > Apr > 94 > Frame/Crossmember - Snapping/Popping Noise > Page 5729 a. Use a flat chisel and hammer (or air chisel) to split the exposed collar of the huck fastener, Figure 1. b. Knock the rivet pin out of the blind side with a 1/4" (6.35 mm) drift punch and hammer, Figure 2. c. Cut the rivet's head off with a hammer and flat chisel, Figure 3. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Component Information > Technical Service Bulletins > Customer Interest for Cross-Member: > 94813 > Apr > 94 > Frame/Crossmember - Snapping/Popping Noise > Page 5730 d. Knock the sleeve out of the blind side with a 3/8" (9.525 mm) drift punch and hammer, Figure 4. CAUTION: REMOVAL OF THE FASTENER WITH A CUTTING TORCH IS NOT RECOMMENDED BECAUSE OF PROBABLE DAMAGE TO THE FRAME STRUCTURE. 3. Line ream the existing hole through the liner, frame flange and crossmember to 9/16" (14.228 mm), Figure 5. 4. Install a 9/16" Grade 8 nut (34990-S4), bolt (58698-S2) and washer (44880-S2), with nut/washer on the bottom, Figure 6. a. Push the bolt into place using a brazing rod to hold the bolt. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Component Information > Technical Service Bulletins > Customer Interest for Cross-Member: > 94813 > Apr > 94 > Frame/Crossmember - Snapping/Popping Noise > Page 5731 b. Slide the bolt into the opening between the front face of the crossmember and frame liner. c. Tighten the nut to 140 4-3 lb.ft. (190 4-4 N-m) and tack weld the nut to the bolt after tightening. CAUTION: DO NOT WELD THE NUT/WASHER TO THE FRAME. OTHER APPLICABLE ARTICLES: 91-11-10 SUPERSEDES: 91-25-18 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 19 2-94 Models, Basic Warranty Coverage For All Other Models OPERATION DESCRIPTION TIME 940813A Perform Diagnostics And 1.9 Hrs. Replace Rivet DEALER CODING BASIC PART NO. CONDITION CODE 5005 56 OASIS CODES: 305000, 390000, 702000, 702100 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cross-Member: > 94813 > Apr > 94 > Frame/Crossmember Snapping/Popping Noise Cross-Member: All Technical Service Bulletins Frame/Crossmember - Snapping/Popping Noise Article No. 94-8-13 ^ FRAME - # 1 CROSSMEMBER - RIVET REPLACEMENT ^ NOISE - "POPPING/CREAKING" SOUNDS - FRAME # 1 CROSSMEMBER LIGHT TRUCK: 1980-94 BRONCO, F-150-350 SERIES 1988-94 F SUPER DUTY, F-47 This TSB article is being republished in its entirety to add certain 1992/94 model year vehicles, to revise the nut specified in the article and its torque specification, and to expand the diagnostic and repair procedures contained in the article. ISSUE: A "popping/creaking" sound may come from the area of the # 1 crossmember attachment to the left frame rail. This occurs because of a slip/stick motion at a loose rivet in the lower flange of the frame near the steering gear. The rivet could be either a standard cold head rivet in light duty applications or a "huck" rivet, which has the appearance of a large "pop" Civet. ACTION: Use the following diagnostic procedure to determine if the noise is originating in this rivet area. If so, replace the rivet with a nut, bolt and washer assembly. The revised parts increase the clamp load at the joint, minimizing the motion that causes the noise. Refer to the following procedure for service details. SOURCES OF VARIOUS FRONT UNDERBODY NOISES: Various front underbody noises may originate from several different sources. Several noises have been misdiagnosed as # 1 crossmember rivet "pop/creak" because the noise tends to propagate to the shock tower area and the shock tower area acts as an amplifier such that the noises all appear to be coming from that area. Other underbody areas that produce similar noises include: ^ loose or improperly seated shock tower rivets ^ loose or misaligned transmission crossmembers ^ loose radius arm brackets ^ loose axle pivot brackets Other service bulletins have been published to address the proper repair of these concerns. DESCRIPTION OF # 1 CROSSMEMBER NOISES: "Pop/creak" - A metal-to-metal rubbing motion which slip/sticks when a twist is induced into the frame. DIAGNOSTIC PROCEDURE: 1. INTERVIEW THE CUSTOMER: a. Understand the customer's description of the noise and of the conditions under which it is heard. b. Road test the vehicle with the customer to fully understand where, how and when the noise occurs. 2. DUPLICATE THE NOISE CONCERN: a. Drive the vehicle around for at least 15 minutes to warm-up and stress the frame joints, so that any frame noise is more likely to be repeatable in the garage. b. Test the following situations: ^ Can the noise be duplicated while stationary and on dry pavement by repeatedly turning the steering wheel from steering stop to steering stop? Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cross-Member: > 94813 > Apr > 94 > Frame/Crossmember Snapping/Popping Noise > Page 5737 ^ Can the noise be repeated while on the hoist without the suspension loaded by repeatedly turning the steering wheel from steering stop to steering stop? Typically, the twist in the frame can be induced by turning the steering wheel back and forth from steering stop to steering stop to duplicate the noise at the # 1 crossmember attachment. IF THE NOISE IS NOT DUPLICATED UNDER ONE OF THESE SITUATIONS, INVESTIGATE OTHER AREAS FOR THE NOISE BEFORE PROCEEDING TO REPAIR THE # 1 CROSSMEMBER RIVET. 3. INSPECT FRAME BOLTS FOR PROPER INSTALLATION TORQUE: a. Inspect and tighten all front end components which bolt to the frame to confirm they are at the proper torque. This includes, but is not limited to: ^ Radius arm bracket bolts - 135 +/- 20 N-m (100 +/- 15 lb.ft.) ^ Axle pivot bracket bolts (torques vary by model - refer to the appropriate light truck Service Manual for proper torque specifications) ^ Bumper bracket bolts - (refer to the appropriate light truck Service Manual for proper torque specifications) b. Inspect the transmission crossmember for proper alignment and bolt torques. If misaligned: ^ Loosen all transmission crossmember fasteners (including to the transmission). ^ Lift the transmission to remove any load on the crossmember. ^ Lift and reposition the transmission crossmember to be centered on the frame attachment holes. ^ Tighten all frame fasteners to the 63 +/- 9 N-m (46 +/- 7 lb.ft.). ^ Lower the transmission and tighten fasteners to 95 +/- 15 N-m (70 +/- 11 lb.ft.). 4. TEST DRIVE THE VEHICLE Road test the vehicle again to duplicate the concern. If the noise is still present, continue. 5. INSPECT THE FRAME RIVETS a. Repeat Step 2 to duplicate the noise in the garage. b. Use a stethoscope or chassis ears to isolate the area of the chassis that the noise appears to be originating from. Areas to check include the shock tower rivets and all # 1 crossmember rivets. 6. SERVICE THE VEHICLE a. If the noise appears to be from the lower left-front # 1 crossmember fastener, follow the procedure outlined below. b. If the noise appears to be coming from another rivet (other than the lower left front # 1 crossmember rivet), refer to TSB 93-6-10 for the proper rivet repair procedure. LOWER LEFT FRONT # 1 CROSSMEMBER RIVET REPLACEMENT: NOTE: THIS SERVICE PROCEDURE DOES NOT APPLY TO STEERING GEAR LINER REPLACEMENT. REFER TO TSB 90-11-10 FOR STEERING GEAR LINER REPAIR PROCEDURE. 1. Remove damaged or loose COLD HEAD RIVETS: a. Drill a 1/8" (3.175 mm) hole through the rivet. b. Redrill the same hole through the shank of the rivet with a 3/8" (9.525 mm) drill. c. Remove the rivet head with an air chisel. d. Drive out the rivet with a punch and hammer. 2. Remove damaged or loose "HUCK" RIVETS: Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cross-Member: > 94813 > Apr > 94 > Frame/Crossmember Snapping/Popping Noise > Page 5738 a. Use a flat chisel and hammer (or air chisel) to split the exposed collar of the huck fastener, Figure 1. b. Knock the rivet pin out of the blind side with a 1/4" (6.35 mm) drift punch and hammer, Figure 2. c. Cut the rivet's head off with a hammer and flat chisel, Figure 3. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cross-Member: > 94813 > Apr > 94 > Frame/Crossmember Snapping/Popping Noise > Page 5739 d. Knock the sleeve out of the blind side with a 3/8" (9.525 mm) drift punch and hammer, Figure 4. CAUTION: REMOVAL OF THE FASTENER WITH A CUTTING TORCH IS NOT RECOMMENDED BECAUSE OF PROBABLE DAMAGE TO THE FRAME STRUCTURE. 3. Line ream the existing hole through the liner, frame flange and crossmember to 9/16" (14.228 mm), Figure 5. 4. Install a 9/16" Grade 8 nut (34990-S4), bolt (58698-S2) and washer (44880-S2), with nut/washer on the bottom, Figure 6. a. Push the bolt into place using a brazing rod to hold the bolt. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cross-Member: > 94813 > Apr > 94 > Frame/Crossmember Snapping/Popping Noise > Page 5740 b. Slide the bolt into the opening between the front face of the crossmember and frame liner. c. Tighten the nut to 140 4-3 lb.ft. (190 4-4 N-m) and tack weld the nut to the bolt after tightening. CAUTION: DO NOT WELD THE NUT/WASHER TO THE FRAME. OTHER APPLICABLE ARTICLES: 91-11-10 SUPERSEDES: 91-25-18 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 19 2-94 Models, Basic Warranty Coverage For All Other Models OPERATION DESCRIPTION TIME 940813A Perform Diagnostics And 1.9 Hrs. Replace Rivet DEALER CODING BASIC PART NO. CONDITION CODE 5005 56 OASIS CODES: 305000, 390000, 702000, 702100 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Service and Repair Front Steering Knuckle: Service and Repair Spindle REMOVE 1. Raise the front of the vehicle and install safety stands. 2. Remove the wheel and tire assembly. 3. Remove the caliper assembly from the rotor and hold it out of the way with wire. 4. Remove the dust cap, cotter pin, nut retainer, nut, washer, and outer bearing, and remove the rotor from the spindle. 5. Remove inner bearing cone and seal. Discard the seal. 6. Remove brake dust shield. 7. Disconnect the steering linkage from the integral spindle and spindle arm by removing the cotter pin and nut and then removing the tie rod end from the spindle arm with TOOL 3290-C. 8. Remove the cotter pin from the upper and lower ball joint studs. Remove the nut from the upper ball joint stud. Loosen the lower nut to the end of the lower stud. 9. Strike the inside area of the spindle to pop the ball joints loose from the spindle. CAUTION: Do not use a pickle fork to separate the ball joint from the spindle as this will damage the seal and the ball joint socket. 10. Remove the spindle. INSTALL 1. Prior to assembly, make sure the upper and lower ball joint seals are in place. 2. Place the spindle over the ball joints. 3. Install the nut on the lower ball joint stud and partially tighten to 41 Nm (30 ft lb). 4. Install the camber adapter in the upper spindle over the upper ball joint stud. Be sure the adapter is aligned properly. If camber adjustment is necessary, special adaptors must be installed. 5. Install the nut on the upper ball joint stud. Hold the camber adaptor with a wrench to keep the ball stud from turning. If the ball stud turns, tap the adaptor lightly into the spindle. Tighten the nut to 116-136 Nm (85-101 ft lbs) and continue tightening the castellated nut until it lines up with the hole in the stud. Install the cotter pin. 6. Retighten lower nut to 190-244 Nm (140-180 ft lb). 7. Install the dust shield. 8. Pack the inner and outer bearing cone with a lithium-base grease, Multi-Purpose Long-Life Lubricant, C1AZ-19590-B (ESA-M1C75-B) or equivalent. Use a bearing packer. If a bearing packer is unavailable, pack the bearing cone by hand working the grease through the cage behind the rollers. 9. Install the inner bearing cone and seal. Install the hub and rotor on the spindle. 10. Install the outer bearing cone, washer, and nut. Adjust bearing end play and install the nut retainer, cotter pin and dust cap. 11. Install the caliper. 12. Connect the steering linkage to the spindle. Tighten the nut to 94-135 Nm (70-100 ft lbs) and advance the nut as required for installation of the cotter pin. 13. Install the wheel and tire assembly. 14. Lower the vehicle. 15. Check and, if necessary adjust the toe setting. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Steering and Suspension > Suspension > Radius Arm > Radius Arm Bushing > Component Information > Technical Service Bulletins > Customer Interest for Radius Arm Bushing: > 921810 > Aug > 92 > Steering Pulls Left When Braking Radius Arm Bushing: Customer Interest Steering - Pulls Left When Braking Article No. 92-18-10 08/26/92 STEERING - LEFT DRIFT OR PULL DURING BRAKING - "RECESSION STEER" - F-SERIES 4X2 LIGHT DUTY AND F-150/BRONCO 4X4 LIGHT TRUCK: 1980-92 BRONCO, F-150 1989-92 F-250 ISSUE: The vehicle may drift or pull left during braking, with no torque in the steering wheel. This condition is known as "recession steer" and may be caused by the radius arm front pivot bushings. ACTION: Confirm that "recession steer" exists and, if necessary, replace the left hand radius arm bushing with the flat front retainer and both front pivot bushings. Refer to the following procedure for service details. NOTE: THIS PROCEDURE CAN ONLY BE USED IN CONJUNCTION WITH TSB 91-21-8 TO COMPLETELY RESOLVE THIS CONDITION. IDENTIFY CONCERN Confirm that "recession steer" exists and segregate it from possible brake pull. ^ "Recession steer" must be correctly identified and segregated from brake pull. "Recession steer" is identified by the vehicle drifting or pulling left during braking with no torque felt in the steering wheel. ^ With the right hand radius arm pivot bracket bolted on, as in current production, and no brake imbalance (correctly performing TSB 91-21-8 will assure this), the amount of left drift that could result from "recession steer", if corrective steering wheel input is not applied, during a moderate hard stop from 50 mph (80 km /h), is no more than 4 feet (1.2 m). The revised bushings are designed to correct this magnitude of "recession steer". REMOVAL AND REPLACEMENT Refer to the to the 1992 F-Series And Bronco Service Manual, Section 04-01A, for removal and replacement of the following components. 1. Replace the left hand (driver's side) radius arm bushing cupped front retainer with the flat front retainer (F2TZ-3B186-A). 2. Replace the left hand (driver's side) radius arm front pivot bushing with the new bushing (F2TZ-3B203-A). It is yellow in color with "LEFT HAND ONLY" molded in the front face. 3. Replace the right hand (passenger side) radius arm front pivot bushing with a new bushing (F2TZ-3B203-B). NOTE: REUSE THE ORIGINAL NYLON REAR BUSHING SPACER AND REAR BUSHING, UNLESS EXCESSIVE WEAR IS FOUND. REPLACE WITH (E5TZ-3B244-A) AND (D9TZ-3B203-A) RESPECTIVELY, IF REPLACEMENT IS NECESSARY. TIGHTEN BOTH THE LEFT HAND AND RIGHT HAND RADIUS ARM NUTS TO THE SPECIFIED 80-120 LB.FT. (109-163 N-m). 4. Set total toe to 1/32" (.794 mm) toe in. PART NUMBER NOTE: TIMES FOR TSB 91-21-8 DIAGNOSTICS WILL VARY DEPENDING ON WHAT IS FOUND. THEREFORE, DIAGNOSTIC TIME IS NOT INCLUDED. REFER TO TSB 91-21-8 FOR DIAGNOSTIC TIMES. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Steering and Suspension > Suspension > Radius Arm > Radius Arm Bushing > Component Information > Technical Service Bulletins > Customer Interest for Radius Arm Bushing: > 921810 > Aug > 92 > Steering Pulls Left When Braking > Page 5753 OPERATION DESCRIPTION Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Steering and Suspension > Suspension > Radius Arm > Radius Arm Bushing > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radius Arm Bushing: > 921810 > Aug > 92 > Steering - Pulls Left When Braking Radius Arm Bushing: All Technical Service Bulletins Steering - Pulls Left When Braking Article No. 92-18-10 08/26/92 STEERING - LEFT DRIFT OR PULL DURING BRAKING - "RECESSION STEER" - F-SERIES 4X2 LIGHT DUTY AND F-150/BRONCO 4X4 LIGHT TRUCK: 1980-92 BRONCO, F-150 1989-92 F-250 ISSUE: The vehicle may drift or pull left during braking, with no torque in the steering wheel. This condition is known as "recession steer" and may be caused by the radius arm front pivot bushings. ACTION: Confirm that "recession steer" exists and, if necessary, replace the left hand radius arm bushing with the flat front retainer and both front pivot bushings. Refer to the following procedure for service details. NOTE: THIS PROCEDURE CAN ONLY BE USED IN CONJUNCTION WITH TSB 91-21-8 TO COMPLETELY RESOLVE THIS CONDITION. IDENTIFY CONCERN Confirm that "recession steer" exists and segregate it from possible brake pull. ^ "Recession steer" must be correctly identified and segregated from brake pull. "Recession steer" is identified by the vehicle drifting or pulling left during braking with no torque felt in the steering wheel. ^ With the right hand radius arm pivot bracket bolted on, as in current production, and no brake imbalance (correctly performing TSB 91-21-8 will assure this), the amount of left drift that could result from "recession steer", if corrective steering wheel input is not applied, during a moderate hard stop from 50 mph (80 km /h), is no more than 4 feet (1.2 m). The revised bushings are designed to correct this magnitude of "recession steer". REMOVAL AND REPLACEMENT Refer to the to the 1992 F-Series And Bronco Service Manual, Section 04-01A, for removal and replacement of the following components. 1. Replace the left hand (driver's side) radius arm bushing cupped front retainer with the flat front retainer (F2TZ-3B186-A). 2. Replace the left hand (driver's side) radius arm front pivot bushing with the new bushing (F2TZ-3B203-A). It is yellow in color with "LEFT HAND ONLY" molded in the front face. 3. Replace the right hand (passenger side) radius arm front pivot bushing with a new bushing (F2TZ-3B203-B). NOTE: REUSE THE ORIGINAL NYLON REAR BUSHING SPACER AND REAR BUSHING, UNLESS EXCESSIVE WEAR IS FOUND. REPLACE WITH (E5TZ-3B244-A) AND (D9TZ-3B203-A) RESPECTIVELY, IF REPLACEMENT IS NECESSARY. TIGHTEN BOTH THE LEFT HAND AND RIGHT HAND RADIUS ARM NUTS TO THE SPECIFIED 80-120 LB.FT. (109-163 N-m). 4. Set total toe to 1/32" (.794 mm) toe in. PART NUMBER NOTE: TIMES FOR TSB 91-21-8 DIAGNOSTICS WILL VARY DEPENDING ON WHAT IS FOUND. THEREFORE, DIAGNOSTIC TIME IS NOT INCLUDED. REFER TO TSB 91-21-8 FOR DIAGNOSTIC TIMES. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Steering and Suspension > Suspension > Radius Arm > Radius Arm Bushing > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radius Arm Bushing: > 921810 > Aug > 92 > Steering - Pulls Left When Braking > Page 5759 OPERATION DESCRIPTION Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Steering and Suspension > Suspension > Spindle > Component Information > Service and Repair Spindle: Service and Repair Spindle REMOVE 1. Raise the front of the vehicle and install safety stands. 2. Remove the wheel and tire assembly. 3. Remove the caliper assembly from the rotor and hold it out of the way with wire. 4. Remove the dust cap, cotter pin, nut retainer, nut, washer, and outer bearing, and remove the rotor from the spindle. 5. Remove inner bearing cone and seal. Discard the seal. 6. Remove brake dust shield. 7. Disconnect the steering linkage from the integral spindle and spindle arm by removing the cotter pin and nut and then removing the tie rod end from the spindle arm with TOOL 3290-C. 8. Remove the cotter pin from the upper and lower ball joint studs. Remove the nut from the upper ball joint stud. Loosen the lower nut to the end of the lower stud. 9. Strike the inside area of the spindle to pop the ball joints loose from the spindle. CAUTION: Do not use a pickle fork to separate the ball joint from the spindle as this will damage the seal and the ball joint socket. 10. Remove the spindle. INSTALL 1. Prior to assembly, make sure the upper and lower ball joint seals are in place. 2. Place the spindle over the ball joints. 3. Install the nut on the lower ball joint stud and partially tighten to 41 Nm (30 ft lb). 4. Install the camber adapter in the upper spindle over the upper ball joint stud. Be sure the adapter is aligned properly. If camber adjustment is necessary, special adaptors must be installed. 5. Install the nut on the upper ball joint stud. Hold the camber adaptor with a wrench to keep the ball stud from turning. If the ball stud turns, tap the adaptor lightly into the spindle. Tighten the nut to 116-136 Nm (85-101 ft lbs) and continue tightening the castellated nut until it lines up with the hole in the stud. Install the cotter pin. 6. Retighten lower nut to 190-244 Nm (140-180 ft lb). 7. Install the dust shield. 8. Pack the inner and outer bearing cone with a lithium-base grease, Multi-Purpose Long-Life Lubricant, C1AZ-19590-B (ESA-M1C75-B) or equivalent. Use a bearing packer. If a bearing packer is unavailable, pack the bearing cone by hand working the grease through the cage behind the rollers. 9. Install the inner bearing cone and seal. Install the hub and rotor on the spindle. 10. Install the outer bearing cone, washer, and nut. Adjust bearing end play and install the nut retainer, cotter pin and dust cap. 11. Install the caliper. 12. Connect the steering linkage to the spindle. Tighten the nut to 94-135 Nm (70-100 ft lbs) and advance the nut as required for installation of the cotter pin. 13. Install the wheel and tire assembly. 14. Lower the vehicle. 15. Check and, if necessary adjust the toe setting. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Component Information > Service and Repair > Front Stabilizer Bar: Service and Repair Front 1. Disconnect both ends of stabilizer bar from link assembly on I-beam bracket. 2. On 1986---87 F-350 models equipped with Dana 60 Monobeam axle, remove nuts, washers and bolts securing links to mounting brackets. 3. Remove stabilizer bar attaching bolts and the stabilizer bar. On 1980---87 F-150 4 4 and Bronco models, the coil spring must be removed to facilitate removal of the stabilizer bar mounting bracket. 4. Reverse procedure to install. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Component Information > Service and Repair > Front > Page 5767 Stabilizer Bar: Service and Repair Rear Fig. 6 Stabilizer bar replacement. 1981---87 F-100---150 & Bronco Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Component Information > Service and Repair > Front > Page 5768 Fig. 7 Stabilizer bar replacement. 1981---87 F-250---350 1981---87 F-100---350 & BRONCO 1. Remove nut from lower end of stabilizer link, Figs. 6 and 7. 2. Remove outer washer and insulator, then disconnect stabilizer from link. 3. Remove inner insulators and washers. 4. Remove stabilizer link attaching nuts and bolts, then disconnect link from frame. 5. Remove U-bolt, bracket and retainer attaching nuts, then the stabilizer bar from vehicle. 6. Reverse procedure to install. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Shackle > Component Information > Technical Service Bulletins > Customer Interest for Shackle: > 861327 > Jul > 86 > Front Spring Shackle - Frame Interference Shackle: Customer Interest Front Spring Shackle - Frame Interference Article No. 86-13-27 SUSPENSION - FRONT - SHACKLE TO FRAME CONTACT - 4x4 VEHICLES LIGHT TRUCK 1985-86 F250/350 A revised front spring shackle is available to resolve contact between the frame and the prior design bracket. The new bracket incorporates a "clearance" notch to gain clearance and should be installed with the closed end forward. Installing the new bracket backwards will create an interference concern. Reversing of the old shackle to create clearance with the vehicle standing still will create greater interferences when the vehicle is operated and should not be done. Figure 20 See Figure 20 to identify the two shackles. PART NUMBER PART NAME CLASS E5TZ-5K316-A Shackle - Front Spring C OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION: SP5316A86 TIME: 0.6 Hr. DLR. CODING: Basic Part No. 5316 - Code: 16 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Shackle > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Shackle: > 861327 > Jul > 86 > Front Spring Shackle - Frame Interference Shackle: All Technical Service Bulletins Front Spring Shackle - Frame Interference Article No. 86-13-27 SUSPENSION - FRONT - SHACKLE TO FRAME CONTACT - 4x4 VEHICLES LIGHT TRUCK 1985-86 F250/350 A revised front spring shackle is available to resolve contact between the frame and the prior design bracket. The new bracket incorporates a "clearance" notch to gain clearance and should be installed with the closed end forward. Installing the new bracket backwards will create an interference concern. Reversing of the old shackle to create clearance with the vehicle standing still will create greater interferences when the vehicle is operated and should not be done. Figure 20 See Figure 20 to identify the two shackles. PART NUMBER PART NAME CLASS E5TZ-5K316-A Shackle - Front Spring C OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION: SP5316A86 TIME: 0.6 Hr. DLR. CODING: Basic Part No. 5316 - Code: 16 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front Air Shock Absorber Suspension Strut / Shock Absorber: Service and Repair Front Air Shock Absorber 1. Disconnect shock absorber from upper mounting. 2. Disconnect shock absorber from lower mounting, then compress shock and remove from vehicle. 3. Reverse procedure to install. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front Air Shock Absorber > Page 5787 Suspension Strut / Shock Absorber: Service and Repair Rear 1. Raise and support rear of vehicle to a point where weight is relieved from rear springs and tires are still in contact with floor. 2. Remove lower attaching nut and bolt from shock absorber and swing lower end free of mounting bracket. 3. Remove upper attaching nut and the shock absorber. 4. Reverse procedure to install. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Specifications Wheel Bearing: Specifications Wheel Adjusting Nut [1] ....................................................................................................................... ........................................... 30-33 Nm (22-25 ft lbs) Bearing End Play .............................................................................................................................................................. 0.025-0.254mm (0.001-0.010 in) [1] Back off the adjusting nut 1/8 turn and install the retainer and new cotter pin without additional movement of the adjusting nut. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Specifications > Page 5791 Wheel Bearing: Adjustments 1. Raise the vehicle until the tire clears the floor and install safety stands. 2. Remove the wheel cover. 3. Remove the grease cap from the hub. Wipe the excess grease from the end of the spindle. Remove the cotter pin and locknut. 4. Loosen the adjusting nut three turns. Attempt to obtain running clearance between the rotor brake surface and the disc pads by rocking the wheel, hub and rotor assembly in and out several times to push the pads away from the rotor. If running clearance cannot be maintained throughout bearing adjustment in Steps 5 and 6, the caliper must be removed. NOTE: Do not pry on the phenolic caliper piston. 5. Tighten the wheel adjusting nut to 30-33 Nm (22-25 ft lbs) while rotating the disc brake rotor in the opposite direction. 6. Back off the adjusting nut 1/8 turn and install the retainer and new cotter pin without additional movement of the adjusting nut. Bearing end play should be 0.025-0.254mm (0.001-0.010 in). Bend the ends of the cotter pin around the castellated flange of the locknut. 7. Check front wheel rotation. If the wheel rotates properly, reinstall the grease cap and wheel cover. If rotation is noisy or rough, remove and inspect the bearings. Service as required. WARNING: Before driving the vehicle, pump the brake pedal several times to restore normal brake pedal travel. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Specifications > Page 5792 Wheel Bearing: Service and Repair Wheel bearing lubricant is a lithium-base grease. Sodium-base grease is not compatible with lithium-base grease and should not be intermixed. Therefore, do not lubricate front and/or rear wheel bearings without first identifying the type of original wheel bearing lubricant. Usage of incompatible bearing lubricants may result in premature lubricant breakdown. REMOVAL Front Hub And Rotor Assembly 1. Raise the vehicle until the tire clears the floor and remove the wheel and tire assembly. 2. Remove the brake caliper and secure to the underbody to prevent damage to the brake hose. It is not necessary to disconnect the hose from the caliper. Do not let the caliper hang with its weight on the brake hose or the hose may become stretched, twisted or ruptured. See: Brakes and Traction Control/Disc Brake System/Brake Caliper/Service and Repair 3. Remove the grease cap, cotter pin, retainer adjusting nut and washer. 4. Remove the outer bearing cone and roller. 5. Pull the hub and rotor off the spindle and remove and discard the grease seal. 6. Remove the inner bearing cone and roller from the hub. Remove all traces of old lubricant from bearings, hub and axle spindle. 7. Inspect the cups for scratches, pits or cracks. If the cups are worn or damaged, remove them with a drift. Clean the inner and outer bearing cones and rollers with solvent and dry thoroughly. CAUTION: Do not spin the bearings dry with compressed air. 8. Inspect the cones and rollers for cracks, nicks, brinelling, or seized rollers. Inspect the grease retainer and replace it if it is cracked, nicked, dented or worn. 9. Cover the spindle with a clean cloth. A water dampened cloth or water based solution should be used to remove and dust or loose dirt from the brake assembly. Remove the cloth from the spindle carefully to prevent dirt from falling on the spindle. NOTE: Do not use compressed air. INSTALLATION Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Specifications > Page 5793 Installing Bearing Cups (Typical) 1. If inner or outer bearing cups were removed, install replacement inner and outer bearing cups in the hub with the appropriate bearing cup replacer tool. Be sure to seat the cups properly in the hub. The cups will be properly seated when they are fully bottomed. Replace grease retainers. Polish grease retainer journal on spindle with 400 grit sandpaper. Clean with clean cloth. 2. Pack the inside of the hub with lithium-base grease or equivalent. Fill the hub until the grease is flush with the inside diameters of both bearing cups. Pack the bearing cones and rollers with wheel bearing grease. Use a bearing packer for this operation. If a packer is not available, work as much lubricant as possible between the rollers and cages. Lubricate the cone surfaces with grease. Installing Grease Seal (Typical) 3. Place the inner bearing cone and roller in the inner cup and install the new grease seal. Be sure that the seal is fully seated. 4. Install the hub and rotor on the wheel spindle. Keep the hub centered on the spindle to prevent damage to the grease retainer or the spindle threads. 5. Install the outer bearing cone and roller and the flat washer on the spindle, then install the adjusting nut, and adjust the wheel bearing. 6. Install the retainer, new cotter pin, and grease cap. 7. Install the caliper. 8. Install the wheel and tire assembly. 9. Lower vehicle and torque the lug nuts to specification. Re-install the wheel cover or hub cap. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Specifications > Page 5794 WARNING: Before driving the vehicle, pump the brake pedal several times to restore normal brake pedal travel. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Axle Nut > Component Information > Technical Service Bulletins > Front Drive Axle - Retaining Nut Revision Axle Nut: Technical Service Bulletins Front Drive Axle - Retaining Nut Revision Article No. 85-21-13 AXLE - FRONT DRIVE (DANA 441FSHD, 501FS, 60F MONOBEAM) - NEW WHEEL BEARING LOCKNUTS LIGHT TRUCK 1985-86 F-250 HD/350 (4x4) Front axle hub and rotor assembly bearing adjusting and retaining nuts and lockwashers have been revised. Removal and installation procedures are the same as outlined in Section 11-12 of the 1985-86 Light Truck Shop Manual except the Front Wheel Bearing Adjusting Spanner, tool number D78T-1197-B (6-prong) is used with the old design adjusting nut (Dana part number 33732) and tool number D85T-1197-A (4- prong) is required for the new nuts (Dana part number 621029). OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Seal > Component Information > Technical Service Bulletins > Customer Interest for Wheel Seal: > 9167 > Mar > 91 > Rear Axle Hub Seal - Lubricant Leaks Wheel Seal: Customer Interest Rear Axle Hub Seal - Lubricant Leaks Article No. 91-6-7 03/18/91 ^ AXLE - NEW HUB SEAL AND HUB SEAL REPLACER TOOL - VEHICLES WITH 10.25 INCH RING GEAR, FULL - FLOATING REAR AXLES ^ LEAKS - AXLE LUBE - 10.25 INCH RING GEAR, FULL - FLOATING REAR AXLES LIGHT TRUCK: 1985-91 F-250, F-350 ISSUE: A new hub seal and a hub seal replacer tool are now available for service. The new hub seal is designed to improve sealing when properly installed using the new hub seal replacer tool. ACTION: Install a new hub seal (FOTZ-1177-A) with the new hub seal replacer tool (T91T-1175-A). Refer to the following inspection list and service procedure for details. NOTE: DO NOT USE THE OLD HUB SEAL REPLACER TOOL (T85T-1175-AH). IT IS NOT DESIGNED TO INSTALL THE NEW SEAL. THE NEW HUB SEAL REPLACER TOOL IS AVAILABLE IN THE 1991 DEALER ESSENTIAL SERVICE TOOL KIT AND IS THE ONLY TOOL APPROVED TO INSTALL THE NEW SEAL. INSPECTION PRIOR TO SEAL INSTALLATION Prior to seal installation, make sure that the following items are checked and servicing action taken where indicated. ^ Inspect the outer diameter of the hub seal to be sure that it is dry and free of oil and grease. ^ Check the hub bore to be sure it is free of grease, dirt and debris. ^ Remove any nicks or burrs from the hub bore. ^ Inspect the inner and outer bearing for damage and replace as required. ^ Pack each hub bearing cone and roller with a bearing packing tool using XG-1-C grease. ^ Make sure that no residual grease from freshly greased bearings gets into the hub bore. ^ Prior to installing the hub assembly, clean the spindle thoroughly and inspect the seal and bearing journals for nicks and/or scratches. Remove nicks or scratches using crocus cloth or similar material. ^ Wipe spindle clean and lightly oil with clean axle lube or engine oil. Figure 1 REMOVAL & INSTALLATION PROCEDURE 1. Install the hub in a soft jawed vice. 2. Remove the hub seal as shown in Figure 1. CAUTION: CARE MUST BE TAKEN NOT TO DAMAGE THE HUB SEAL BORE WITH THE SEAL REMOVAL TOOL. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Seal > Component Information > Technical Service Bulletins > Customer Interest for Wheel Seal: > 9167 > Mar > 91 > Rear Axle Hub Seal - Lubricant Leaks > Page 5808 Figure 2 3. Thoroughly clean and inspect the hub bore, Figure 2. CAUTION: MAKE SURE THE HUB BORE IS FREE OF DIRT, GREASE, BURRS OR NICKS. NOTE: HUB BEARINGS MUST BE PRELUBED WITH GREASE PRIOR TO INSTALLATION. USE XG-1-C GREASE OR EQUIVALENT. 4. Pack each bearing cone and roller assembly with a bearing packing tool. Figure 3 5. Install the seal in the hub with the Ford logo facing up, Figure 3. CAUTION: HUB SEAL MUST BE FREE OF DIRT OR GREASE. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Seal > Component Information > Technical Service Bulletins > Customer Interest for Wheel Seal: > 9167 > Mar > 91 > Rear Axle Hub Seal - Lubricant Leaks > Page 5809 Figure 4 6. Install the hub oil seal on the hub seal installer tool, T91T-1175-A, Figure 4. Figure 5 7. Insert the tool with the seal squarely into the hub, Figure 5. Figure 6 8. Hold the tool straight. Strike the handle until the hub seal is fully seated (until tool strikes hub), Figure 6. CAUTION: INSTALL NEW SEAL IF SEAL IS MISALIGNED DURING OR AFTER INSTALLATION. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Seal > Component Information > Technical Service Bulletins > Customer Interest for Wheel Seal: > 9167 > Mar > 91 > Rear Axle Hub Seal - Lubricant Leaks > Page 5810 It is extremely important that the 1991 F-Series Shop Manual procedures be followed when installing the hub assembly. CAUTION: THE SPECIFIED TORQUING AND BACKING OFF OF THE HUB NUT IS CRITICAL IN ORDER TO PERFORM THE REPAIR CORRECTLY. NOTE: ALWAYS TURN THE HUB WHILE TIGHTENING THE HUB NUT. ONCE THE SPECIFIED TORQUE 55-65 LB.FT., (75-88 N-m) IS ACHIEVED, RATCHETING BACK ON THE HUB NUT VARIES DEPENDING ON WHETHER THE HUB BEARINGS ARE NEW OR USED. BACK OFF 5 CLICKS FOR NEW BEARING AND 8 CLICKS FOR USED BEARINGS. Make sure hub nut wrench tool (T85T-4252-AH) is used as shown in the Shop Manual procedure. Consult The 1991 F-Series Light Truck Shop Manual, Section 05-02B, for service procedures and torque specifications. PART NUMBER PART NAME CLASS FOTZ-1177-A Hub Seal B XG-1-C Grease (14 oz. cartridge, Pkg. V 60) OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 509000 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Seal > Component Information > Technical Service Bulletins > Customer Interest for Wheel Seal: > 862223 > Nov > 86 > Axle - Rear Axle Hub Seals Leak Wheel Seal: Customer Interest Axle - Rear Axle Hub Seals Leak Article No. 86-22-23 AXLE (10.25") - REAR - HUB SEALS LEAK - VENT PLUGGED LIGHT TRUCK 1985-86 F-250/350 A plugged rear axle vent may cause water to be sucked in through the seals and grease to be pushed out. This happens when pressures rise and fall inside the axle during various driving conditions and temperatures. The purpose of the vent is to relieve those pressures. If the vent is plugged with mud or other foreign materials, the axle cannot "breathe". To eliminate this concern, perform the following procedure: Figure 17 1. Remove the vent from the axle (Figure 17). 2. Place the vent in a vise so as not to damage the threads. 3. Drill out the vent using a 3/16 inch drill bit. Clean all shavings from vent. 4. Install vent. 5. Make sure entire vent hose is clear of dirt and mud, etc. 6. Install hose. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION: SP4022A86 TIME: 0.5 Hr. DLR. CODING: Basic Part No. 4022 - Code: 55 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Seal > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Seal: > 9167 > Mar > 91 > Rear Axle Hub Seal - Lubricant Leaks Wheel Seal: All Technical Service Bulletins Rear Axle Hub Seal - Lubricant Leaks Article No. 91-6-7 03/18/91 ^ AXLE - NEW HUB SEAL AND HUB SEAL REPLACER TOOL - VEHICLES WITH 10.25 INCH RING GEAR, FULL - FLOATING REAR AXLES ^ LEAKS - AXLE LUBE - 10.25 INCH RING GEAR, FULL - FLOATING REAR AXLES LIGHT TRUCK: 1985-91 F-250, F-350 ISSUE: A new hub seal and a hub seal replacer tool are now available for service. The new hub seal is designed to improve sealing when properly installed using the new hub seal replacer tool. ACTION: Install a new hub seal (FOTZ-1177-A) with the new hub seal replacer tool (T91T-1175-A). Refer to the following inspection list and service procedure for details. NOTE: DO NOT USE THE OLD HUB SEAL REPLACER TOOL (T85T-1175-AH). IT IS NOT DESIGNED TO INSTALL THE NEW SEAL. THE NEW HUB SEAL REPLACER TOOL IS AVAILABLE IN THE 1991 DEALER ESSENTIAL SERVICE TOOL KIT AND IS THE ONLY TOOL APPROVED TO INSTALL THE NEW SEAL. INSPECTION PRIOR TO SEAL INSTALLATION Prior to seal installation, make sure that the following items are checked and servicing action taken where indicated. ^ Inspect the outer diameter of the hub seal to be sure that it is dry and free of oil and grease. ^ Check the hub bore to be sure it is free of grease, dirt and debris. ^ Remove any nicks or burrs from the hub bore. ^ Inspect the inner and outer bearing for damage and replace as required. ^ Pack each hub bearing cone and roller with a bearing packing tool using XG-1-C grease. ^ Make sure that no residual grease from freshly greased bearings gets into the hub bore. ^ Prior to installing the hub assembly, clean the spindle thoroughly and inspect the seal and bearing journals for nicks and/or scratches. Remove nicks or scratches using crocus cloth or similar material. ^ Wipe spindle clean and lightly oil with clean axle lube or engine oil. Figure 1 REMOVAL & INSTALLATION PROCEDURE 1. Install the hub in a soft jawed vice. 2. Remove the hub seal as shown in Figure 1. CAUTION: CARE MUST BE TAKEN NOT TO DAMAGE THE HUB SEAL BORE WITH THE SEAL REMOVAL TOOL. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Seal > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Seal: > 9167 > Mar > 91 > Rear Axle Hub Seal - Lubricant Leaks > Page 5820 Figure 2 3. Thoroughly clean and inspect the hub bore, Figure 2. CAUTION: MAKE SURE THE HUB BORE IS FREE OF DIRT, GREASE, BURRS OR NICKS. NOTE: HUB BEARINGS MUST BE PRELUBED WITH GREASE PRIOR TO INSTALLATION. USE XG-1-C GREASE OR EQUIVALENT. 4. Pack each bearing cone and roller assembly with a bearing packing tool. Figure 3 5. Install the seal in the hub with the Ford logo facing up, Figure 3. CAUTION: HUB SEAL MUST BE FREE OF DIRT OR GREASE. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Seal > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Seal: > 9167 > Mar > 91 > Rear Axle Hub Seal - Lubricant Leaks > Page 5821 Figure 4 6. Install the hub oil seal on the hub seal installer tool, T91T-1175-A, Figure 4. Figure 5 7. Insert the tool with the seal squarely into the hub, Figure 5. Figure 6 8. Hold the tool straight. Strike the handle until the hub seal is fully seated (until tool strikes hub), Figure 6. CAUTION: INSTALL NEW SEAL IF SEAL IS MISALIGNED DURING OR AFTER INSTALLATION. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Seal > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Seal: > 9167 > Mar > 91 > Rear Axle Hub Seal - Lubricant Leaks > Page 5822 It is extremely important that the 1991 F-Series Shop Manual procedures be followed when installing the hub assembly. CAUTION: THE SPECIFIED TORQUING AND BACKING OFF OF THE HUB NUT IS CRITICAL IN ORDER TO PERFORM THE REPAIR CORRECTLY. NOTE: ALWAYS TURN THE HUB WHILE TIGHTENING THE HUB NUT. ONCE THE SPECIFIED TORQUE 55-65 LB.FT., (75-88 N-m) IS ACHIEVED, RATCHETING BACK ON THE HUB NUT VARIES DEPENDING ON WHETHER THE HUB BEARINGS ARE NEW OR USED. BACK OFF 5 CLICKS FOR NEW BEARING AND 8 CLICKS FOR USED BEARINGS. Make sure hub nut wrench tool (T85T-4252-AH) is used as shown in the Shop Manual procedure. Consult The 1991 F-Series Light Truck Shop Manual, Section 05-02B, for service procedures and torque specifications. PART NUMBER PART NAME CLASS FOTZ-1177-A Hub Seal B XG-1-C Grease (14 oz. cartridge, Pkg. V 60) OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 509000 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Seal > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Seal: > 862223 > Nov > 86 > Axle - Rear Axle Hub Seals Leak Wheel Seal: All Technical Service Bulletins Axle - Rear Axle Hub Seals Leak Article No. 86-22-23 AXLE (10.25") - REAR - HUB SEALS LEAK - VENT PLUGGED LIGHT TRUCK 1985-86 F-250/350 A plugged rear axle vent may cause water to be sucked in through the seals and grease to be pushed out. This happens when pressures rise and fall inside the axle during various driving conditions and temperatures. The purpose of the vent is to relieve those pressures. If the vent is plugged with mud or other foreign materials, the axle cannot "breathe". To eliminate this concern, perform the following procedure: Figure 17 1. Remove the vent from the axle (Figure 17). 2. Place the vent in a vise so as not to damage the threads. 3. Drill out the vent using a 3/16 inch drill bit. Clean all shavings from vent. 4. Install vent. 5. Make sure entire vent hose is clear of dirt and mud, etc. 6. Install hose. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION: SP4022A86 TIME: 0.5 Hr. DLR. CODING: Basic Part No. 4022 - Code: 55 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Tire Wear - Toe Set Prior Vehicle Service Tires: Technical Service Bulletins Tire Wear - Toe Set Prior Vehicle Service Article No. 86-24-28 TIRE WEAR - TOE SET PRIOR TO VEHICLE PLACEMENT INTO SERVICE VEHICLES WITH SNOWPLOW SCHOOL BUSES, AMBULANCES LIGHT TRUCK 1985-86 RANGER, F-SERIES, BRONCO, ECONOLINE Certain model vehicles have a significant weight change on the front axle between manufacture by Ford and placement into service. This occurs when incomplete vehicles are completed by a body company or when equipment is added to a complete vehicle (i.e., winches, plows, tool boxes, etc.). This weight change can affect toe setting so these vehicles require that toe be reset. Figure 25 The tag shown in Figure 25 is attached to the steering column of vehicles originally built with the intent to add additional equipment. These vehicles require toe reset. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Tire Wear - Toe Set Prior Vehicle Service > Page 5832 Tires: Technical Service Bulletins Front Tires - Irregular Wear Pattern Article No. 86-24-27 TIRE WEAR - FRONT - IRREGULAR PATTERN LIGHT TRUCK 1985-87 ALL LIGHT TRUCKS Vehicles may experience front tire wear with all season/all terrain tires described as irregular, heel and toe, or diagonal. The condition may be related to alignment settings, vehicle usage, and tire tread/ carcass/compound design. Tires with minimal wear conditions should be crossrotated to the rear and alignment checked and set to Shop Manual preferred settings for toe. In cases of severe wear, obtain the complete alignment readings and tire information. Contact both your Ford Representative and Tire Manufacturer's Representative for their assistance and participation in resolving the customer's concern. Contacting the "local" tire store may not obtain the assistance which may be available from the tire manufacturer. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Tire Wear - Toe Set Prior Vehicle Service > Page 5833 Tires: Technical Service Bulletins Tires - Best Pressure For Load Application ^33GTIRE - LOAD CAPACITY VERSUS INFLATION PRESSURE ^ TIRE - P - METRIC PASSENGER TIRES USED ON LIGHT TRUCKS ^ TIRE WEAR - EFFECTS OF INFLATION AND LOAD Article No. 89-9-16 LIGHT TRUCK: 1984-89 ALL LIGHT TRUCK LINES ISSUE: Tire wear can be affected by inflation and load. Good tread life is dependent on maintaining proper air pressure in the tires. Other factors that affect tire wear are: ^ alignment ^ speed ^ road surfaces ACTION: Keep tires inflated to the recommended pressures to obtain maximum tread life. Use the following charts and procedures to arrive at the best tire pressure for each load application. FIGURE 1 The chart in Figure 1 shows the affect of inflation and load on tire tread life. Use the chart by finding the specified inflation pressure for the vehicle as shown on the certification label and locating that pressure on the specified inflation pressure on the chart. The affects of actual air pressure and load can now be read directly off the chart. Tire load carrying capacity is a function of tire design and inflation pressures. Each tire has molded into the sidewall a maximum pressure for a specific usage. Use the following guidelines to determine load carrying capacity. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Tire Wear - Toe Set Prior Vehicle Service > Page 5834 FIGURE 2 ^ For P-metric passenger tires on passenger cars, the values are as shown on the tire. ^ For P-metric passenger tires on light trucks, the load ratings are reduced to 91% to reflect the "harsher" truck environment, Figure 2. ^ For light truck style tires used on light trucks, the values are as shown for tires used in single wheel applications. ^ For light truck style tires used in dual wheel applications, the tire capacities are derated. Often, inflation pressures for specific vehicles are less than maximum capacity because the load to be carried is less than the maximum tire capacity. Inflation pressures for originally installed size tires on a vehicle are shown on the vehicle certification label along with the tire size and rated capacity for the axle system. Check the size and inflation information on the label to properly inflate the tires. Be sure that the same size tire is actually on the vehicle and then inflate it to the label's specified pressure. If other than original size tires are on the vehicle, the label's pressures are probably not correct To find proper pressures for other than original tires, use the following procedure. 1. Obtain both front and rear axle capacity ratings (GAWRR and GAWRF). 2. Divide each number by 2 to obtain the capacity at the tire. FIGURE 3 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Tire Wear - Toe Set Prior Vehicle Service > Page 5835 3. For single wheel usage, look up the pressure in the proper chart which will meet the needed capacity, Figure 3. 4. Check the tire side wall label to see if it permits inflation to that pressure. If lower load range tires were installed (i.e., C vs. D or E), the tires may not have the needed capability. 5. Divide the value found in Step 2 by 2 again to obtain individual tire requirements for dual rear wheels. 6. Using a dual wheel inflation pressure chart, Figure 3, determine correct pressure to achieve adequate load capacities. 7. Consult the local tire outlet or the tire manufacturer's home office about tires not shown in the tables. OTHER APPLICABLE ARTICLES: 87-10-11 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 3300 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 911116 > May > 91 > Wheel - Mounting Surface Distorted Lug/Pilot Holes Wheels: Customer Interest Wheel - Mounting Surface Distorted Lug/Pilot Holes Article No. 91-11-16 05/30/91 ^ WHEEL - DISTORTED PILOT HOLES OR LUG HOLES - WITH 16 X 6 SINGLE STEEL WHEELS ^ VIBRATION - WHEEL MOUNTING SURFACE DISTORTED - WITH 16 X 6 SINGLE STEEL WHEELS LIGHT TRUCK: 1985-91 E-250-350, F-250-350 ISSUE: Wheel vibration may be caused by distorted pilot holes or lug holes on the wheel. This does not allow sufficient clamp load between the lug nut, the wheel and the rotor/hub. It may also be difficult to remove the distorted wheel from the vehicle or to place the wheel on the vehicle in a different location. ACTION: To determine if a wheel has been damaged and should not be reused, refer to the following service procedure for details. NOTE: THIS PROCEDURE ONLY APPLIES TO PART # E7UA-1015-JA (16 X 6 SINGLE STEEL WHEEL) INSPECT FOR WHEEL DAMAGE 1. Remove the wheel from the hub. If the wheel is difficult to remove, DO NOT reuse the wheel. 2. Visually inspect the wheel for distortion (turned-up) scallops in the pilot hole. If the pilot hole is distorted, DO NOT reuse the wheel. 3. Inspect the distorted lug holes by placing a lug nut in the lug hole cone seat of the wheel and inspect from the reverse side. If the lug protrudes through the lug hole, DO NOT reuse the wheel. 4. Inspect the wheel mounting surface for distortion. a. Lay a straight edge across the mounting surface of the wheel (the surface of the wheel which makes contact with the rear brake drum or front rotor). b. The straight edge should contact the outer edge of the mounting surface, lying between the bolt holes and across the center of the pilot hole. c. The clearance between the straight edge and the pilot hole can not exceed 0.0300 inch, the straight edge should not contact the pilot holes. If the clearance is more than 0.0300 or the straight edge makes contact with the pilot holes, DO NOT reuse the wheel. INSTALL WHEEL 1. Inspect for lubricants on the studs and lug nuts. 2. If lubricants are present, clean throughly using naphtha or equivalent. 3. Torque lug nuts to (140 ft.lbs./190 N-m) using a torque wrench according to the Shop Manual, Section 04-04. CAUTION: EXCESSIVE TORQUE MAY CAUSE DISTORTION OF THE WHEEL. INADEQUATE TORQUE MAY NOT PROVIDE ADEQUATE CLAMPING FORCE TO ASSURE WHEEL RETENTION. PART NUMBER PART NAME CLASS E5TZ-1015-B Wheel AM OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION DESCRIPTION TIME 911116A Wheel-Inspect 0.7 hrs 911116B Replace One Wheel And 0.4 Hr. Dynamic Balance 911116C Replace Two Wheels And 0.8 Hr. Dynamic Balance Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 911116 > May > 91 > Wheel - Mounting Surface Distorted Lug/Pilot Holes > Page 5844 911116D Replace Three Wheels And 1.2 Hr. Dynamic Balance 911116E Replace Four Wheels And 1.6 Hr. Dynamic Balance DEALER CODING BASIC PART NO. CONDITION CODE 1015 67 OASIS CODES: 306000, 703000 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 911116 > May > 91 > Wheel - Mounting Surface Distorted Lug/Pilot Holes Wheels: All Technical Service Bulletins Wheel - Mounting Surface Distorted Lug/Pilot Holes Article No. 91-11-16 05/30/91 ^ WHEEL - DISTORTED PILOT HOLES OR LUG HOLES - WITH 16 X 6 SINGLE STEEL WHEELS ^ VIBRATION - WHEEL MOUNTING SURFACE DISTORTED - WITH 16 X 6 SINGLE STEEL WHEELS LIGHT TRUCK: 1985-91 E-250-350, F-250-350 ISSUE: Wheel vibration may be caused by distorted pilot holes or lug holes on the wheel. This does not allow sufficient clamp load between the lug nut, the wheel and the rotor/hub. It may also be difficult to remove the distorted wheel from the vehicle or to place the wheel on the vehicle in a different location. ACTION: To determine if a wheel has been damaged and should not be reused, refer to the following service procedure for details. NOTE: THIS PROCEDURE ONLY APPLIES TO PART # E7UA-1015-JA (16 X 6 SINGLE STEEL WHEEL) INSPECT FOR WHEEL DAMAGE 1. Remove the wheel from the hub. If the wheel is difficult to remove, DO NOT reuse the wheel. 2. Visually inspect the wheel for distortion (turned-up) scallops in the pilot hole. If the pilot hole is distorted, DO NOT reuse the wheel. 3. Inspect the distorted lug holes by placing a lug nut in the lug hole cone seat of the wheel and inspect from the reverse side. If the lug protrudes through the lug hole, DO NOT reuse the wheel. 4. Inspect the wheel mounting surface for distortion. a. Lay a straight edge across the mounting surface of the wheel (the surface of the wheel which makes contact with the rear brake drum or front rotor). b. The straight edge should contact the outer edge of the mounting surface, lying between the bolt holes and across the center of the pilot hole. c. The clearance between the straight edge and the pilot hole can not exceed 0.0300 inch, the straight edge should not contact the pilot holes. If the clearance is more than 0.0300 or the straight edge makes contact with the pilot holes, DO NOT reuse the wheel. INSTALL WHEEL 1. Inspect for lubricants on the studs and lug nuts. 2. If lubricants are present, clean throughly using naphtha or equivalent. 3. Torque lug nuts to (140 ft.lbs./190 N-m) using a torque wrench according to the Shop Manual, Section 04-04. CAUTION: EXCESSIVE TORQUE MAY CAUSE DISTORTION OF THE WHEEL. INADEQUATE TORQUE MAY NOT PROVIDE ADEQUATE CLAMPING FORCE TO ASSURE WHEEL RETENTION. PART NUMBER PART NAME CLASS E5TZ-1015-B Wheel AM OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION DESCRIPTION TIME 911116A Wheel-Inspect 0.7 hrs 911116B Replace One Wheel And 0.4 Hr. Dynamic Balance 911116C Replace Two Wheels And 0.8 Hr. Dynamic Balance Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 911116 > May > 91 > Wheel - Mounting Surface Distorted Lug/Pilot Holes > Page 5850 911116D Replace Three Wheels And 1.2 Hr. Dynamic Balance 911116E Replace Four Wheels And 1.6 Hr. Dynamic Balance DEALER CODING BASIC PART NO. CONDITION CODE 1015 67 OASIS CODES: 306000, 703000 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 90199 > Sep > 90 > Lug Nuts - Proper Torqueing Procedure Wheels: All Technical Service Bulletins Lug Nuts - Proper Torqueing Procedure ^ BRAKE SHUDDER - ROTOR DISTORTED - OVERTIGHTENED LUG NUTS ^ WHEEL - NUT INSTALLATION - SERVICE TIP Article No. 90-19-9 FORD: 1986-91 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS, TEMPO, THUNDERBIRD 1988-91 FESTIVA 1989-91 PROBE LINCOLN-MERCURY: 1986 CAPRI 1986-87 LYNX 1986-91 CONTINENTAL, COUGAR, GRAND MARQUIS, MARK VII, SABLE, TOPAZ, TOPAZ, TOWN CAR 1987-89 TRACER 1991 CAPRI, TRACER MERKUR: 1985-88 XR4TI 1988-89 SCORPIO LIGHT TRUCK: 1986-90 BRONCO II 1986-91 AEROSTAR, BRONCO, ECONOLINE, F-150-350 SERIES, RANGER 1988-91 F SUPER DUTY 1991 EXPLORER ISSUE: The use of a power impact wrench to install wheel nuts provides minimal torque control. Undertightening may allow the lug nuts to loosen, and can result in the wheel separating from the vehicle. Overtightening of wheel nuts may cause brake rotor distortion that could result in a brake shudder. Overtightening may cause distortion of the wheel. This can result in a change in the diameter of the center (axle) hole and make it difficult to remove from the axle it is mounted on or difficult or impossible to install on another axle with a smaller center hole diameter. ACTION: Use a manual torque wrench to tighten wheel nuts. Refer to the approriate Shop Manual for specific torque values. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 306000, 301000 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 911211 > Jun > 91 > Engine - Lack of Power/No Start Diagnosis Ignition Rotor: All Technical Service Bulletins Engine - Lack of Power/No Start Diagnosis Article No. 91-12-11 06/12/91 LACK OF POWER 7.5L, 5.8L, 5.0L, 4.9L - CATALYTIC CONVERTER DIAGNOSTIC TIPS LIGHT TRUCK: 1986-91 BRONCO, ECONOLINE, F-150-350 SERIES 1988-91 F SUPER DUTY, F47 ISSUE: Lack of power or a no start condition may be diagnosed as an exhaust restriction caused by a plugged catalytic converter. A plugged catalytic converter (internal deterioration) is usually caused by abnormal engine operation. ACTION: Diagnose the catalytic converter to confirm internal failure. Refer to the Catalyst and Exhaust System Diagnostic Section, in the Engine/Emissions Diagnostic Shop Manual and the following procedures for service details. 1. Lack of proper HEGO operation may cause, or be the result of a rich or lean fuel condition, which could cause additional heat in the catalyst. Perform self test KOEO and KOER, service any codes. NOTE: IF TWO DIGIT CODES 41, 42, 85 OR THREE DIGIT CODES 171, 172, 173, 179, 181, 182, 183 AND 565 ARE RECEIVED, CHECK FOR PROPER HEGO GROUND. If the HEGO ground is good, the following areas may be at fault: ^ Ignition Coil ^ Distributor Cap ^ Distributor Rotor ^ Fouled Spark Plug ^ Spark Plug Wires ^ Air Filter ^ Stuck Open Injector ^ Fuel Contamination Engine OIL ^ Manifold Leaks Intake/ Exhaust ^ Fuel Pressure ^ Poor Power Ground ^ Engine Not At Normal Operating Temperature ^ HEGO Sensor 2. Spark timing that is retarded from specification may increase exhaust gas temperature and shorten catalyst life. Refer to the following procedure for service details. a. Check spark timing. Check base timing with spout disconnected. Set base timing to the specification on the vehicle emission decal. b. Check computed timing with spout connected. NOTE: COMPUTED TIMING IS EQUAL TO BASE TIMING PLUS 20~ BTDC +/- 3~. 3. Misfiring spark plugs may cause an unburned fuel air mixture to pass through the catalyst, which could cause higher than normal catalyst temperatures. Refer to the following procedure for service details. a. Check secondary ignition, hook the vehicle up to an engine analyzer and check for a secondary ignition misfire. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 911211 > Jun > 91 > Engine - Lack of Power/No Start Diagnosis > Page 5860 NOTE: SERVICE ANY ITEM THAT IS NOT PERFORMING AT PROPER SPECIFICATIONS BEFORE CONTINUING. 4. Fuel pressure that is too high may cause rich air fuel mixtures to pass through the catalyst which could cause higher than normal catalyst temperatures. Refer to the following procedure for service details. a. Check fuel pressure, install fuel pressure gauge, start and run the engine at idle. Fuel pressures between 28 and 34 PSI are typical (4.9L typically is 15 PSI higher). b. Disconnect the vacuum line going to the fuel pressure regulator. Fuel pressure typically jumps to 40 PSI +/- 3 PSI (4.9L typically is 15 PSI higher). Visually inspect vacuum line for raw fuel. NOTE: FUEL PRESSURES ABOVE THESE VALUES SHOULD BE CORRECTED. HOWEVER, THIS MAY NOT BE THE CAUSE OF THE CONCERN. SERVICE AS NECESSARY. 5. Throttle plates in the throttle body not returning to the proper closed position may cause excessive catalyst temperatures during downhill grades. Refer to the following procedure for service details. a. Visually inspect the throttle body and linkage for: ^ Binding or sticking throttle linkage. ^ Tight speed control linkage or cable. ^ Vacuum line interference. ^ Electrical harness interference. NOTE: AFTERMARKET GOVERNORS, THROTTLE LINKAGE AND CABLES ASSOCIATED WITH POWER TAKE-OFF UNITS, MAY ALSO INTERFERE WITH PROPER THROTTLE RETURN. SERVICE AS NECESSARY. 6. It is extremely important that all systems related to the engine and emission systems operate properly. a. Visually inspect the engine compartment to make sure all vacuum hoses and spark plug wires are properly routed and securely connected. b. Inspect all wiring harnesses and connectors for insulation damage, burned, overheated, loose or broken conditions. c. Verify proper operation of the thermactor system. Thermactor systems that fail to dump thermactor air to the atmosphere properly or at the correct time can cause high catalyst temperatures. d. Visually inspect thermactor system for damaged or kinked hoses and perform a function test on following components: air control valve, check valve, silencer, filter and the air bypass solenoid. e. Verify proper operation of the engine cooling system thermostat. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under Basic Warranty Coverage, Emissions Warranty Coverage OPERATION DESCRIPTION TIME 911211A Diagnostics - Perform 0.5 Hrs. KOEO And KOER Self Tests 911211B Timing - Check Or Adjust 0.5 Hrs. Spark Timing, Check Computed Timing And Check Secondary Ignition System With Engine Analyzer. 911211C Check - Fuel Pressure And 0.2 Hrs. Inspect Vacuum Line For Raw Fuel. 911211D Inspect - Throttle Body And 0.1 Hrs. Linkage. 911211E Inspect - Vacuum Hoses, 0.1 Hrs. Electrical Harnesses, Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 911211 > Jun > 91 > Engine - Lack of Power/No Start Diagnosis > Page 5861 Connectors And Spark Plug Wires For Routing Damage. 911211F Thermactor System - 0.3 Hrs. Inspect For Proper Operation And Damaged Component. Includes Function Check Of Air Control Valve, Thermactor Air Bypass Solenoid, Check Valves, Silencer And Filter. 911211G Thermostat - Check For 0.2 Hrs. Proper Operation. DEALER CODING BASIC PART NO. CONDITION CODE 5E212 25 OASIS CODES: 403000, 603300, 614000 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 85218 > Oct > 85 > Distributor Rotor - Engine Bucking/Surging Ignition Rotor: All Technical Service Bulletins Distributor Rotor - Engine Bucking/Surging Article No. 85-21-8 ENGINE MISS - DISTRIBUTOR WITH BLADE ROTOR - SILICONE GREASE ENGINE SURGE - DISTRIBUTOR WITH BLADE ROTOR - SILICONE GREASE RADIO NOISE - DISTRIBUTOR WITH BLADE ROTOR - SILICONE GREASE FORD 1986 ESCORT, EXP, TEMPO, MUSTANG, THUNDERBIRD, TAURUS, LTD, CROWN VICTORIA LINCOLN-MERCURY 1986 LYNX, TOPAZ, CAPRI, COUGAR, SABLE, MARQUIS, CONTINENTAL, MARK VII, LINCOLN LIGHT TRUCK 1986 E/F SERIES, BRONCO, RANGER, BRONCO II, AEROSTAR CALIBRATION: All with EEC IV 1986 vehicles are equipped with a new "blade" design distributor rotor. This design replaces the multi-point rotor used in recent model years. This new rotor requires the use of silicone grease on the blade. Electrical interference can result from a blade rotor that does not have silicone grease. The electrical interference affects the distributor stator assembly and can cause engine "missing", "bucking", or "surging". These drive concerns are usually intermittent and tend to occur during crank and heavy or wide-open throttle. It is important to remember not to remove the silicone grease for radio noise concerns, on 1986 vehicles with EEC IV; removing the grease can cause driveability concerns. A future TSB article will address the radio noise issue. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 911211 > Jun > 91 > Engine - Lack of Power/No Start Diagnosis > Page 5871 NOTE: SERVICE ANY ITEM THAT IS NOT PERFORMING AT PROPER SPECIFICATIONS BEFORE CONTINUING. 4. Fuel pressure that is too high may cause rich air fuel mixtures to pass through the catalyst which could cause higher than normal catalyst temperatures. Refer to the following procedure for service details. a. Check fuel pressure, install fuel pressure gauge, start and run the engine at idle. Fuel pressures between 28 and 34 PSI are typical (4.9L typically is 15 PSI higher). b. Disconnect the vacuum line going to the fuel pressure regulator. Fuel pressure typically jumps to 40 PSI +/- 3 PSI (4.9L typically is 15 PSI higher). Visually inspect vacuum line for raw fuel. NOTE: FUEL PRESSURES ABOVE THESE VALUES SHOULD BE CORRECTED. HOWEVER, THIS MAY NOT BE THE CAUSE OF THE CONCERN. SERVICE AS NECESSARY. 5. Throttle plates in the throttle body not returning to the proper closed position may cause excessive catalyst temperatures during downhill grades. Refer to the following procedure for service details. a. Visually inspect the throttle body and linkage for: ^ Binding or sticking throttle linkage. ^ Tight speed control linkage or cable. ^ Vacuum line interference. ^ Electrical harness interference. NOTE: AFTERMARKET GOVERNORS, THROTTLE LINKAGE AND CABLES ASSOCIATED WITH POWER TAKE-OFF UNITS, MAY ALSO INTERFERE WITH PROPER THROTTLE RETURN. SERVICE AS NECESSARY. 6. It is extremely important that all systems related to the engine and emission systems operate properly. a. Visually inspect the engine compartment to make sure all vacuum hoses and spark plug wires are properly routed and securely connected. b. Inspect all wiring harnesses and connectors for insulation damage, burned, overheated, loose or broken conditions. c. Verify proper operation of the thermactor system. Thermactor systems that fail to dump thermactor air to the atmosphere properly or at the correct time can cause high catalyst temperatures. d. Visually inspect thermactor system for damaged or kinked hoses and perform a function test on following components: air control valve, check valve, silencer, filter and the air bypass solenoid. e. Verify proper operation of the engine cooling system thermostat. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under Basic Warranty Coverage, Emissions Warranty Coverage OPERATION DESCRIPTION TIME 911211A Diagnostics - Perform 0.5 Hrs. KOEO And KOER Self Tests 911211B Timing - Check Or Adjust 0.5 Hrs. Spark Timing, Check Computed Timing And Check Secondary Ignition System With Engine Analyzer. 911211C Check - Fuel Pressure And 0.2 Hrs. Inspect Vacuum Line For Raw Fuel. 911211D Inspect - Throttle Body And 0.1 Hrs. Linkage. 911211E Inspect - Vacuum Hoses, 0.1 Hrs. Electrical Harnesses, Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 911211 > Jun > 91 > Engine - Lack of Power/No Start Diagnosis > Page 5872 Connectors And Spark Plug Wires For Routing Damage. 911211F Thermactor System - 0.3 Hrs. Inspect For Proper Operation And Damaged Component. Includes Function Check Of Air Control Valve, Thermactor Air Bypass Solenoid, Check Valves, Silencer And Filter. 911211G Thermostat - Check For 0.2 Hrs. Proper Operation. DEALER CODING BASIC PART NO. CONDITION CODE 5E212 25 OASIS CODES: 403000, 603300, 614000 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Page 5877 Wheels: Specifications 5 LUG WHEEL 1/2-20 .................................................................................................................................................. ........................................... 135 Nm (100 lb ft) 8 LUG WHEEL 9/16-18 ................................................................................................................................................ ........................................... 190 Nm (140 lb ft) NOTE: Torque specifications are for clean, dirt and paint free dry bolt and nut threads. Never use oil or grease on studs and nuts. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Specifications Wheel Bearing: Specifications Wheel Adjusting Nut [1] ....................................................................................................................... ........................................... 30-33 Nm (22-25 ft lbs) Bearing End Play .............................................................................................................................................................. 0.025-0.254mm (0.001-0.010 in) [1] Back off the adjusting nut 1/8 turn and install the retainer and new cotter pin without additional movement of the adjusting nut. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Specifications > Page 5881 Wheel Bearing: Adjustments 1. Raise the vehicle until the tire clears the floor and install safety stands. 2. Remove the wheel cover. 3. Remove the grease cap from the hub. Wipe the excess grease from the end of the spindle. Remove the cotter pin and locknut. 4. Loosen the adjusting nut three turns. Attempt to obtain running clearance between the rotor brake surface and the disc pads by rocking the wheel, hub and rotor assembly in and out several times to push the pads away from the rotor. If running clearance cannot be maintained throughout bearing adjustment in Steps 5 and 6, the caliper must be removed. NOTE: Do not pry on the phenolic caliper piston. 5. Tighten the wheel adjusting nut to 30-33 Nm (22-25 ft lbs) while rotating the disc brake rotor in the opposite direction. 6. Back off the adjusting nut 1/8 turn and install the retainer and new cotter pin without additional movement of the adjusting nut. Bearing end play should be 0.025-0.254mm (0.001-0.010 in). Bend the ends of the cotter pin around the castellated flange of the locknut. 7. Check front wheel rotation. If the wheel rotates properly, reinstall the grease cap and wheel cover. If rotation is noisy or rough, remove and inspect the bearings. Service as required. WARNING: Before driving the vehicle, pump the brake pedal several times to restore normal brake pedal travel. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Specifications > Page 5882 Wheel Bearing: Service and Repair Wheel bearing lubricant is a lithium-base grease. Sodium-base grease is not compatible with lithium-base grease and should not be intermixed. Therefore, do not lubricate front and/or rear wheel bearings without first identifying the type of original wheel bearing lubricant. Usage of incompatible bearing lubricants may result in premature lubricant breakdown. REMOVAL Front Hub And Rotor Assembly 1. Raise the vehicle until the tire clears the floor and remove the wheel and tire assembly. 2. Remove the brake caliper and secure to the underbody to prevent damage to the brake hose. It is not necessary to disconnect the hose from the caliper. Do not let the caliper hang with its weight on the brake hose or the hose may become stretched, twisted or ruptured. See: Brakes and Traction Control/Disc Brake System/Brake Caliper/Service and Repair 3. Remove the grease cap, cotter pin, retainer adjusting nut and washer. 4. Remove the outer bearing cone and roller. 5. Pull the hub and rotor off the spindle and remove and discard the grease seal. 6. Remove the inner bearing cone and roller from the hub. Remove all traces of old lubricant from bearings, hub and axle spindle. 7. Inspect the cups for scratches, pits or cracks. If the cups are worn or damaged, remove them with a drift. Clean the inner and outer bearing cones and rollers with solvent and dry thoroughly. CAUTION: Do not spin the bearings dry with compressed air. 8. Inspect the cones and rollers for cracks, nicks, brinelling, or seized rollers. Inspect the grease retainer and replace it if it is cracked, nicked, dented or worn. 9. Cover the spindle with a clean cloth. A water dampened cloth or water based solution should be used to remove and dust or loose dirt from the brake assembly. Remove the cloth from the spindle carefully to prevent dirt from falling on the spindle. NOTE: Do not use compressed air. INSTALLATION Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Specifications > Page 5883 Installing Bearing Cups (Typical) 1. If inner or outer bearing cups were removed, install replacement inner and outer bearing cups in the hub with the appropriate bearing cup replacer tool. Be sure to seat the cups properly in the hub. The cups will be properly seated when they are fully bottomed. Replace grease retainers. Polish grease retainer journal on spindle with 400 grit sandpaper. Clean with clean cloth. 2. Pack the inside of the hub with lithium-base grease or equivalent. Fill the hub until the grease is flush with the inside diameters of both bearing cups. Pack the bearing cones and rollers with wheel bearing grease. Use a bearing packer for this operation. If a packer is not available, work as much lubricant as possible between the rollers and cages. Lubricate the cone surfaces with grease. Installing Grease Seal (Typical) 3. Place the inner bearing cone and roller in the inner cup and install the new grease seal. Be sure that the seal is fully seated. 4. Install the hub and rotor on the wheel spindle. Keep the hub centered on the spindle to prevent damage to the grease retainer or the spindle threads. 5. Install the outer bearing cone and roller and the flat washer on the spindle, then install the adjusting nut, and adjust the wheel bearing. 6. Install the retainer, new cotter pin, and grease cap. 7. Install the caliper. 8. Install the wheel and tire assembly. 9. Lower vehicle and torque the lug nuts to specification. Re-install the wheel cover or hub cap. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Specifications > Page 5884 WARNING: Before driving the vehicle, pump the brake pedal several times to restore normal brake pedal travel. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Cover > Component Information > Technical Service Bulletins > Customer Interest for Wheel Cover: > 90118 > May > 90 > Wheel Cover - Centers Damaged By Stones Wheel Cover: Customer Interest Wheel Cover - Centers Damaged By Stones Article No. 90-11-8 WHEEL COVERS-16 INCH TURBINE WHEEL-CENTERS DAMAGED BY STONES LIGHT TRUCK: 1986-90 E-250, E-350, F-250, F-350 ISSUE: The wheel cover centers may be damaged by stones and debris hitting the cover. This condition is most noticeable during cold weather because the wheel cover material becomes very brittle. ACTION: Install new wheel covers made of a more durable plastic. The color of the new plastic material is gray which will help hide any stone chips. Refer to the following Wheel Cover Application Chart for correct parts usage. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION DESCRIPTION TIME 901108A Install Wheel Covers 0.2 Hr. DEALER CODING BASIC PART NO. CONDITION CODE 1130 01 OASIS CODES: 1052, 3300 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Cover > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Cover: > 90118 > May > 90 > Wheel Cover - Centers Damaged By Stones Wheel Cover: All Technical Service Bulletins Wheel Cover - Centers Damaged By Stones Article No. 90-11-8 WHEEL COVERS-16 INCH TURBINE WHEEL-CENTERS DAMAGED BY STONES LIGHT TRUCK: 1986-90 E-250, E-350, F-250, F-350 ISSUE: The wheel cover centers may be damaged by stones and debris hitting the cover. This condition is most noticeable during cold weather because the wheel cover material becomes very brittle. ACTION: Install new wheel covers made of a more durable plastic. The color of the new plastic material is gray which will help hide any stone chips. Refer to the following Wheel Cover Application Chart for correct parts usage. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION DESCRIPTION TIME 901108A Install Wheel Covers 0.2 Hr. DEALER CODING BASIC PART NO. CONDITION CODE 1130 01 OASIS CODES: 1052, 3300 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub > Axle Nut > Component Information > Technical Service Bulletins > Front Drive Axle - Retaining Nut Revision Axle Nut: Technical Service Bulletins Front Drive Axle - Retaining Nut Revision Article No. 85-21-13 AXLE - FRONT DRIVE (DANA 441FSHD, 501FS, 60F MONOBEAM) - NEW WHEEL BEARING LOCKNUTS LIGHT TRUCK 1985-86 F-250 HD/350 (4x4) Front axle hub and rotor assembly bearing adjusting and retaining nuts and lockwashers have been revised. Removal and installation procedures are the same as outlined in Section 11-12 of the 1985-86 Light Truck Shop Manual except the Front Wheel Bearing Adjusting Spanner, tool number D78T-1197-B (6-prong) is used with the old design adjusting nut (Dana part number 33732) and tool number D85T-1197-A (4- prong) is required for the new nuts (Dana part number 621029). OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > Customer Interest: > 87721 > Apr > 87 > Wheels- Lug Nuts Bind On Studs Wheel Fastener: Customer Interest Wheels- Lug Nuts Bind On Studs Article No. WHEEL - LUG NUTS BIND ON STUDS - VEHICLES 87-7-21 WITH 9/16" STUDS AND SINGLE REAR WHEELS LIGHT TRUCK: 1983-87 E-250/350, F-250/350 ISSUE: Some lug nuts may be difficult to remove due to nut crimping. The lug nuts are designed to be free-running as opposed to a "prevailing" torque style. The freerunning nuts may have "crimped in" against the stud when torqued. ACTION: To correct this, use new replacement nuts which will not "crimp in" when tightened to the recommended torque of 140 ft.lbs. (190 N-m). CAUTION: Lug nuts should be torqued by hand, not with an impact wrench, and retorqued at intervals specified in the Owner Guide. PART NUMBER PART NAME CLASS E7TZ-1120-A Lug Nut - R.H. Thread A - Package of 4 E7TZ-1121-A Lug Nut - L.H. Thread A - Package of 4 OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual OPERATION: SP870721A - Replace lug nuts TIME: 0.5 Hr. OPERATION: 1107B - Replace wheel studs TIME: Refer to the appropriate Service Labor Time Standards Manual OPERATION: "M" Time - Replace lug nut stuck on spinning stud, if required Requires District Authorization DLR. CODING: Basic Part No. 1120 - Code: 41 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 98-5A-4 > Mar > 98 > Lug Nuts - Proper Installation/Torqueing Procedure Wheel Fastener: All Technical Service Bulletins Lug Nuts - Proper Installation/Torqueing Procedure Article No. 98-5A-4 ^ BRAKES - PREVENTING BRAKE VIBRATION - SERVICE TIP ^ WHEELS - PROPER LUG TORQUE PROCEDURES - SERVICE TIP FORD: 1972-97 THUNDERBIRD 1976-86 LTD 1976-97 MUSTANG 1981-97 CROWN VICTORIA 1982-88 EXP 1982-98 ESCORT 1984-94 TEMPO 1986-97 TAURUS 1988-93 FESTIVA 1989-97 PROBE 1994-97 ASPIRE 1995-98 CONTOUR LINCOLN-MERCURY: 1979-83 MONARCH, ZEPHYR 1979-97 COUGAR 1980-83 MARK VI 1980-98 CONTINENTAL, TOWN CAR 1981-86 LYNX 1983-86 MARQUIS 1984-92 MARK VII 1984-94 TOPAZ 1986-97 SABLE 1987-89 TRACER 1987-97 GRAND MARQUIS 1991-94 CAPRI 1991-97 TRACER 1993-98 MARK VIII 1995-98 MYSTIQUE LIGHT TRUCK: 1979-96 BRONCO 1979-97 ECONOLINE, F-150-350 SERIES 1984-90 BRONCO II 1984-97 RANGER 1986-97 AEROSTAR 1988-97 F SUPER DUTY 1991-97 EXPLORER 1993-97 VILLAGER 1995-98 WINDSTAR 1997 EXPEDITION 1998 NAVIGATOR ISSUE: The use of air impact tools to tighten wheel lug nuts can lead to overtightened and/or unevenly tightened wheel lug nuts. Air impact tools typically used for wheel lug nut removal and installation can generate up to 475 N.m (350 lb-ft) of torque. Overtightened and/or unevenly torqued wheel lug nuts may cause: ^ Brake vibration ^ Distortion of the wheel hub ^ Distortion of the brake rotor Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 98-5A-4 > Mar > 98 > Lug Nuts - Proper Installation/Torqueing Procedure > Page 5916 ^ Brake rotor runout ^ Damage to the wheel ^ Damage to the wheel nuts and studs ACTION: All wheel lug nuts should only be tightened to specification using a torque wrench or by using the Rotunda ACCUTORO 164-R0314 or equivalent on a 1/2" drive air impact tool. The "ACCUTORO" lug nut sockets limit the torque of the air impact tool, preventing overtightening or uneven tightening of the wheel lug nuts. The torque limiting devices (regulators) on air impact tools will not reduce the output torque enough to prevent overtightening of the wheel lug nuts. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 98-5A-4 > Mar > 98 > Lug Nuts - Proper Installation/Torqueing Procedure > Page 5917 NOTE: REFER TO THE APPROPRIATE SERVICE MANUAL OR THE CHART IN FIGURE 1 FOR THE CORRECT WHEEL LUG NUT TORQUE SPECIFICATION. THE CHART IN FIGURE 1 ALSO PROVIDES THE CORRECT "ACCUTORO" LUG NUT SOCKET TO USE. The "ACCUTORO" socket is intended for lug nut installation, not removal. When using the "ACCUTORO" socket, the output torque of the air impact tool must be set to 217-339 N.m (160-250 lb-ft), usually this will be the lowest setting on the air impact tool. The "ACCUTORO" lug nut sockets are available through Rotunda Equipment. The four-piece set (164-R0314) fits most Ford Motor Company cars and light trucks. The tool set consists of four (4) lug nut sockets and a storage case. The set can be ordered by calling Rotunda Equipment at 1-800-ROT-UNDA (768-8632). CAUTION: AIR IMPACT TOOLS SHOULD NOT BE USED TO TIGHTEN WHEEL LUG NUTS UNLESS THE "ACCUTORO" LUG NUT SOCKET OF THE CORRECT SPECIFICATION IS USED. NOTE: DO NOT USE AIR IMPACT TOOLS ON LOCKING WHEEL LUG NUTS. THEY ARE TO BE HAND-TORQUED ONLY. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 97-17-6 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 301000, 303000, 306000 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 87721 > Apr > 87 > Wheels- Lug Nuts Bind On Studs Wheel Fastener: All Technical Service Bulletins Wheels- Lug Nuts Bind On Studs Article No. WHEEL - LUG NUTS BIND ON STUDS - VEHICLES 87-7-21 WITH 9/16" STUDS AND SINGLE REAR WHEELS LIGHT TRUCK: 1983-87 E-250/350, F-250/350 ISSUE: Some lug nuts may be difficult to remove due to nut crimping. The lug nuts are designed to be free-running as opposed to a "prevailing" torque style. The freerunning nuts may have "crimped in" against the stud when torqued. ACTION: To correct this, use new replacement nuts which will not "crimp in" when tightened to the recommended torque of 140 ft.lbs. (190 N-m). CAUTION: Lug nuts should be torqued by hand, not with an impact wrench, and retorqued at intervals specified in the Owner Guide. PART NUMBER PART NAME CLASS E7TZ-1120-A Lug Nut - R.H. Thread A - Package of 4 E7TZ-1121-A Lug Nut - L.H. Thread A - Package of 4 OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual OPERATION: SP870721A - Replace lug nuts TIME: 0.5 Hr. OPERATION: 1107B - Replace wheel studs TIME: Refer to the appropriate Service Labor Time Standards Manual OPERATION: "M" Time - Replace lug nut stuck on spinning stud, if required Requires District Authorization DLR. CODING: Basic Part No. 1120 - Code: 41 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Fastener: > 911211 > Jun > 91 > Engine - Lack of Power/No Start Diagnosis Ignition Rotor: All Technical Service Bulletins Engine - Lack of Power/No Start Diagnosis Article No. 91-12-11 06/12/91 LACK OF POWER 7.5L, 5.8L, 5.0L, 4.9L - CATALYTIC CONVERTER DIAGNOSTIC TIPS LIGHT TRUCK: 1986-91 BRONCO, ECONOLINE, F-150-350 SERIES 1988-91 F SUPER DUTY, F47 ISSUE: Lack of power or a no start condition may be diagnosed as an exhaust restriction caused by a plugged catalytic converter. A plugged catalytic converter (internal deterioration) is usually caused by abnormal engine operation. ACTION: Diagnose the catalytic converter to confirm internal failure. Refer to the Catalyst and Exhaust System Diagnostic Section, in the Engine/Emissions Diagnostic Shop Manual and the following procedures for service details. 1. Lack of proper HEGO operation may cause, or be the result of a rich or lean fuel condition, which could cause additional heat in the catalyst. Perform self test KOEO and KOER, service any codes. NOTE: IF TWO DIGIT CODES 41, 42, 85 OR THREE DIGIT CODES 171, 172, 173, 179, 181, 182, 183 AND 565 ARE RECEIVED, CHECK FOR PROPER HEGO GROUND. If the HEGO ground is good, the following areas may be at fault: ^ Ignition Coil ^ Distributor Cap ^ Distributor Rotor ^ Fouled Spark Plug ^ Spark Plug Wires ^ Air Filter ^ Stuck Open Injector ^ Fuel Contamination Engine OIL ^ Manifold Leaks Intake/ Exhaust ^ Fuel Pressure ^ Poor Power Ground ^ Engine Not At Normal Operating Temperature ^ HEGO Sensor 2. Spark timing that is retarded from specification may increase exhaust gas temperature and shorten catalyst life. Refer to the following procedure for service details. a. Check spark timing. Check base timing with spout disconnected. Set base timing to the specification on the vehicle emission decal. b. Check computed timing with spout connected. NOTE: COMPUTED TIMING IS EQUAL TO BASE TIMING PLUS 20~ BTDC +/- 3~. 3. Misfiring spark plugs may cause an unburned fuel air mixture to pass through the catalyst, which could cause higher than normal catalyst temperatures. Refer to the following procedure for service details. a. Check secondary ignition, hook the vehicle up to an engine analyzer and check for a secondary ignition misfire. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Fastener: > 911211 > Jun > 91 > Engine - Lack of Power/No Start Diagnosis > Page 5927 NOTE: SERVICE ANY ITEM THAT IS NOT PERFORMING AT PROPER SPECIFICATIONS BEFORE CONTINUING. 4. Fuel pressure that is too high may cause rich air fuel mixtures to pass through the catalyst which could cause higher than normal catalyst temperatures. Refer to the following procedure for service details. a. Check fuel pressure, install fuel pressure gauge, start and run the engine at idle. Fuel pressures between 28 and 34 PSI are typical (4.9L typically is 15 PSI higher). b. Disconnect the vacuum line going to the fuel pressure regulator. Fuel pressure typically jumps to 40 PSI +/- 3 PSI (4.9L typically is 15 PSI higher). Visually inspect vacuum line for raw fuel. NOTE: FUEL PRESSURES ABOVE THESE VALUES SHOULD BE CORRECTED. HOWEVER, THIS MAY NOT BE THE CAUSE OF THE CONCERN. SERVICE AS NECESSARY. 5. Throttle plates in the throttle body not returning to the proper closed position may cause excessive catalyst temperatures during downhill grades. Refer to the following procedure for service details. a. Visually inspect the throttle body and linkage for: ^ Binding or sticking throttle linkage. ^ Tight speed control linkage or cable. ^ Vacuum line interference. ^ Electrical harness interference. NOTE: AFTERMARKET GOVERNORS, THROTTLE LINKAGE AND CABLES ASSOCIATED WITH POWER TAKE-OFF UNITS, MAY ALSO INTERFERE WITH PROPER THROTTLE RETURN. SERVICE AS NECESSARY. 6. It is extremely important that all systems related to the engine and emission systems operate properly. a. Visually inspect the engine compartment to make sure all vacuum hoses and spark plug wires are properly routed and securely connected. b. Inspect all wiring harnesses and connectors for insulation damage, burned, overheated, loose or broken conditions. c. Verify proper operation of the thermactor system. Thermactor systems that fail to dump thermactor air to the atmosphere properly or at the correct time can cause high catalyst temperatures. d. Visually inspect thermactor system for damaged or kinked hoses and perform a function test on following components: air control valve, check valve, silencer, filter and the air bypass solenoid. e. Verify proper operation of the engine cooling system thermostat. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under Basic Warranty Coverage, Emissions Warranty Coverage OPERATION DESCRIPTION TIME 911211A Diagnostics - Perform 0.5 Hrs. KOEO And KOER Self Tests 911211B Timing - Check Or Adjust 0.5 Hrs. Spark Timing, Check Computed Timing And Check Secondary Ignition System With Engine Analyzer. 911211C Check - Fuel Pressure And 0.2 Hrs. Inspect Vacuum Line For Raw Fuel. 911211D Inspect - Throttle Body And 0.1 Hrs. Linkage. 911211E Inspect - Vacuum Hoses, 0.1 Hrs. Electrical Harnesses, Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Fastener: > 911211 > Jun > 91 > Engine - Lack of Power/No Start Diagnosis > Page 5928 Connectors And Spark Plug Wires For Routing Damage. 911211F Thermactor System - 0.3 Hrs. Inspect For Proper Operation And Damaged Component. Includes Function Check Of Air Control Valve, Thermactor Air Bypass Solenoid, Check Valves, Silencer And Filter. 911211G Thermostat - Check For 0.2 Hrs. Proper Operation. DEALER CODING BASIC PART NO. CONDITION CODE 5E212 25 OASIS CODES: 403000, 603300, 614000 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Fastener: > 85218 > Oct > 85 > Distributor Rotor Engine Bucking/Surging Ignition Rotor: All Technical Service Bulletins Distributor Rotor - Engine Bucking/Surging Article No. 85-21-8 ENGINE MISS - DISTRIBUTOR WITH BLADE ROTOR - SILICONE GREASE ENGINE SURGE - DISTRIBUTOR WITH BLADE ROTOR - SILICONE GREASE RADIO NOISE - DISTRIBUTOR WITH BLADE ROTOR - SILICONE GREASE FORD 1986 ESCORT, EXP, TEMPO, MUSTANG, THUNDERBIRD, TAURUS, LTD, CROWN VICTORIA LINCOLN-MERCURY 1986 LYNX, TOPAZ, CAPRI, COUGAR, SABLE, MARQUIS, CONTINENTAL, MARK VII, LINCOLN LIGHT TRUCK 1986 E/F SERIES, BRONCO, RANGER, BRONCO II, AEROSTAR CALIBRATION: All with EEC IV 1986 vehicles are equipped with a new "blade" design distributor rotor. This design replaces the multi-point rotor used in recent model years. This new rotor requires the use of silicone grease on the blade. Electrical interference can result from a blade rotor that does not have silicone grease. The electrical interference affects the distributor stator assembly and can cause engine "missing", "bucking", or "surging". These drive concerns are usually intermittent and tend to occur during crank and heavy or wide-open throttle. It is important to remember not to remove the silicone grease for radio noise concerns, on 1986 vehicles with EEC IV; removing the grease can cause driveability concerns. A future TSB article will address the radio noise issue. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Fastener: > 911211 > Jun > 91 > Engine - Lack of Power/No Start Diagnosis > Page 5938 NOTE: SERVICE ANY ITEM THAT IS NOT PERFORMING AT PROPER SPECIFICATIONS BEFORE CONTINUING. 4. Fuel pressure that is too high may cause rich air fuel mixtures to pass through the catalyst which could cause higher than normal catalyst temperatures. Refer to the following procedure for service details. a. Check fuel pressure, install fuel pressure gauge, start and run the engine at idle. Fuel pressures between 28 and 34 PSI are typical (4.9L typically is 15 PSI higher). b. Disconnect the vacuum line going to the fuel pressure regulator. Fuel pressure typically jumps to 40 PSI +/- 3 PSI (4.9L typically is 15 PSI higher). Visually inspect vacuum line for raw fuel. NOTE: FUEL PRESSURES ABOVE THESE VALUES SHOULD BE CORRECTED. HOWEVER, THIS MAY NOT BE THE CAUSE OF THE CONCERN. SERVICE AS NECESSARY. 5. Throttle plates in the throttle body not returning to the proper closed position may cause excessive catalyst temperatures during downhill grades. Refer to the following procedure for service details. a. Visually inspect the throttle body and linkage for: ^ Binding or sticking throttle linkage. ^ Tight speed control linkage or cable. ^ Vacuum line interference. ^ Electrical harness interference. NOTE: AFTERMARKET GOVERNORS, THROTTLE LINKAGE AND CABLES ASSOCIATED WITH POWER TAKE-OFF UNITS, MAY ALSO INTERFERE WITH PROPER THROTTLE RETURN. SERVICE AS NECESSARY. 6. It is extremely important that all systems related to the engine and emission systems operate properly. a. Visually inspect the engine compartment to make sure all vacuum hoses and spark plug wires are properly routed and securely connected. b. Inspect all wiring harnesses and connectors for insulation damage, burned, overheated, loose or broken conditions. c. Verify proper operation of the thermactor system. Thermactor systems that fail to dump thermactor air to the atmosphere properly or at the correct time can cause high catalyst temperatures. d. Visually inspect thermactor system for damaged or kinked hoses and perform a function test on following components: air control valve, check valve, silencer, filter and the air bypass solenoid. e. Verify proper operation of the engine cooling system thermostat. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under Basic Warranty Coverage, Emissions Warranty Coverage OPERATION DESCRIPTION TIME 911211A Diagnostics - Perform 0.5 Hrs. KOEO And KOER Self Tests 911211B Timing - Check Or Adjust 0.5 Hrs. Spark Timing, Check Computed Timing And Check Secondary Ignition System With Engine Analyzer. 911211C Check - Fuel Pressure And 0.2 Hrs. Inspect Vacuum Line For Raw Fuel. 911211D Inspect - Throttle Body And 0.1 Hrs. Linkage. 911211E Inspect - Vacuum Hoses, 0.1 Hrs. Electrical Harnesses, Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Fastener: > 911211 > Jun > 91 > Engine - Lack of Power/No Start Diagnosis > Page 5939 Connectors And Spark Plug Wires For Routing Damage. 911211F Thermactor System - 0.3 Hrs. Inspect For Proper Operation And Damaged Component. Includes Function Check Of Air Control Valve, Thermactor Air Bypass Solenoid, Check Valves, Silencer And Filter. 911211G Thermostat - Check For 0.2 Hrs. Proper Operation. DEALER CODING BASIC PART NO. CONDITION CODE 5E212 25 OASIS CODES: 403000, 603300, 614000 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > Page 5944 Wheel Fastener: Specifications 5 LUG WHEEL 1/2-20 .................................................................................................................................................. ........................................... 135 Nm (100 lb ft) 8 LUG WHEEL 9/16-18 ................................................................................................................................................ ........................................... 190 Nm (140 lb ft) NOTE: Torque specifications are for clean, dirt and paint free dry bolt and nut threads. Never use oil or grease on studs and nuts. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > Page 5945 Wheel Fastener: Service and Repair Lug Nut Torque Patterns IMPORTANT Check all parts, including rims, lug studs, lug nuts, and mating surfaces of hubs and tire rims for rust, damage, or dirt. Clean mating surfaces with a wire brush to remove any foreign material. Replace any damaged parts as needed. Careless installation of tire/rim assemblies in a vehicle is a major cause of tire installation problems. Proper installation, including fastener torque, is essential to economical, safe and trouble free service. Use only the proper sizes and types of fasteners for safe and proper service. Tighten the fasteners a quarter turn at a time using the tightening sequence diagram as a guide. This is very important to prevent misalignment of the wheel. Continue tightening the fasteners in sequence until the fasteners are tightened to the proper torque (See WHEEL FASTENER TORQUE). CAUTION: Improper torque or tightening sequence can cause distortion, fatigue cracks, or alignment problems. After driving the vehicle for a short distance, recheck the wheel fastener torque. Parts will usually seat naturally, reducing the torque on the fasteners. Retorque all fasteners to the proper torque. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Seal > Component Information > Technical Service Bulletins > Customer Interest for Wheel Seal: > 9167 > Mar > 91 > Rear Axle Hub Seal - Lubricant Leaks Wheel Seal: Customer Interest Rear Axle Hub Seal - Lubricant Leaks Article No. 91-6-7 03/18/91 ^ AXLE - NEW HUB SEAL AND HUB SEAL REPLACER TOOL - VEHICLES WITH 10.25 INCH RING GEAR, FULL - FLOATING REAR AXLES ^ LEAKS - AXLE LUBE - 10.25 INCH RING GEAR, FULL - FLOATING REAR AXLES LIGHT TRUCK: 1985-91 F-250, F-350 ISSUE: A new hub seal and a hub seal replacer tool are now available for service. The new hub seal is designed to improve sealing when properly installed using the new hub seal replacer tool. ACTION: Install a new hub seal (FOTZ-1177-A) with the new hub seal replacer tool (T91T-1175-A). Refer to the following inspection list and service procedure for details. NOTE: DO NOT USE THE OLD HUB SEAL REPLACER TOOL (T85T-1175-AH). IT IS NOT DESIGNED TO INSTALL THE NEW SEAL. THE NEW HUB SEAL REPLACER TOOL IS AVAILABLE IN THE 1991 DEALER ESSENTIAL SERVICE TOOL KIT AND IS THE ONLY TOOL APPROVED TO INSTALL THE NEW SEAL. INSPECTION PRIOR TO SEAL INSTALLATION Prior to seal installation, make sure that the following items are checked and servicing action taken where indicated. ^ Inspect the outer diameter of the hub seal to be sure that it is dry and free of oil and grease. ^ Check the hub bore to be sure it is free of grease, dirt and debris. ^ Remove any nicks or burrs from the hub bore. ^ Inspect the inner and outer bearing for damage and replace as required. ^ Pack each hub bearing cone and roller with a bearing packing tool using XG-1-C grease. ^ Make sure that no residual grease from freshly greased bearings gets into the hub bore. ^ Prior to installing the hub assembly, clean the spindle thoroughly and inspect the seal and bearing journals for nicks and/or scratches. Remove nicks or scratches using crocus cloth or similar material. ^ Wipe spindle clean and lightly oil with clean axle lube or engine oil. Figure 1 REMOVAL & INSTALLATION PROCEDURE 1. Install the hub in a soft jawed vice. 2. Remove the hub seal as shown in Figure 1. CAUTION: CARE MUST BE TAKEN NOT TO DAMAGE THE HUB SEAL BORE WITH THE SEAL REMOVAL TOOL. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Seal > Component Information > Technical Service Bulletins > Customer Interest for Wheel Seal: > 9167 > Mar > 91 > Rear Axle Hub Seal - Lubricant Leaks > Page 5954 Figure 2 3. Thoroughly clean and inspect the hub bore, Figure 2. CAUTION: MAKE SURE THE HUB BORE IS FREE OF DIRT, GREASE, BURRS OR NICKS. NOTE: HUB BEARINGS MUST BE PRELUBED WITH GREASE PRIOR TO INSTALLATION. USE XG-1-C GREASE OR EQUIVALENT. 4. Pack each bearing cone and roller assembly with a bearing packing tool. Figure 3 5. Install the seal in the hub with the Ford logo facing up, Figure 3. CAUTION: HUB SEAL MUST BE FREE OF DIRT OR GREASE. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Seal > Component Information > Technical Service Bulletins > Customer Interest for Wheel Seal: > 9167 > Mar > 91 > Rear Axle Hub Seal - Lubricant Leaks > Page 5955 Figure 4 6. Install the hub oil seal on the hub seal installer tool, T91T-1175-A, Figure 4. Figure 5 7. Insert the tool with the seal squarely into the hub, Figure 5. Figure 6 8. Hold the tool straight. Strike the handle until the hub seal is fully seated (until tool strikes hub), Figure 6. CAUTION: INSTALL NEW SEAL IF SEAL IS MISALIGNED DURING OR AFTER INSTALLATION. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Seal > Component Information > Technical Service Bulletins > Customer Interest for Wheel Seal: > 9167 > Mar > 91 > Rear Axle Hub Seal - Lubricant Leaks > Page 5956 It is extremely important that the 1991 F-Series Shop Manual procedures be followed when installing the hub assembly. CAUTION: THE SPECIFIED TORQUING AND BACKING OFF OF THE HUB NUT IS CRITICAL IN ORDER TO PERFORM THE REPAIR CORRECTLY. NOTE: ALWAYS TURN THE HUB WHILE TIGHTENING THE HUB NUT. ONCE THE SPECIFIED TORQUE 55-65 LB.FT., (75-88 N-m) IS ACHIEVED, RATCHETING BACK ON THE HUB NUT VARIES DEPENDING ON WHETHER THE HUB BEARINGS ARE NEW OR USED. BACK OFF 5 CLICKS FOR NEW BEARING AND 8 CLICKS FOR USED BEARINGS. Make sure hub nut wrench tool (T85T-4252-AH) is used as shown in the Shop Manual procedure. Consult The 1991 F-Series Light Truck Shop Manual, Section 05-02B, for service procedures and torque specifications. PART NUMBER PART NAME CLASS FOTZ-1177-A Hub Seal B XG-1-C Grease (14 oz. cartridge, Pkg. V 60) OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 509000 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Seal > Component Information > Technical Service Bulletins > Customer Interest for Wheel Seal: > 862223 > Nov > 86 > Axle - Rear Axle Hub Seals Leak Wheel Seal: Customer Interest Axle - Rear Axle Hub Seals Leak Article No. 86-22-23 AXLE (10.25") - REAR - HUB SEALS LEAK - VENT PLUGGED LIGHT TRUCK 1985-86 F-250/350 A plugged rear axle vent may cause water to be sucked in through the seals and grease to be pushed out. This happens when pressures rise and fall inside the axle during various driving conditions and temperatures. The purpose of the vent is to relieve those pressures. If the vent is plugged with mud or other foreign materials, the axle cannot "breathe". To eliminate this concern, perform the following procedure: Figure 17 1. Remove the vent from the axle (Figure 17). 2. Place the vent in a vise so as not to damage the threads. 3. Drill out the vent using a 3/16 inch drill bit. Clean all shavings from vent. 4. Install vent. 5. Make sure entire vent hose is clear of dirt and mud, etc. 6. Install hose. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION: SP4022A86 TIME: 0.5 Hr. DLR. CODING: Basic Part No. 4022 - Code: 55 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Seal > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Seal: > 9167 > Mar > 91 > Rear Axle Hub Seal Lubricant Leaks Wheel Seal: All Technical Service Bulletins Rear Axle Hub Seal - Lubricant Leaks Article No. 91-6-7 03/18/91 ^ AXLE - NEW HUB SEAL AND HUB SEAL REPLACER TOOL - VEHICLES WITH 10.25 INCH RING GEAR, FULL - FLOATING REAR AXLES ^ LEAKS - AXLE LUBE - 10.25 INCH RING GEAR, FULL - FLOATING REAR AXLES LIGHT TRUCK: 1985-91 F-250, F-350 ISSUE: A new hub seal and a hub seal replacer tool are now available for service. The new hub seal is designed to improve sealing when properly installed using the new hub seal replacer tool. ACTION: Install a new hub seal (FOTZ-1177-A) with the new hub seal replacer tool (T91T-1175-A). Refer to the following inspection list and service procedure for details. NOTE: DO NOT USE THE OLD HUB SEAL REPLACER TOOL (T85T-1175-AH). IT IS NOT DESIGNED TO INSTALL THE NEW SEAL. THE NEW HUB SEAL REPLACER TOOL IS AVAILABLE IN THE 1991 DEALER ESSENTIAL SERVICE TOOL KIT AND IS THE ONLY TOOL APPROVED TO INSTALL THE NEW SEAL. INSPECTION PRIOR TO SEAL INSTALLATION Prior to seal installation, make sure that the following items are checked and servicing action taken where indicated. ^ Inspect the outer diameter of the hub seal to be sure that it is dry and free of oil and grease. ^ Check the hub bore to be sure it is free of grease, dirt and debris. ^ Remove any nicks or burrs from the hub bore. ^ Inspect the inner and outer bearing for damage and replace as required. ^ Pack each hub bearing cone and roller with a bearing packing tool using XG-1-C grease. ^ Make sure that no residual grease from freshly greased bearings gets into the hub bore. ^ Prior to installing the hub assembly, clean the spindle thoroughly and inspect the seal and bearing journals for nicks and/or scratches. Remove nicks or scratches using crocus cloth or similar material. ^ Wipe spindle clean and lightly oil with clean axle lube or engine oil. Figure 1 REMOVAL & INSTALLATION PROCEDURE 1. Install the hub in a soft jawed vice. 2. Remove the hub seal as shown in Figure 1. CAUTION: CARE MUST BE TAKEN NOT TO DAMAGE THE HUB SEAL BORE WITH THE SEAL REMOVAL TOOL. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Seal > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Seal: > 9167 > Mar > 91 > Rear Axle Hub Seal Lubricant Leaks > Page 5966 Figure 2 3. Thoroughly clean and inspect the hub bore, Figure 2. CAUTION: MAKE SURE THE HUB BORE IS FREE OF DIRT, GREASE, BURRS OR NICKS. NOTE: HUB BEARINGS MUST BE PRELUBED WITH GREASE PRIOR TO INSTALLATION. USE XG-1-C GREASE OR EQUIVALENT. 4. Pack each bearing cone and roller assembly with a bearing packing tool. Figure 3 5. Install the seal in the hub with the Ford logo facing up, Figure 3. CAUTION: HUB SEAL MUST BE FREE OF DIRT OR GREASE. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Seal > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Seal: > 9167 > Mar > 91 > Rear Axle Hub Seal Lubricant Leaks > Page 5967 Figure 4 6. Install the hub oil seal on the hub seal installer tool, T91T-1175-A, Figure 4. Figure 5 7. Insert the tool with the seal squarely into the hub, Figure 5. Figure 6 8. Hold the tool straight. Strike the handle until the hub seal is fully seated (until tool strikes hub), Figure 6. CAUTION: INSTALL NEW SEAL IF SEAL IS MISALIGNED DURING OR AFTER INSTALLATION. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Seal > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Seal: > 9167 > Mar > 91 > Rear Axle Hub Seal Lubricant Leaks > Page 5968 It is extremely important that the 1991 F-Series Shop Manual procedures be followed when installing the hub assembly. CAUTION: THE SPECIFIED TORQUING AND BACKING OFF OF THE HUB NUT IS CRITICAL IN ORDER TO PERFORM THE REPAIR CORRECTLY. NOTE: ALWAYS TURN THE HUB WHILE TIGHTENING THE HUB NUT. ONCE THE SPECIFIED TORQUE 55-65 LB.FT., (75-88 N-m) IS ACHIEVED, RATCHETING BACK ON THE HUB NUT VARIES DEPENDING ON WHETHER THE HUB BEARINGS ARE NEW OR USED. BACK OFF 5 CLICKS FOR NEW BEARING AND 8 CLICKS FOR USED BEARINGS. Make sure hub nut wrench tool (T85T-4252-AH) is used as shown in the Shop Manual procedure. Consult The 1991 F-Series Light Truck Shop Manual, Section 05-02B, for service procedures and torque specifications. PART NUMBER PART NAME CLASS FOTZ-1177-A Hub Seal B XG-1-C Grease (14 oz. cartridge, Pkg. V 60) OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 509000 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Seal > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Seal: > 862223 > Nov > 86 > Axle - Rear Axle Hub Seals Leak Wheel Seal: All Technical Service Bulletins Axle - Rear Axle Hub Seals Leak Article No. 86-22-23 AXLE (10.25") - REAR - HUB SEALS LEAK - VENT PLUGGED LIGHT TRUCK 1985-86 F-250/350 A plugged rear axle vent may cause water to be sucked in through the seals and grease to be pushed out. This happens when pressures rise and fall inside the axle during various driving conditions and temperatures. The purpose of the vent is to relieve those pressures. If the vent is plugged with mud or other foreign materials, the axle cannot "breathe". To eliminate this concern, perform the following procedure: Figure 17 1. Remove the vent from the axle (Figure 17). 2. Place the vent in a vise so as not to damage the threads. 3. Drill out the vent using a 3/16 inch drill bit. Clean all shavings from vent. 4. Install vent. 5. Make sure entire vent hose is clear of dirt and mud, etc. 6. Install hose. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION: SP4022A86 TIME: 0.5 Hr. DLR. CODING: Basic Part No. 4022 - Code: 55 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Technical Service Bulletins > A/C Suction Accumulator - Manual Revision Accumulator HVAC: Technical Service Bulletins A/C Suction Accumulator - Manual Revision AIR CONDITIONING - SUCTION ACCUMULATOR/ DRIER - SHOP MANUAL REVISION Article No. 88-25-5 FORD: 1986-88 ESCORT, EXP, TEMPO, MUSTANG, THUNDERBIRD, TAURUS, CROWN VICTORIA LINCOLN-MERCURY: 1986-87 LYNX, CAPRI 1986-88 TOPAZ, COUGAR, SABLE, GRAND MARQUIS, MARK VII, CONTINENTAL, LINCOLN TOWN CAR LIGHT TRUCK: 1986-88 AEROSTAR, RANGER, BRONCO II, F-SERIES BRONCO 1988 ECONOLINE ISSUE: The recommended service replacement guidelines for the suction accumulator/ drier assembly have been changed. The suction accumulator/drier should be replaced whenever a major A/C system component such as the compressor, evaporator core, condenser or refrigerant lines are replaced. ACTION: If a major A/C system component is replaced, replace the suction accumulator/drier assembly. This information should be noted in your 1986-88 Shop Manuals. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" OASIS CODES: 2610, 2611, 2612, 2800 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Locations Blower Motor: Locations Rear RH Side Of Engine Compartment On Plenum, At RH Side Of Dash Panel Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions Blower Motor: Diagram Information and Instructions Symbol Identification Wire Color Code Identification Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 5983 NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 5984 Fig. 37 Heater Wiring Circuit (Less A/C) Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Page 5985 Blower Motor: Service and Repair Fig. 17 Blower motor replacement. 1980---81 F-100---350 & Bronco less air conditioning Blower Motor Replacement (Less A/C) Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Page 5986 Blower Motor Replacement (With A/C) F-100---350 & BRONCO 1. Disconnect battery ground cable. 2. Disconnect blower motor electrical connector, and on 1980---81 models less air conditioning, remove ground wire screw. 3. On models equipped with air conditioning, disconnect air cooling tube from blower motor. 4. On all models, remove blower motor attaching screws and the blower motor, Figs. 17, 18 and 19. 5. Reverse procedure to install. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Locations Blower Motor Resistor: Locations Rear RH Side Of Engine Compartment Mounted On Plenum, Next To Blower Motor Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Component Information > Diagrams > Diagram Information and Instructions Compressor HVAC: Diagram Information and Instructions Symbol Identification Wire Color Code Identification Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 5994 NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Technical Service Bulletins > Air Conditioning - Approved Flushing Procedures Condenser HVAC: Technical Service Bulletins Air Conditioning - Approved Flushing Procedures Article No. 95-18-4 09/11/95 AIR CONDITIONING - FORD APPROVED FLUSHING PROCEDURES - SERVICE TIP FORD: 1985-86 LTD 1985-88 EXP 1985-94 TEMPO 1985-95 CROWN VICTORIA, ESCORT, MUSTANG, THUNDERBIRD 1986-96 TAURUS 1989-93 FESTIVA 1989-95 PROBE 1994-95 ASPIRE 1995-96 CONTOUR LINCOLN-MERCURY: 1984-92 MARK VII 1985-86 MARQUIS 1985-87 LYNX 1985-94 TOPAZ 1985-95 COUGAR, GRAND MARQUIS, TOWN CAR 1985-96 CONTINENTAL 1986-96 SABLE 1987-89 TRACER 1991-93 CAPRI 1991-95 TRACER 1993-95 MARK VIII 1995-96 MYSTIQUE MERKUR: 1985-89 XR4TI 1988-89 SCORPIO LIGHT TRUCK: 1985-90 BRONCO II 1985-95 BRONCO, ECONOLINE, F-150-350 SERIES 1985-96 RANGER 1986-95 AEROSTAR 1991-96 EXPLORER 1993-95 VILLAGER 1995-96 WINDSTAR This TSB is being republished in its entirety to include Labor Operations for system flushing. ISSUE: Ford Motor Company has approved a procedure to provide technicians with a non-CFC method of flushing contaminated A/C system heat exchangers (evaporators and condensers). This procedure allows the A/C components to be cleaned and flushed while installed in the vehicle. The types of contamination flushed include particle matter which results from compressor or desiccant failure and the gummy residue which may form when refrigerant oil is overheated. Some Ford authorized HFC-134a retrofit kit procedures will also require A/C system flushing to remove mineral oil for capacity reasons. ACTION: Refer to the following text for proper flushing procedures. The flushing procedure is a two-step process which involves the use of an A/C Flusher. The Flusher is used to do the following: 1. Circulate the flushing solvent through the A/C system heat exchangers in the reverse direction of normal refrigerant flow (back flushing). Particle matter is filtered from the returning solvent and the solvent is returned to the reservoir for continued circulation. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Technical Service Bulletins > Air Conditioning - Approved Flushing Procedures > Page 5999 2. Remove the flushing solvent from the A/C system. In this step, pressurized air (90-125 psi/620-862 kPa) is used to push and evaporate any remaining flush solvent from the heat exchangers. Only Rotunda Item No. 014-00990 A/C Flushing kit which includes 014-00991 A/C Flusher, 014-00992 A/C Flusher Filling Kit. and F4AZ-19579-A A/C Flushing Solvent (case of 4 gallons/15 L), is approved for use on Ford vehicles. No other flushing device or solvent is approved by Ford Motor Company for flushing A/C systems. The use of other equipment or solvent may cause damage to the A/C system and the flushing unit. Minimum time for flushing is 15 minutes and minimum time for air flushing is 30 minutes. Failure to continue air purge for the entire 30 minutes as specified may result in residual amounts of flush solvent contaminating the A/C system. Residual flush solvent in a functioning A/C system may lead to A/C system failure. Do not flush through orifice tubes. TXVs, accumulator/driers, receiver/driers, mufflers or hoses. Internal plumbing and material make-up of these components make it impossible to properly remove the debris and/or residual flushing solvent. One (1) gallon (3.8 L) of Ford A/C System Flushing Solvent is used in this device and is intended for one (1) vehicle only. It may be used to flush both heat exchangers on an individual vehicle, but under no circumstances should it be used on more than one (1) vehicle. The filter used when flushing is also intended for use on one (1) vehicle only. NOTE: DURING THE FLUSHING PROCESS, THIS MATERIAL MAY COLLECT RESIDUE FROM THE A/C SYSTEM, WHICH MAY INCLUDE CFC-12. DISPOSE OF THE SOLVENT AND FILTER IN ACCORDANCE WITH FEDERAL, STATE AND LOCAL REGULATIONS. Use of A/C system filter kits as prescribed in TSB 94-15-5 is optional if the A/C system is flushed. Filter kit use is recommended after flushing if the system is highly contaminated. If the hoses are clogged with debris, hose replacement is required. Always remember to match oil properly, replace the accumulator/drier and orifice tube, or TXV and receiver/drier when servicing an A/C system with a compressor or desiccant failure. The following vehicles require A/C system flushing with retrofit kits to remove mineral oil for capacity reasons. ^ 1993 Probe 2.0L and 2.5L ^ 1988-90 Escort 1.9L EFI ^ 1989-93 Thunderbird Super Coupe ^ 1986-92 Mark VII ^ 1991-93 Capri 1.6L and 1.6T ^ 1988-93 Festiva 1 .3L ^ 1987-90 Tracer 1.6L ^ 1985-89 XR4Ti ^ 1988-89 Scorpio OTHER APPLICABLE ARTICLES: 94-15-5 SUPERSEDES: 95-8-1 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 1991-95 Lincolns And All Other 1992-95 Models OPERATION DESCRIPTION TIME 951804A Flush Evaporator 1.0 Hr. 951804B Flush Condenser 1.0 Hr. DEALER CODING CONDITION BASIC PART NO. CODE 19703 49 OASIS CODES: 208000, 208200, 208999 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > A/C Coupler O-ring > Component Information > Technical Service Bulletins > A/C - New Refrigerant O-Rings A/C Coupler O-ring: Technical Service Bulletins A/C - New Refrigerant O-Rings Article No. 91-22-5 10/30/91 AIR CONDITIONING - NEW REFRIGERANT FITTING "O" RINGS (GREEN COLOR) AVAILABLE TO PROVIDE IMPROVED SEALING AND DURABILITY FORD: 1985-86 LTD 1985-92 CROWN VICTORIA, ESCORT, MUSTANG, TEMPO, THUNDERBIRD 1986-92 TAURUS LINCOLN-MERCURY: 1985-86 CAPRI, MARQUIS 1985-87 LYNX 1985-92 CONTINENTAL, COUGAR, GRAND MARQUIS, MARK VII, TOPAZ, TOWN CAR 1986-92 SABLE 1991-92 TRACER LIGHT TRUCK: 1985-90 BRONCO II 1985-92 BRONCO, ECONOLINE, F-150-350 SERIES, RANGER 1986-92 AEROSTAR 1988-92 F SUPER DUTY 1989-92 F-47 1991-92 EXPLORER ISSUE: New refrigerant 0-rings (GREEN COLOR) are available for use in the Ford Spring Lock Coupling (SLC) and threaded (Tube-0) connections. The new GREEN COLORED 0-ring material provides improved sealing and longer seal life. Use of any other 0-ring for Ford refrigerant fittings is not recommended and may result in premature leakage at the fitting. ACTION: If a refrigerant system repair is made which requires an A/C fitting to be disconnected, replace the existing 0-rings with the new GREEN COLORED type. Refer to the following 0-ring Usage Chart for identifying the correct 0-ring. O-RING USAGE CHART (SLC) (SLC) (TUBE-0) (TUBE-0) MOTORCRAFT SERVICE MOTORCRAFT SERVICE SIZE PART NO. PART NO. PART NO. PART NO. 3/8" YF-1753 391302-S100 YF-1753 391302-S100 1/2" YF-1754 391303-S100 YF-1754 391303-S100 5/8" YF-1755 391304-S100 YF-1756 391306-S100 3/4" YF-1752 3913O5-S100 YF-1757 391307-S100 PART NUMBER PART NAME CLASS 391302-S100 3/8" 0-ring (SLC & TUBE-0, S Pkg./6) 391303-S100 1/2" 0-ring (SLC & TUBE-0, S Pkg./6) 391304-S100 5/8" 0-ring (SLC, Pkg./6) S 391306-S100 5/8" 0-ring (TUBE-0, Pkg./6) S 391305-S100 3/4" 0-ring (SLC, Pkg./6) S 391307-S100 3/4" 0-ring (TUBE-0, Pkg./4) S OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 90-14-8 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 208000, 208999 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > A/C Coupler O-ring > Component Information > Technical Service Bulletins > A/C - New Refrigerant O-Rings > Page 6005 A/C Coupler O-ring: Technical Service Bulletins Air Conditioning - O Ring Removal Service Tip Article No. 95-2-2 01/30/95 AIR CONDITIONING - O-RING REMOVAL FROM SPRING LOCK COUPLER - SERVICE TIP FORD: 1981-95 MUSTANG 1982-83 FAIRMONT 1982-88 EXP 1982-95 CROWN VICTORIA, ESCORT, THUNDERBIRD 1983-86 LTD 1984-94 TEMPO 1986-95 TAURUS 1989-95 PROBE 1995 CONTOUR LINCOLN-MERCURY: 1982-83 LN7, ZEPHYR 1982-87 LYNX 1982-95 CONTINENTAL, COUGAR, GRAND MARQUIS, TOWN CAR 1983-86 MARQUIS 1984-92 MARK VII 1984-94 TOPAZ 1986-95 SABLE 1991-95 TRACER 1993-94 CAPRI 1993-95 MARK VIII 1995 MYSTIQUE LIGHT TRUCK: 1982-95 BRONCO, F SUPER DUTY, F-150-350 SERIES, RANGER 1983-90 BRONCO II 1986-95 AEROSTAR 1988-95 ECONOLINE 1991-95 EXPLORER 1995 WINDSTAR This TSB is being republished in its entirety to include the latest level tools and procedures available. ISSUE: Some technicians may use small screwdrivers to remove 0-rings from spring lock coupling fittings. This practice can and has resulted in scratches across the 0-ring grooves in the fittings. Loss of refrigerant charge in the system may result. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > A/C Coupler O-ring > Component Information > Technical Service Bulletins > A/C - New Refrigerant O-Rings > Page 6006 ACTION: It is recommended that a plastic toothpick, or equivalent tool, be used to remove 0-rings. Refer to Figure 1. Do not use the metal O-Ring Tool (T71P-19703-C). Only plastic O-Ring Tool (F5VH-17B017-AA) is approved for O-ring removal. OTHER APPLICABLE ARTICLES: 91-22-5, 93-6-5 SUPERSEDES: 93-15-5 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 208000, 208999 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > A/C Coupler O-ring > Component Information > Technical Service Bulletins > A/C - New Refrigerant O-Rings > Page 6007 A/C Coupler O-ring: Technical Service Bulletins A/C Coupling - Cleaning Procedures Article No. 93-6-5 03/17/93 ^ AIR CONDITIONING - AVAILABILITY OF NEW GREEN O-RING SERVICE KIT TO PROVIDE IMPROVED SEALING AND DURABILITY ^ AIR CONDITIONING - SPRING LOCK COUPLING REFRIGERANT FITTINGS - CLEANING PROCEDURE FORD: 1981-91 MUSTANG 1982-88 EXP 1982-91 CROWN VICTORIA, ESCORT, THUNDERBIRD 1983-86 LTD 1984-91 TEMPO 1986-91 TAURUS LINCOLN-MERCURY: 1981-86 CAPRI 1982-83 MARK VI 1982-87 LYNX 1982-91 CONTINENTAL, COUGAR, GRAND MARQUIS, TOWN CAR 1983-86 MARQUIS 1984-91 MARK VII, TOPAZ 1986-91 SABLE 1991 TRACER LIGHT TRUCK: 1982-91 BRONCO, F-150-350 SERIES 1983-90 BRONCO II 1983-91 RANGER 1986-91 AEROSTAR 1988-91 ECONOLINE 1991 EXPLORER ISSUE: A procedure has been developed for cleaning Spring Lock Coupling (SLC) refrigerant fittings during air conditioning system repairs. This procedure and replacement of black O-rings with the improved green O-rings will reduce the potential of refrigerant leaks. ACTION: When servicing the air conditioning system on the subject vehicles, or if a refrigerant leak is suspected at any of the SLC connections, disconnect all SLC connections and replace all black O-rings with new green O-rings which are made of an improved material. Use the following service procedure to clean the coupling before installing new green O-rings. Refer to the Parts Block in this article for correct parts usage. CLEANING PROCEDURE 1. Remove all refrigerant from the vehicle A/C system using an U.L. approved Refrigerant/Recovery device prior to disconnecting the refrigerant couplings. Refer to the appropriate model year Service Manual for a detailed A/C discharging procedure. 2. Disconnect the SLC coupling. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > A/C Coupler O-ring > Component Information > Technical Service Bulletins > A/C - New Refrigerant O-Rings > Page 6008 3. Remove the black O-rings. Be careful not to scratch the O-ring grooves. CAUTION: A SCRATCH CAN CAUSE FUTURE REFRIGERANT LEAKS. 4. Remove any surface residue from the inside of the female SLC and the grooves of the male SLC by polishing with 400 grit emery cloth or equivalent. Polish the female surface by using a twisting motion, Figure 1, so that any scratches made will not cross the O-ring sealing surface. 5. Perform additional polishing of the surface using 600 grit emery cloth or equivalent. 6. Remove all residue from polishing operations from both fittings by wiping with a lint-free rag. 7. Install new green O-rings. If the O-rings are not prelubricated, lube with YN-9 A/C compressor oil (F73Z-19577-A) before installing them. 8. Lubricate the inside of the female portion of the SLC with YN-9 compressor oil (F73Z-19577-A) and apply additional oil to the O-rings. 9. Reconnect the fitting. 10. Recharge the A/C system. Refer to the appropriate model year Service Manual for specific detailed instructions. OTHER APPLICABLE ARTICLES: 91-22-5 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 208000, 208999 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > A/C Coupler Spring > Component Information > Technical Service Bulletins > A/C Coupling - Cleaning Procedures A/C Coupler Spring: Technical Service Bulletins A/C Coupling - Cleaning Procedures Article No. 93-6-5 03/17/93 ^ AIR CONDITIONING - AVAILABILITY OF NEW GREEN O-RING SERVICE KIT TO PROVIDE IMPROVED SEALING AND DURABILITY ^ AIR CONDITIONING - SPRING LOCK COUPLING REFRIGERANT FITTINGS - CLEANING PROCEDURE FORD: 1981-91 MUSTANG 1982-88 EXP 1982-91 CROWN VICTORIA, ESCORT, THUNDERBIRD 1983-86 LTD 1984-91 TEMPO 1986-91 TAURUS LINCOLN-MERCURY: 1981-86 CAPRI 1982-83 MARK VI 1982-87 LYNX 1982-91 CONTINENTAL, COUGAR, GRAND MARQUIS, TOWN CAR 1983-86 MARQUIS 1984-91 MARK VII, TOPAZ 1986-91 SABLE 1991 TRACER LIGHT TRUCK: 1982-91 BRONCO, F-150-350 SERIES 1983-90 BRONCO II 1983-91 RANGER 1986-91 AEROSTAR 1988-91 ECONOLINE 1991 EXPLORER ISSUE: A procedure has been developed for cleaning Spring Lock Coupling (SLC) refrigerant fittings during air conditioning system repairs. This procedure and replacement of black O-rings with the improved green O-rings will reduce the potential of refrigerant leaks. ACTION: When servicing the air conditioning system on the subject vehicles, or if a refrigerant leak is suspected at any of the SLC connections, disconnect all SLC connections and replace all black O-rings with new green O-rings which are made of an improved material. Use the following service procedure to clean the coupling before installing new green O-rings. Refer to the Parts Block in this article for correct parts usage. CLEANING PROCEDURE 1. Remove all refrigerant from the vehicle A/C system using an U.L. approved Refrigerant/Recovery device prior to disconnecting the refrigerant couplings. Refer to the appropriate model year Service Manual for a detailed A/C discharging procedure. 2. Disconnect the SLC coupling. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > A/C Coupler Spring > Component Information > Technical Service Bulletins > A/C Coupling - Cleaning Procedures > Page 6013 3. Remove the black O-rings. Be careful not to scratch the O-ring grooves. CAUTION: A SCRATCH CAN CAUSE FUTURE REFRIGERANT LEAKS. 4. Remove any surface residue from the inside of the female SLC and the grooves of the male SLC by polishing with 400 grit emery cloth or equivalent. Polish the female surface by using a twisting motion, Figure 1, so that any scratches made will not cross the O-ring sealing surface. 5. Perform additional polishing of the surface using 600 grit emery cloth or equivalent. 6. Remove all residue from polishing operations from both fittings by wiping with a lint-free rag. 7. Install new green O-rings. If the O-rings are not prelubricated, lube with YN-9 A/C compressor oil (F73Z-19577-A) before installing them. 8. Lubricate the inside of the female portion of the SLC with YN-9 compressor oil (F73Z-19577-A) and apply additional oil to the O-rings. 9. Reconnect the fitting. 10. Recharge the A/C system. Refer to the appropriate model year Service Manual for specific detailed instructions. OTHER APPLICABLE ARTICLES: 91-22-5 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 208000, 208999 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Air Conditioning - Approved Flushing Procedures Evaporator Core: Technical Service Bulletins Air Conditioning - Approved Flushing Procedures Article No. 95-18-4 09/11/95 AIR CONDITIONING - FORD APPROVED FLUSHING PROCEDURES - SERVICE TIP FORD: 1985-86 LTD 1985-88 EXP 1985-94 TEMPO 1985-95 CROWN VICTORIA, ESCORT, MUSTANG, THUNDERBIRD 1986-96 TAURUS 1989-93 FESTIVA 1989-95 PROBE 1994-95 ASPIRE 1995-96 CONTOUR LINCOLN-MERCURY: 1984-92 MARK VII 1985-86 MARQUIS 1985-87 LYNX 1985-94 TOPAZ 1985-95 COUGAR, GRAND MARQUIS, TOWN CAR 1985-96 CONTINENTAL 1986-96 SABLE 1987-89 TRACER 1991-93 CAPRI 1991-95 TRACER 1993-95 MARK VIII 1995-96 MYSTIQUE MERKUR: 1985-89 XR4TI 1988-89 SCORPIO LIGHT TRUCK: 1985-90 BRONCO II 1985-95 BRONCO, ECONOLINE, F-150-350 SERIES 1985-96 RANGER 1986-95 AEROSTAR 1991-96 EXPLORER 1993-95 VILLAGER 1995-96 WINDSTAR This TSB is being republished in its entirety to include Labor Operations for system flushing. ISSUE: Ford Motor Company has approved a procedure to provide technicians with a non-CFC method of flushing contaminated A/C system heat exchangers (evaporators and condensers). This procedure allows the A/C components to be cleaned and flushed while installed in the vehicle. The types of contamination flushed include particle matter which results from compressor or desiccant failure and the gummy residue which may form when refrigerant oil is overheated. Some Ford authorized HFC-134a retrofit kit procedures will also require A/C system flushing to remove mineral oil for capacity reasons. ACTION: Refer to the following text for proper flushing procedures. The flushing procedure is a two-step process which involves the use of an A/C Flusher. The Flusher is used to do the following: 1. Circulate the flushing solvent through the A/C system heat exchangers in the reverse direction of normal refrigerant flow (back flushing). Particle matter is filtered from the returning solvent and the solvent is returned to the reservoir for continued circulation. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Air Conditioning - Approved Flushing Procedures > Page 6018 2. Remove the flushing solvent from the A/C system. In this step, pressurized air (90-125 psi/620-862 kPa) is used to push and evaporate any remaining flush solvent from the heat exchangers. Only Rotunda Item No. 014-00990 A/C Flushing kit which includes 014-00991 A/C Flusher, 014-00992 A/C Flusher Filling Kit. and F4AZ-19579-A A/C Flushing Solvent (case of 4 gallons/15 L), is approved for use on Ford vehicles. No other flushing device or solvent is approved by Ford Motor Company for flushing A/C systems. The use of other equipment or solvent may cause damage to the A/C system and the flushing unit. Minimum time for flushing is 15 minutes and minimum time for air flushing is 30 minutes. Failure to continue air purge for the entire 30 minutes as specified may result in residual amounts of flush solvent contaminating the A/C system. Residual flush solvent in a functioning A/C system may lead to A/C system failure. Do not flush through orifice tubes. TXVs, accumulator/driers, receiver/driers, mufflers or hoses. Internal plumbing and material make-up of these components make it impossible to properly remove the debris and/or residual flushing solvent. One (1) gallon (3.8 L) of Ford A/C System Flushing Solvent is used in this device and is intended for one (1) vehicle only. It may be used to flush both heat exchangers on an individual vehicle, but under no circumstances should it be used on more than one (1) vehicle. The filter used when flushing is also intended for use on one (1) vehicle only. NOTE: DURING THE FLUSHING PROCESS, THIS MATERIAL MAY COLLECT RESIDUE FROM THE A/C SYSTEM, WHICH MAY INCLUDE CFC-12. DISPOSE OF THE SOLVENT AND FILTER IN ACCORDANCE WITH FEDERAL, STATE AND LOCAL REGULATIONS. Use of A/C system filter kits as prescribed in TSB 94-15-5 is optional if the A/C system is flushed. Filter kit use is recommended after flushing if the system is highly contaminated. If the hoses are clogged with debris, hose replacement is required. Always remember to match oil properly, replace the accumulator/drier and orifice tube, or TXV and receiver/drier when servicing an A/C system with a compressor or desiccant failure. The following vehicles require A/C system flushing with retrofit kits to remove mineral oil for capacity reasons. ^ 1993 Probe 2.0L and 2.5L ^ 1988-90 Escort 1.9L EFI ^ 1989-93 Thunderbird Super Coupe ^ 1986-92 Mark VII ^ 1991-93 Capri 1.6L and 1.6T ^ 1988-93 Festiva 1 .3L ^ 1987-90 Tracer 1.6L ^ 1985-89 XR4Ti ^ 1988-89 Scorpio OTHER APPLICABLE ARTICLES: 94-15-5 SUPERSEDES: 95-8-1 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 1991-95 Lincolns And All Other 1992-95 Models OPERATION DESCRIPTION TIME 951804A Flush Evaporator 1.0 Hr. 951804B Flush Condenser 1.0 Hr. DEALER CODING CONDITION BASIC PART NO. CODE 19703 49 OASIS CODES: 208000, 208200, 208999 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service and Repair Heater Core: Service and Repair Fig. 13 Heater core replacement. F-100---350 & Bronco less air conditioning F-100---350 & BRONCO Less Air Conditioning 1. Disconnect battery ground cable. 2. Disconnect cable from temperature blend door and the mounting bracket from top of heater assembly. 3. Disconnect blower motor and resistor electrical connectors. 4. Disconnect and plug hoses from heater core. 5. Working under instrument panel, remove 2 nuts on 1980---81 models, or 3 nuts on 1982---87 models, attaching left side of heater assembly and right side of plenum to dash. 6. On 1980---81 models, remove screw attaching top center of heater assembly to dash. 7. On all models, remove 2 screws attaching right side of heater assembly to dash, then lift heater assembly out of vehicle. 8. Remove heater housing plate attaching screws, nut and bolt and the plate. 9. On 1980---82 models, remove 3 heater core frame attaching screws and the frame. 10. On all models, slide heater core and seal out of heater assembly, Fig. 13. 11. Reverse procedure to install. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service and Repair > Page 6022 Fig. 14 Heater core replacement. F-100---350 & Bronco w/air conditioning W/Air Conditioning 1. Disconnect battery ground cable. 2. Disconnect and plug hoses from heater core. 3. Remove glove compartment liner. 4. Remove 8 heater core cover attaching screws and the cover. 5. Remove heater core from plenum, Fig. 14. 6. Reverse procedure to install. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Heating and Air Conditioning > Receiver Dryer > Component Information > Technical Service Bulletins > A/C Suction Accumulator - Manual Revision Receiver Dryer: Technical Service Bulletins A/C Suction Accumulator - Manual Revision AIR CONDITIONING - SUCTION ACCUMULATOR/ DRIER - SHOP MANUAL REVISION Article No. 88-25-5 FORD: 1986-88 ESCORT, EXP, TEMPO, MUSTANG, THUNDERBIRD, TAURUS, CROWN VICTORIA LINCOLN-MERCURY: 1986-87 LYNX, CAPRI 1986-88 TOPAZ, COUGAR, SABLE, GRAND MARQUIS, MARK VII, CONTINENTAL, LINCOLN TOWN CAR LIGHT TRUCK: 1986-88 AEROSTAR, RANGER, BRONCO II, F-SERIES BRONCO 1988 ECONOLINE ISSUE: The recommended service replacement guidelines for the suction accumulator/ drier assembly have been changed. The suction accumulator/drier should be replaced whenever a major A/C system component such as the compressor, evaporator core, condenser or refrigerant lines are replaced. ACTION: If a major A/C system component is replaced, replace the suction accumulator/drier assembly. This information should be noted in your 1986-88 Shop Manuals. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" OASIS CODES: 2610, 2611, 2612, 2800 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > A/C - Identification of Non Approved Refrigerants Technical Service Bulletin # 99-19-6 Date: 990920 A/C - Identification of Non Approved Refrigerants Article No. 99-19-6 09/20/99 ^ AIR CONDITIONING - IDENTIFICATION OF NON-FORD APPROVED REFRIGERANTS ^ AIR CONDITIONING - PURGING AIR FROM SYSTEM FORD: 1985-1986 LTD 1985-1988 EXP 1985-1994 TEMPO 1985-1997 THUNDERBIRD 1985-2000 CROWN VICTORIA, ESCORT, MUSTANG 1986-2000 TAURUS 1988-1993 FESTIVA 1989-1997 PROBE 1994-1997 ASPIRE 1995-2000 CONTOUR 2000 FOCUS 1985-1990 BRONCO II 1985-1996 BRONCO 1985-1997 F-250 HD, F-350 1985-2000 ECONOLINE, F-150, F-250 LD, RANGER 1986-1997 AEROSTAR 1988-1997 F SUPER DUTY 1991-2000 EXPLORER 1995-2000 WINDSTAR 1997-2000 EXPEDITION 1999-2000 SUPER DUTY F SERIES 1985-1991 CL-CLT-9000 SERIES 1985-1999 L SERIES 1985-2000 F & B SERIES 1986-1998 CARGO SERIES 1997-1998 AEROMAX, LOUISVILLE LINCOLN: 1985-1992 MARK VII 1985-2000 CONTINENTAL, TOWN CAR 1993-1998 MARK VIII 2000 LS 1998-2000 NAVIGATOR MERCURY: 1985-1986 MARQUIS 1985-1987 LYNX 1985-1994 TOPAZ 1985-1997 COUGAR 1985-2000 GRAND MARQUIS 1986-2000 SABLE 1987-1989 TRACER 1991-1994 CAPRI 1991-2000 TRACER 1995-2000 MYSTIQUE 1999-2000 COUGAR 1993-2000 VILLAGER 1997-2000 MOUNTAINEER MERKUR: 1985-1989 XR4TI 1988-1989 SCORPIO Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > A/C - Identification of Non Approved Refrigerants > Page 6031 This TSB article is being republished in its entirety to add model year vehicles ISSUE A number of non-approved/alternate refrigerants have entered the marketplace and are being advertised as "drop-in replacements" for R-12 and R-134a. The use of non-approved refrigerants such as R-22, hydrocarbons, and other refrigerant blends could cause safety, durability, and performance concerns if they are installed in Ford A/C systems. Identification of the type of refrigerant contained in vehicle A/C systems, before servicing, is necessary to prevent dealer service equipment and refrigerant supplies from being contaminated with non-approved refrigerants. ACTION Refrigerant identification must be performed prior to recovering the refrigerant into a recovery machine to prevent cross-contamination of the recovery machine and other A/C systems being serviced with that recovery machine. Refer to the following text. OTHER APPLICABLE ARTICLES: 94-14-3, 95-18-4 SUPERSEDES: 98-12-8 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 1993-2000 Model Year Vehicles, Basic Warranty Coverage For All Other Model Year Vehicles OPERATION DESCRIPTION TIME 991906A Test A/C System For 0.3 Hr. Contaminated Refrigerant DEALER CODING CONDITION BASIC PART NO. CODE R-12 49 OASIS CODES: 208000, 208999 A/C Refrigerant Analyzer Function Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > A/C - Identification of Non Approved Refrigerants > Page 6032 Ford Motor Company has approved the Rotunda Deluxe A/C Refrigerant Analyzer (198-00003) for use on Ford and Lincoln-Mercury vehicles (Figure 1). The analyzer provides the technician with a quick and easy way to identify the type and percentage of refrigerant (R-134a, R-12, R-22, or flammable hydrocarbon). The analyzer can also provide the percentage of air in the A/C system and automatically purge air from the system. The A/C Refrigerant Analyzer is designed to identify vapor gas samples taken directly from automotive air conditioning systems or refrigerant storage cylinders. Refrigerant vapor passes through the multiple sensor Non-Dispersive Infra-Red (NDIR) sensing unit. The microprocessor calculates each refrigerant type and purity percentage which is displayed on the analyzer's Liquid Crystal Display (LCD). The analyzer identifies the purity percentage of R-134a, R-12, R-22, hydrocarbon; and air in the sample. If the purity percentage of the R-134a or R-12 is 98% or greater by weight, a green "PASS" Light Emitting Diode (LED) will light. If refrigerants R-134a or R-12 do not meet 98% purity levels, the red "FAIL" LED will light. Levels of R-22 and flammable hydrocarbons above 2% will light the red "FAIL" light. If a hydrocarbon is detected above 5%, both the "FAIL" light and "HYDROCARBON" light will illuminate and a horn will sound alerting the user of potential hazards. The percent of air contained in the sample will be displayed if the R-134a or R-12 content is 98% or above. The analyzer eliminates the effect of air Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > A/C - Identification of Non Approved Refrigerants > Page 6033 when determining the refrigerant sample content because air is not considered a contaminant although air can affect A/C system performance. Air will automatically be purged until a pure refrigerant with a less than 2% by weight air measurement is reached. Recovery of Contaminated Refrigerant If contaminated refrigerant is detected, DO NOT recover the refrigerant into your R-134a or R-12 recovery/recycling equipment. Take the following actions: 1. Repeat the test to verify contaminated refrigerant is present. 2. Advise the customer of the contaminated A/C system and any additional cost to repair the system. The customer may wish to return to the service facility which performed the last A/C service. 3. Recover the contaminated refrigerant using suitable recovery-only equipment designed for capturing and storing contaminated refrigerant. This equipment must only be used to recover contaminated refrigerant to prevent the spread to other vehicles. As an alternative, contact an A/C service facility in your area which has the proper equipment for refrigerant recovery. Repairing A Contaminated A/C System Once the contaminated refrigerant is removed from the system it will be necessary to repair the system. Ford recommends that you do the following to be sure a quality repair is made: 1. Determine the cause of the failure. 2. Determine which parts will need to be replaced. 3. Flush the heat exchangers to remove any oil that may be degraded due to the contaminated refrigerant. 4. Install a new suction/accumulator. 5. Properly oil match the system to verify that the correct amount of clean refrigerant oil is present in the system. 6. Evacuate the system for 45 minutes. 7. Recharge the system, verify proper operation, and leak test. Disposal of Contaminated Refrigerant Disposal of contaminated refrigerant is a new process to the automotive industry Listed below are companies that will assist with disposal of contaminated refrigerant. Ford Motor Company has not evaluated the processes of the listed refrigerant disposal companies and is not endorsing or promoting their companies Business transactions are between the dealership and disposal companies. Disposal costs will vary between $3.00 and $5.00 per pound, plus the cost of round trip cylinder shipping. ^ Omega Refrigerant Reclamation ^ 5263 North Fourth St. ^ Irwindale, CA 91706 ^ (310) 698-0991 FAX: (310) 696-7908 ^ Full Cycle Global ^ 2966 Wireton ^ Blue Island, IL 60406 ^ (708) 388-8551 FAX: (708) 399-6550 ^ U.S. Refrigerant Reclaim, Inc. ^ 12420 North Green River Road ^ Evansville, IN 47711 ^ (800) 207-5931 FAX: (812) 867-1463 ^ Full Cycle Global ^ 343 South Airline Highway Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > A/C - Identification of Non Approved Refrigerants > Page 6034 ^ Gonzales, LA 70737 ^ (504) 644-5333 FAX: (504) 644-1609 ^ CFC Reclamation ^ 1321 Swift North ^ Kansas City, MO 64116 ^ (816) 471-2511 ^ Full Cycle Global ^ 550 James St. ^ Lakewood, NJ 08701 ^ (908) 370-3400 FAX: (908) 370-3088 ^ National Refrigerants, Inc. ^ 11401 Roosevelt Blvd. ^ Philadelphia, PA 19154 ^ (215) 698-6620 FAX: (215) 602-8205 ^ Gartech Refrigerant Reclamation ^ 2002 Platinum ^ Garland, TX 75042 ^ (214) 272-4070 FAX: (214) 272-6548 ^ Refrigerant Reclaim Services ^ 121 S. Norwood Dr. ^ Hurst, TX 76053-7807 ^ (817) 282-0022 FAX: (800) 831-6182 ^ Full Cycle Global ^ 2055 Silber, Suite 109 ^ Houston, TX 77055 ^ (713) 681-7370 FAX: (713) 681-9947 ^ Refrigerant Reclaim, Inc. ^ 122 Old Stage Coach Road ^ Dumfries, VA 22026 ^ (800) 238-5902 FAX: (703) 441-0393 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > 99-19-6 > Sep > 99 > A/C - Identification of Non Approved Refrigerants Technical Service Bulletin # 99-19-6 Date: 990920 A/C - Identification of Non Approved Refrigerants Article No. 99-19-6 09/20/99 ^ AIR CONDITIONING - IDENTIFICATION OF NON-FORD APPROVED REFRIGERANTS ^ AIR CONDITIONING - PURGING AIR FROM SYSTEM FORD: 1985-1986 LTD 1985-1988 EXP 1985-1994 TEMPO 1985-1997 THUNDERBIRD 1985-2000 CROWN VICTORIA, ESCORT, MUSTANG 1986-2000 TAURUS 1988-1993 FESTIVA 1989-1997 PROBE 1994-1997 ASPIRE 1995-2000 CONTOUR 2000 FOCUS 1985-1990 BRONCO II 1985-1996 BRONCO 1985-1997 F-250 HD, F-350 1985-2000 ECONOLINE, F-150, F-250 LD, RANGER 1986-1997 AEROSTAR 1988-1997 F SUPER DUTY 1991-2000 EXPLORER 1995-2000 WINDSTAR 1997-2000 EXPEDITION 1999-2000 SUPER DUTY F SERIES 1985-1991 CL-CLT-9000 SERIES 1985-1999 L SERIES 1985-2000 F & B SERIES 1986-1998 CARGO SERIES 1997-1998 AEROMAX, LOUISVILLE LINCOLN: 1985-1992 MARK VII 1985-2000 CONTINENTAL, TOWN CAR 1993-1998 MARK VIII 2000 LS 1998-2000 NAVIGATOR MERCURY: 1985-1986 MARQUIS 1985-1987 LYNX 1985-1994 TOPAZ 1985-1997 COUGAR 1985-2000 GRAND MARQUIS 1986-2000 SABLE 1987-1989 TRACER 1991-1994 CAPRI 1991-2000 TRACER 1995-2000 MYSTIQUE 1999-2000 COUGAR 1993-2000 VILLAGER 1997-2000 MOUNTAINEER MERKUR: 1985-1989 XR4TI 1988-1989 SCORPIO Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > 99-19-6 > Sep > 99 > A/C - Identification of Non Approved Refrigerants > Page 6040 This TSB article is being republished in its entirety to add model year vehicles ISSUE A number of non-approved/alternate refrigerants have entered the marketplace and are being advertised as "drop-in replacements" for R-12 and R-134a. The use of non-approved refrigerants such as R-22, hydrocarbons, and other refrigerant blends could cause safety, durability, and performance concerns if they are installed in Ford A/C systems. Identification of the type of refrigerant contained in vehicle A/C systems, before servicing, is necessary to prevent dealer service equipment and refrigerant supplies from being contaminated with non-approved refrigerants. ACTION Refrigerant identification must be performed prior to recovering the refrigerant into a recovery machine to prevent cross-contamination of the recovery machine and other A/C systems being serviced with that recovery machine. Refer to the following text. OTHER APPLICABLE ARTICLES: 94-14-3, 95-18-4 SUPERSEDES: 98-12-8 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 1993-2000 Model Year Vehicles, Basic Warranty Coverage For All Other Model Year Vehicles OPERATION DESCRIPTION TIME 991906A Test A/C System For 0.3 Hr. Contaminated Refrigerant DEALER CODING CONDITION BASIC PART NO. CODE R-12 49 OASIS CODES: 208000, 208999 A/C Refrigerant Analyzer Function Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > 99-19-6 > Sep > 99 > A/C - Identification of Non Approved Refrigerants > Page 6041 Ford Motor Company has approved the Rotunda Deluxe A/C Refrigerant Analyzer (198-00003) for use on Ford and Lincoln-Mercury vehicles (Figure 1). The analyzer provides the technician with a quick and easy way to identify the type and percentage of refrigerant (R-134a, R-12, R-22, or flammable hydrocarbon). The analyzer can also provide the percentage of air in the A/C system and automatically purge air from the system. The A/C Refrigerant Analyzer is designed to identify vapor gas samples taken directly from automotive air conditioning systems or refrigerant storage cylinders. Refrigerant vapor passes through the multiple sensor Non-Dispersive Infra-Red (NDIR) sensing unit. The microprocessor calculates each refrigerant type and purity percentage which is displayed on the analyzer's Liquid Crystal Display (LCD). The analyzer identifies the purity percentage of R-134a, R-12, R-22, hydrocarbon; and air in the sample. If the purity percentage of the R-134a or R-12 is 98% or greater by weight, a green "PASS" Light Emitting Diode (LED) will light. If refrigerants R-134a or R-12 do not meet 98% purity levels, the red "FAIL" LED will light. Levels of R-22 and flammable hydrocarbons above 2% will light the red "FAIL" light. If a hydrocarbon is detected above 5%, both the "FAIL" light and "HYDROCARBON" light will illuminate and a horn will sound alerting the user of potential hazards. The percent of air contained in the sample will be displayed if the R-134a or R-12 content is 98% or above. The analyzer eliminates the effect of air Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > 99-19-6 > Sep > 99 > A/C - Identification of Non Approved Refrigerants > Page 6042 when determining the refrigerant sample content because air is not considered a contaminant although air can affect A/C system performance. Air will automatically be purged until a pure refrigerant with a less than 2% by weight air measurement is reached. Recovery of Contaminated Refrigerant If contaminated refrigerant is detected, DO NOT recover the refrigerant into your R-134a or R-12 recovery/recycling equipment. Take the following actions: 1. Repeat the test to verify contaminated refrigerant is present. 2. Advise the customer of the contaminated A/C system and any additional cost to repair the system. The customer may wish to return to the service facility which performed the last A/C service. 3. Recover the contaminated refrigerant using suitable recovery-only equipment designed for capturing and storing contaminated refrigerant. This equipment must only be used to recover contaminated refrigerant to prevent the spread to other vehicles. As an alternative, contact an A/C service facility in your area which has the proper equipment for refrigerant recovery. Repairing A Contaminated A/C System Once the contaminated refrigerant is removed from the system it will be necessary to repair the system. Ford recommends that you do the following to be sure a quality repair is made: 1. Determine the cause of the failure. 2. Determine which parts will need to be replaced. 3. Flush the heat exchangers to remove any oil that may be degraded due to the contaminated refrigerant. 4. Install a new suction/accumulator. 5. Properly oil match the system to verify that the correct amount of clean refrigerant oil is present in the system. 6. Evacuate the system for 45 minutes. 7. Recharge the system, verify proper operation, and leak test. Disposal of Contaminated Refrigerant Disposal of contaminated refrigerant is a new process to the automotive industry Listed below are companies that will assist with disposal of contaminated refrigerant. Ford Motor Company has not evaluated the processes of the listed refrigerant disposal companies and is not endorsing or promoting their companies Business transactions are between the dealership and disposal companies. Disposal costs will vary between $3.00 and $5.00 per pound, plus the cost of round trip cylinder shipping. ^ Omega Refrigerant Reclamation ^ 5263 North Fourth St. ^ Irwindale, CA 91706 ^ (310) 698-0991 FAX: (310) 696-7908 ^ Full Cycle Global ^ 2966 Wireton ^ Blue Island, IL 60406 ^ (708) 388-8551 FAX: (708) 399-6550 ^ U.S. Refrigerant Reclaim, Inc. ^ 12420 North Green River Road ^ Evansville, IN 47711 ^ (800) 207-5931 FAX: (812) 867-1463 ^ Full Cycle Global ^ 343 South Airline Highway Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > 99-19-6 > Sep > 99 > A/C - Identification of Non Approved Refrigerants > Page 6043 ^ Gonzales, LA 70737 ^ (504) 644-5333 FAX: (504) 644-1609 ^ CFC Reclamation ^ 1321 Swift North ^ Kansas City, MO 64116 ^ (816) 471-2511 ^ Full Cycle Global ^ 550 James St. ^ Lakewood, NJ 08701 ^ (908) 370-3400 FAX: (908) 370-3088 ^ National Refrigerants, Inc. ^ 11401 Roosevelt Blvd. ^ Philadelphia, PA 19154 ^ (215) 698-6620 FAX: (215) 602-8205 ^ Gartech Refrigerant Reclamation ^ 2002 Platinum ^ Garland, TX 75042 ^ (214) 272-4070 FAX: (214) 272-6548 ^ Refrigerant Reclaim Services ^ 121 S. Norwood Dr. ^ Hurst, TX 76053-7807 ^ (817) 282-0022 FAX: (800) 831-6182 ^ Full Cycle Global ^ 2055 Silber, Suite 109 ^ Houston, TX 77055 ^ (713) 681-7370 FAX: (713) 681-9947 ^ Refrigerant Reclaim, Inc. ^ 122 Old Stage Coach Road ^ Dumfries, VA 22026 ^ (800) 238-5902 FAX: (703) 441-0393 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > 98-12-5 > Jun > 98 > A/C - Filtering Refrigerant After Compressor Replacement Technical Service Bulletin # 98-12-5 Date: 980622 A/C - Filtering Refrigerant After Compressor Replacement Article No. 98-12-5 06/22/98 AIR CONDITIONING - FILTERING REFRIGERANT AFTER A/C COMPRESSOR REPLACEMENT - SERVICE TIPS FORD: 1980-98 CROWN VICTORIA 1981-98 ESCORT 1982-83 FAIRMONT 1982-88 EXP 1982-97 THUNDERBIRD 1982-98 MUSTANG 1983-86 LTD 1984-94 TEMPO 1986-98 TAURUS 1988-93 FESTIVA 1989-97 PROBE 1994-98 ASPIRE 1995-98 CONTOUR LINCOLN-MERCURY: 1980-98 GRAND MARQUIS, TOWN CAR 1982-83 ZEPHYR 1982-86 CAPRI 1982-87 LN7 1982-97 COUGAR 1982-98 CONTINENTAL 1983-86 MARQUIS 1984-92 MARK VII 1984-94 TOPAZ 1986-98 SABLE 1991-94 CAPRI 1991-98 TRACER 1993-98 MARK VIII 1995-98-MYSTIQUE 1999 COUGAR LIGHT TRUCK: 1980-96 BRONCO 1980-97 F SUPER DUTY 1980-98 ECONOLINE, F-150, F-150, F-350 1983-98 RANGER 1984-90 BRONCO II 1986-97 AEROSTAR 1988-97 F-47 1991-98 EXPLORER 1993-98 VILLAGER 1995-98 WINDSTAR 1997-98 EXPEDITION, MOUNTAINEER 1999 SUPER DUTY F SERIES This TSB article is being republished in its entirety to revise the Service Procedure and to update the model years. ISSUE Vehicles that have and inoperative A/C compressor, due to internal causes, MUST have the refrigerant system cleaned to remove any debris or contaminants that may be present to prevent damage to the replacement compressor. ACTION Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > 98-12-5 > Jun > 98 > A/C - Filtering Refrigerant After Compressor Replacement > Page 6048 Install a Service Filter Kit in the refrigerant system prior to installing the replacement compressor. Refer to the following Service Procedure for details. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 96-15-5 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 1992-99 Models And 1991 Lincolns, Basic Warranty Coverage For All Other Models And Major Component Warranty Coverage For All Other Lincoins OPERATION DESCRIPTION TIME 981205A Kit Installation 1.2 Hrs. 981205B Extra Time For Refrigerant 0.4 Hr. (R-12) Recovery DEALER CODING CONDITION BASIC PART NO. CODE 19703 49 OASIS CODES: 208000, 208999 Service Procedure THIS PROCEDURE IS OPTIONAL IF THE SYSTEM IS FLUSHED USING THE ROTUNDA A/C FLUSHER. CAUTION THIS FILTERING PROCEDURE MAY BE USED FOR EITHER R-12 OR R-134a REFRIGERANT SYSTEMS. BECAUSE THE TWO (2) SYSTEMS USE DIFFERENT REFRIGERANT OILS AND BECAUSE THE COMPRESSOR COULD BE DAMAGED IF THE WRONG OIL IS USED, SYSTEM IDENTIFICATION IS VERY IMPORTANT. BE SURE SYSTEM IS CORRECTLY IDENTIFIED BEFORE STARTING THE FILTERING PROCEDURE. Each Service Filter Kit includes the following items: ^ One (1) Pancake Filter (to be installed in the liquid line between the condenser and the orifice tube) ^ One (1) Instruction Sheet NOTE ON 1993-94 RANGER/EXPLORER VEHICLES, TECHNICIANS MAY EXPERIENCE DIFFICULTY WHEN CONNECTING THE PANCAKE FILTER HOSE FITTINGS TO THE EVAPORATOR INLET WITH THE ORIFICE TUBE INSTALLED. REMOVE THE OFFICE TUBE AND RUN THE SYSTEM FOR 1 HOUR AS DESCRIBED IN THE FILTERING PROCEDURE. REINSTALL THE ORIFICE TUBE AFTER FILTERING IS COMPLETE. CAUTION FOLLOW ALL REFRIGERANT SYSTEM SAFETY AND SERVICE PRECAUTIONS OUTLINED IN THE APPROPRIATE SERVICE OR WORKSHOP MANUAL. 1. Before removing any refrigerant system components, recover the refrigerant from the system following the recycling methods outlined In the appropriate Service/Workshop Manual. 2. Remove the suction accumulator/drier assembly and drain the oil into a calibrated container. 3. Install a new suction accumulator/drier and add new refrigerant oil to replace the old oil. The quantity of the new oil to be added is the amount to match that drained from the old accumulator plus 60 mL (2 oz). Refer to the Dealer Master Parts Catalog for the correct suction accumulator/drier part number. CAUTION REMEMBER TO USE MOTORCRAFT YN-9-A REFRIGERANT COMPRESSOR OIL WITH R-12 SYSTEMS AND MOTORCRAFT YN-12-C REFRIGERANT COMPRESSOR OIL WITH R-134a SYSTEMS. FAILURE TO USE THE CORRECT REFRIGERANT OIL MAY RESULT IN DAMAGE TO SYSTEM COMPONENTS. 4. Install a new orifice tube. Refer to the Dealer Master Parts Catalog for the correct orifice tube part number. If the orifice tube in the vehicle is located in the liquid line between the condenser and the evaporator, replace the liquid line assembly. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > 98-12-5 > Jun > 98 > A/C - Filtering Refrigerant After Compressor Replacement > Page 6049 5. Install pancake filter in the liquid line between the condenser and the orifice tube, Figure 1. a. Be sure orifice inlet is toward the condenser. b. Connections can be made using Test Adapter Set D93L-19703-B, or equivalent, and flexible refrigerant hose of 2500 psi burst rating. Individual fittings are also available. 6. Remove the old compressor following Service/Workshop Manual procedures. Drain the oil into a calibrated container. 7. Drain the oil from the replacement compressor into a clean calibrated container. NOTE: IT WILL BE NECESSARY TO TRANSFER THE MAGNET CLUTCH FROM THE OLD COMPRESSOR TO THE REPLACEMENT COMPRESSOR. FOLLOW SERVICE/WORKSHOP MANUAL PROCEDURES. 8. A new FX-15 service compressor contains 207 mL (7 oz.) of R-12 refrigerant oil. A new FS-10 service compressor does not contain any oil and can be used with an R-12 or an R-134a system. CAUTION REMEMBER TO USE YN-9-A (MINERAL) OIL WITH R-12 SYSTEMS AND YN-12-C (PAG) OIL WITH R-134a SYSTEMS. FAILURE TO USE THE CORRECT REFRIGERANT OIL MAY RESULT IN DAMAGE TO SYSTEM COMPONENTS. ^ If the amount of oil drained from the removed compressor is between 90 and 148 mL (3-5 oz), pour the same amount of clean refrigerant oil into the new compressor. ^ If the amount of oil drained from the old compressor is greater than 90 mL (3 oz), pour 90 mL (3 oz) of clean refrigerant oil into the new compressor. 9. Install the new compressor following Service/Workshop Manual procedures. Make sure all mounting bolts are tightened properly. Check the tension of the compressor drive belt. Adjust if necessary. 10. Evacuate, charge and leak test the system, following Service/Workshop Manual procedures. 11. Check all refrigerant system hoses, lines and the position of the newly-installed filters to make sure they do not interfere with other engine compartment components. If necessary, use tie straps to make adjustments. 12. Set the A/C control on Max A/C, high blower and temperature control at full cold. a. Start engine and let idle briefly. b. Be sure A/C system is operating properly. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > 98-12-5 > Jun > 98 > A/C - Filtering Refrigerant After Compressor Replacement > Page 6050 13. Gradually bring the engine up to 1200 rpm by running it at lower rpms for short periods (first at 800 rpm, then at 1000 rpm). Set the engine at 1200 rpm and run it for an hour with the A/C system operating. 14. Stop the engine. NOTE: IT WILL BE NECESSARY TO RECOVER THE SYSTEM REFRIGERANT CHARGE BEFORE PROCEEDING. 15. Allow the engine to cool sufficiently to remove the fittings, flexible hoses and pancake filter from the liquid line. 16. Discard the filter. It can be used one (1) tie only. 17. Reconnect the liquid line back into the system. 18. Evacuate, charge and leak test the system. Make any necessary adjustments. 19. Check the operation of the system in all models. PART NUMBER PART NAME F8VZ-19E773-AA Filter Kit F73Z-19577-AA Refrigerant Oil - Motorcraft YN-9-A (For R-12 Refrigerant Systems Only) F7AZ-19589-DA Refrigerant Oil - Motorcraft YN-12-C (PAG-Type Oil For R-134a Refrigerant Systems Only) NOTE THE TOTAL REPAIR TIME IS FOR INSTALLING SERVICE FILTER KIT PER INSTRUCTIONS THIS INCLUDES INSTALLATION OF AND DISCARD OF FILTER. REFER TO SERVICE LABOR TIME STANDARDS MANUALS IF ADDITIONAL LABOR OPERATIONS ARE REQUIRED. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > 961710 > Aug > 96 > A/C - R12 Refrigerant Substitutes Service Tip Refrigerant: Technical Service Bulletins A/C - R12 Refrigerant Substitutes Service Tip Article No. 96-17-10 08/12/96 AIR CONDITIONING - USE OF R-12 REFRIGERANT SUBSTITUTES - SERVICE TIP FORD: 1980-93 CROWN VICTORIA 1981-93 ESCORT 1982-83 FAIRMONT 1982-88 EXP 1982-93 MUSTANG, THUNDERBIRD 1983-86 LTD 1984-94 TEMPO 1986-93 TAURUS 1988-93 FESTIVA 1989-93 PROBE LINCOLN-MERCURY: 1980-93 GRAND MARQUIS, TOWN CAR 1981-87 LYNX 1982-83 LN7, ZEPHYR 1982-86 CAPRI 1982-93 COUGAR 1982-94 CONTINENTAL 1983-86 MARQUIS 1984-92 MARK VII 1984-94 TOPAZ 1986-93 SABLE 1991-93 CAPRI, TRACER MERKUR: 1985-89 XR4TI 1988-90 SCORPIO LIGHT TRUCK: 1980-93 BRONCO, ECONOLINE, F SUPER DUTY, F-150-350 SERIES 1983-93 RANGER 1984-90 BRONCO II 1986-93 AEROSTAR 1988-93 F-47 1991-93 EXPLORER 1993 VILLAGER MEDIUM/HEAVY TRUCK: 1985-94 CARGO SERIES, F & B SERIES, L SERIES This TSB article is being republished in its entirety to list Environmental Protection Agency (EPA) reviewed NC substitutes for R-12 refrigerant. ISSUE: A number of manufacturers are producing refrigerant products which are described as being direct replacements for refrigerant R-12. ACTION: If service is required, use only new or of known quality recycled refrigerant R-12. Ford Motor Company has approved R-134a as the only refrigerant substitute for R-12. CAUTION: USING ANY UNAUTHORIZED SUBSTITUTE REFRIGERANT FOR R-12 MAY RESULT IN SEVERE DAMAGE TO THE A/C SYSTEM COMPONENTS. INFORMATION FROM THE EPA Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > 961710 > Aug > 96 > A/C - R12 Refrigerant Substitutes Service Tip > Page 6055 This information has been taken from EPA documents to address Ford specific applications and recommendations. Further EPA information on ozone-depleting substances and regulations regarding its handling can be found on the Internet at World Wide Web site: http://www.epa.gov/ozone/ In 1994, EPA established the Significant New Alternatives Policy (SNAP) program to review alternatives to ozone-depleting substances like R-12. EPA examines new substitutes for their ozone depleting, global warming, flammability, and toxicity characteristics. The SNAP process does not test these substitutes for A/C system compatibility, reliability, durability, or performance. Under the SNAP rule, each new refrigerant must be used in accordance with the following conditions: 1. Unique Fittings - Each new refrigerant must be used with a unique set of fittings to prevent the accidental mixing of different refrigerants. 2. Unique Equipment - Each refrigerant must have dedicated recovery/recycling equipment for that refrigerant. 3. Labels - Whether a vehicle is originally designed to use a new refrigerant or is retrofitted, the technician must apply a detailed label giving specific information about the alternative. This label covers up information about the old refrigerant and provides valuable details on the alternative and how it was used. The technician is required to fill in their name, company performing the retrofit, address and the date retrofitted. 4. Remove Original Refrigerant - The original R-12 must be removed from the system prior to charging with the new refrigerant. This will guarantee that the largest amount of clean R-12 is available for use in vehicles that still need it. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > 961710 > Aug > 96 > A/C - R12 Refrigerant Substitutes Service Tip > Page 6056 A summary of the refrigerants reviewed under EPA's SNAP program for use in motor vehicle air conditioning systems is in the table. OTHER APPLICABLE ARTICLES: 91-9-7, 96-15-7 SUPERSEDES: 93-23-11 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 208000, 208999, 290000 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > 94-14-3 > Jul > 94 > R-12 Refrigerant - Substitutes Refrigerant: Technical Service Bulletins R-12 Refrigerant - Substitutes Article No. 94-14-3 07/13/94 Air Conditioning - Use Of R-12 Refrigerant Substitutes - Service Tip FORD: 1980-93 CROWN VICTORIA 1981-93 ESCORT 1982-83 FAIRMONT 1982-88 EXP 1982-93 MUSTANG, THUNDERBIRD 1983-86 LTD 1984-93 TEMPO 1986-93 TAURUS 1988-93 FESTIVA 1989-93 PROBE LINCOLN-MERCURY: 1980-93 GRAND MARQUIS, TOWN CAR 1981-87 LYNX 1982-83 LN7, ZEPHYR 1982-86 CAPRI 1982-93 CONTINENTAL, COUGAR 1983-86 MARQUIS 1984-92 MARK VII 1984-93 TOPAZ 1986-93 SABLE 1991-93 CAPRI, TRACER MERKUR: 1986-89 SCORPIO, XR4TI LIGHT TRUCK: 1980-93 BRONCO, ECONOLINE, F-150-350 SERIES 1983-93 RANGER 1984-90 BRONCO II 1986-93 AEROSTAR 1988-93 F-47 1991-93 EXPLORER 1992-94 F-53 1993 VILLAGER MEDIUM/HEAVY TRUCK: 1954-90 C SERIES 1970-94 L SERIES 1979-90 CL-9000, CL-CLT-9000 SERIES 1980-94 F SERIES 1986-94 CARGO SERIES This TSB is being republished in its entirety to include Heavy Truck models. ISSUE: A number of manufacturers are producing refrigerant products which are described as being direct replacements for refrigerant R-12. The use of any unauthorized substitute refrigerant may severely damage the A/C system components. ACTION: If service is required, use only NEW or RECYCLED refrigerant R-12. Ford Motor Company has not tested or approved any R-12 refrigerant substitute at this time. R-134a is approved only for systems which specify R-134a, Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > 94-14-3 > Jul > 94 > R-12 Refrigerant - Substitutes > Page 6061 and is not compatible with R-12 systems. R-22 likewise, is not compatible with R-12 systems. CAUTION: USING ANY UNAUTHORIZED SUBSTITUTE REFRIGERANT FOR R-12 MAY RESULT IN SEVERE DAMAGE TO THE A/C SYSTEM COMPONENTS. OTHER APPLICABLE ARTICLES: 91-9-7 SUPERSEDES: 93-23-11 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 208000, 208999, 290000 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > 93206 > Sep > 93 > Air Conditioning - Use of Correct Fluorescent Tracer Dye Refrigerant: Technical Service Bulletins Air Conditioning - Use of Correct Fluorescent Tracer Dye Article No. 93-20-6 09/29/93 AIR CONDITIONING - USE OF CORRECT FLUORESCENT TRACER DYE - SERVICE TIP FORD: 1980-93 CROWN VICTORIA 1981-93 ESCORT 1982-83 FAIRMONT 1982-88 EXP 1982-93 MUSTANG, THUNDERBIRD 1983-86 LTD 1984-93 TEMPO 1986-93 TAURUS 1988-93 FESTIVA 1989-93 PROBE LINCOLN-MERCURY: 1980-93 GRAND MARQUIS, TOWN CAR 1981-87 LYNX 1982-83 LN7, ZEPHYR 1982-86 CAPRI 1982-93 CONTINENTAL, COUGAR 1983-86 MARQUIS 1984-92 MARK VII 1984-93 TOPAZ 1986-93 SABLE 1991-93 CAPRI, TRACER LIGHT TRUCK: 1980-93 BRONCO, ECONOLINE, F-150-350 SERIES 1983-93 RANGER 1984-90 BRONCO II 1986-93 AEROSTAR 1988-93 F-47 1991-93 EXPLORER 1993 VILLAGER ISSUE: Use of untested, unapproved fluorescent tracer dyes for A/C system leak checking may damage the air conditioning system. Some of these materials may not be compatible with Ford A/C systems. ACTION: When leak-checking an R-12 A/C system with a "black light", use only Rotunda-supplied Part No. 112-R0027, Fluoro-Lite brand dye. No other dyes have been approved by Ford Motor Company. NOTE: 112-R0027 DYE IS NOT COMPATIBLE WITH R-134a REFRIGERANT. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 208999 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > 9197 > May > 91 > A/C - R12 Refrigerant Service Tips Refrigerant: Technical Service Bulletins A/C - R12 Refrigerant Service Tips Article No. 91-9-7 05/01/91 AIR CONDITIONING - REFRIGERANT R-12 - SERVICE TIPS FORD: 1985-86 LTD 1985-88 EXP 1985-91 CROWN VICTORIA, ESCORT, MUSTANG, TEMPO, THUNDERBIRD 1986-91 TAURUS 1988-91 FESTIVA 1989-91 PROBE LINCOLN-MERCURY: 1985-87 LYNX 1985-91 CONTINENTAL, COUGAR, GRAND MARQUIS, MARK VII, TOPAZ, TOWN CAR 1986-91 SABLE 1987-91 TRACER 1991 CAPRI MERKUR: 1985-89 XR4TI 1988-89 SCORPIO LIGHT TRUCK: 1985-90 BRONCO II 1985-91 BRONCO, ECONOLINE, F-150-350 SERIES, RANGER 1986-91 AEROSTAR 1988-91 F SUPER DUTY 1991 EXPLORER MEDIUM/HEAVY TRUCK: 1985-90 C SERIES 1985-91 CL-CLT-9000 SERIES, F & B SERIES, L SERIES 1986-91 CARGO SERIES ISSUE: A number of manufacturers are producing refrigerant products which are described as being direct replacements for Refrigerant R-12. The use of any unauthorized substitute refrigerant may severely damage the A/C components. ACTION: If service is required, use only NEW or RECYCLED Refrigerant R-12. CAUTION: USING ANY UNAUTHORIZED SUBSTITUTE REFRIGERANT FOR R-12 MAY RESULT IN SEVERE DAMAGE TO THE A/C SYSTEM COMPONENTS. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 208000, 208200 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > Page 6070 Technical Service Bulletin # 98-12-5 Date: 980622 A/C - Filtering Refrigerant After Compressor Replacement Article No. 98-12-5 06/22/98 AIR CONDITIONING - FILTERING REFRIGERANT AFTER A/C COMPRESSOR REPLACEMENT - SERVICE TIPS FORD: 1980-98 CROWN VICTORIA 1981-98 ESCORT 1982-83 FAIRMONT 1982-88 EXP 1982-97 THUNDERBIRD 1982-98 MUSTANG 1983-86 LTD 1984-94 TEMPO 1986-98 TAURUS 1988-93 FESTIVA 1989-97 PROBE 1994-98 ASPIRE 1995-98 CONTOUR LINCOLN-MERCURY: 1980-98 GRAND MARQUIS, TOWN CAR 1982-83 ZEPHYR 1982-86 CAPRI 1982-87 LN7 1982-97 COUGAR 1982-98 CONTINENTAL 1983-86 MARQUIS 1984-92 MARK VII 1984-94 TOPAZ 1986-98 SABLE 1991-94 CAPRI 1991-98 TRACER 1993-98 MARK VIII 1995-98-MYSTIQUE 1999 COUGAR LIGHT TRUCK: 1980-96 BRONCO 1980-97 F SUPER DUTY 1980-98 ECONOLINE, F-150, F-150, F-350 1983-98 RANGER 1984-90 BRONCO II 1986-97 AEROSTAR 1988-97 F-47 1991-98 EXPLORER 1993-98 VILLAGER 1995-98 WINDSTAR 1997-98 EXPEDITION, MOUNTAINEER 1999 SUPER DUTY F SERIES This TSB article is being republished in its entirety to revise the Service Procedure and to update the model years. ISSUE Vehicles that have and inoperative A/C compressor, due to internal causes, MUST have the refrigerant system cleaned to remove any debris or contaminants that may be present to prevent damage to the replacement compressor. ACTION Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > Page 6071 Install a Service Filter Kit in the refrigerant system prior to installing the replacement compressor. Refer to the following Service Procedure for details. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 96-15-5 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 1992-99 Models And 1991 Lincolns, Basic Warranty Coverage For All Other Models And Major Component Warranty Coverage For All Other Lincoins OPERATION DESCRIPTION TIME 981205A Kit Installation 1.2 Hrs. 981205B Extra Time For Refrigerant 0.4 Hr. (R-12) Recovery DEALER CODING CONDITION BASIC PART NO. CODE 19703 49 OASIS CODES: 208000, 208999 Service Procedure THIS PROCEDURE IS OPTIONAL IF THE SYSTEM IS FLUSHED USING THE ROTUNDA A/C FLUSHER. CAUTION THIS FILTERING PROCEDURE MAY BE USED FOR EITHER R-12 OR R-134a REFRIGERANT SYSTEMS. BECAUSE THE TWO (2) SYSTEMS USE DIFFERENT REFRIGERANT OILS AND BECAUSE THE COMPRESSOR COULD BE DAMAGED IF THE WRONG OIL IS USED, SYSTEM IDENTIFICATION IS VERY IMPORTANT. BE SURE SYSTEM IS CORRECTLY IDENTIFIED BEFORE STARTING THE FILTERING PROCEDURE. Each Service Filter Kit includes the following items: ^ One (1) Pancake Filter (to be installed in the liquid line between the condenser and the orifice tube) ^ One (1) Instruction Sheet NOTE ON 1993-94 RANGER/EXPLORER VEHICLES, TECHNICIANS MAY EXPERIENCE DIFFICULTY WHEN CONNECTING THE PANCAKE FILTER HOSE FITTINGS TO THE EVAPORATOR INLET WITH THE ORIFICE TUBE INSTALLED. REMOVE THE OFFICE TUBE AND RUN THE SYSTEM FOR 1 HOUR AS DESCRIBED IN THE FILTERING PROCEDURE. REINSTALL THE ORIFICE TUBE AFTER FILTERING IS COMPLETE. CAUTION FOLLOW ALL REFRIGERANT SYSTEM SAFETY AND SERVICE PRECAUTIONS OUTLINED IN THE APPROPRIATE SERVICE OR WORKSHOP MANUAL. 1. Before removing any refrigerant system components, recover the refrigerant from the system following the recycling methods outlined In the appropriate Service/Workshop Manual. 2. Remove the suction accumulator/drier assembly and drain the oil into a calibrated container. 3. Install a new suction accumulator/drier and add new refrigerant oil to replace the old oil. The quantity of the new oil to be added is the amount to match that drained from the old accumulator plus 60 mL (2 oz). Refer to the Dealer Master Parts Catalog for the correct suction accumulator/drier part number. CAUTION REMEMBER TO USE MOTORCRAFT YN-9-A REFRIGERANT COMPRESSOR OIL WITH R-12 SYSTEMS AND MOTORCRAFT YN-12-C REFRIGERANT COMPRESSOR OIL WITH R-134a SYSTEMS. FAILURE TO USE THE CORRECT REFRIGERANT OIL MAY RESULT IN DAMAGE TO SYSTEM COMPONENTS. 4. Install a new orifice tube. Refer to the Dealer Master Parts Catalog for the correct orifice tube part number. If the orifice tube in the vehicle is located in the liquid line between the condenser and the evaporator, replace the liquid line assembly. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > Page 6072 5. Install pancake filter in the liquid line between the condenser and the orifice tube, Figure 1. a. Be sure orifice inlet is toward the condenser. b. Connections can be made using Test Adapter Set D93L-19703-B, or equivalent, and flexible refrigerant hose of 2500 psi burst rating. Individual fittings are also available. 6. Remove the old compressor following Service/Workshop Manual procedures. Drain the oil into a calibrated container. 7. Drain the oil from the replacement compressor into a clean calibrated container. NOTE: IT WILL BE NECESSARY TO TRANSFER THE MAGNET CLUTCH FROM THE OLD COMPRESSOR TO THE REPLACEMENT COMPRESSOR. FOLLOW SERVICE/WORKSHOP MANUAL PROCEDURES. 8. A new FX-15 service compressor contains 207 mL (7 oz.) of R-12 refrigerant oil. A new FS-10 service compressor does not contain any oil and can be used with an R-12 or an R-134a system. CAUTION REMEMBER TO USE YN-9-A (MINERAL) OIL WITH R-12 SYSTEMS AND YN-12-C (PAG) OIL WITH R-134a SYSTEMS. FAILURE TO USE THE CORRECT REFRIGERANT OIL MAY RESULT IN DAMAGE TO SYSTEM COMPONENTS. ^ If the amount of oil drained from the removed compressor is between 90 and 148 mL (3-5 oz), pour the same amount of clean refrigerant oil into the new compressor. ^ If the amount of oil drained from the old compressor is greater than 90 mL (3 oz), pour 90 mL (3 oz) of clean refrigerant oil into the new compressor. 9. Install the new compressor following Service/Workshop Manual procedures. Make sure all mounting bolts are tightened properly. Check the tension of the compressor drive belt. Adjust if necessary. 10. Evacuate, charge and leak test the system, following Service/Workshop Manual procedures. 11. Check all refrigerant system hoses, lines and the position of the newly-installed filters to make sure they do not interfere with other engine compartment components. If necessary, use tie straps to make adjustments. 12. Set the A/C control on Max A/C, high blower and temperature control at full cold. a. Start engine and let idle briefly. b. Be sure A/C system is operating properly. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > Page 6073 13. Gradually bring the engine up to 1200 rpm by running it at lower rpms for short periods (first at 800 rpm, then at 1000 rpm). Set the engine at 1200 rpm and run it for an hour with the A/C system operating. 14. Stop the engine. NOTE: IT WILL BE NECESSARY TO RECOVER THE SYSTEM REFRIGERANT CHARGE BEFORE PROCEEDING. 15. Allow the engine to cool sufficiently to remove the fittings, flexible hoses and pancake filter from the liquid line. 16. Discard the filter. It can be used one (1) tie only. 17. Reconnect the liquid line back into the system. 18. Evacuate, charge and leak test the system. Make any necessary adjustments. 19. Check the operation of the system in all models. PART NUMBER PART NAME F8VZ-19E773-AA Filter Kit F73Z-19577-AA Refrigerant Oil - Motorcraft YN-9-A (For R-12 Refrigerant Systems Only) F7AZ-19589-DA Refrigerant Oil - Motorcraft YN-12-C (PAG-Type Oil For R-134a Refrigerant Systems Only) NOTE THE TOTAL REPAIR TIME IS FOR INSTALLING SERVICE FILTER KIT PER INSTRUCTIONS THIS INCLUDES INSTALLATION OF AND DISCARD OF FILTER. REFER TO SERVICE LABOR TIME STANDARDS MANUALS IF ADDITIONAL LABOR OPERATIONS ARE REQUIRED. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > Page 6074 Refrigerant: Technical Service Bulletins Air Conditioning - Use of Correct Fluorescent Tracer Dye Article No. 93-20-6 09/29/93 AIR CONDITIONING - USE OF CORRECT FLUORESCENT TRACER DYE - SERVICE TIP FORD: 1980-93 CROWN VICTORIA 1981-93 ESCORT 1982-83 FAIRMONT 1982-88 EXP 1982-93 MUSTANG, THUNDERBIRD 1983-86 LTD 1984-93 TEMPO 1986-93 TAURUS 1988-93 FESTIVA 1989-93 PROBE LINCOLN-MERCURY: 1980-93 GRAND MARQUIS, TOWN CAR 1981-87 LYNX 1982-83 LN7, ZEPHYR 1982-86 CAPRI 1982-93 CONTINENTAL, COUGAR 1983-86 MARQUIS 1984-92 MARK VII 1984-93 TOPAZ 1986-93 SABLE 1991-93 CAPRI, TRACER LIGHT TRUCK: 1980-93 BRONCO, ECONOLINE, F-150-350 SERIES 1983-93 RANGER 1984-90 BRONCO II 1986-93 AEROSTAR 1988-93 F-47 1991-93 EXPLORER 1993 VILLAGER ISSUE: Use of untested, unapproved fluorescent tracer dyes for A/C system leak checking may damage the air conditioning system. Some of these materials may not be compatible with Ford A/C systems. ACTION: When leak-checking an R-12 A/C system with a "black light", use only Rotunda-supplied Part No. 112-R0027, Fluoro-Lite brand dye. No other dyes have been approved by Ford Motor Company. NOTE: 112-R0027 DYE IS NOT COMPATIBLE WITH R-134a REFRIGERANT. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 208999 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > Page 6075 Refrigerant: Technical Service Bulletins R-12 Refrigerant - Substitutes Article No. 94-14-3 07/13/94 Air Conditioning - Use Of R-12 Refrigerant Substitutes - Service Tip FORD: 1980-93 CROWN VICTORIA 1981-93 ESCORT 1982-83 FAIRMONT 1982-88 EXP 1982-93 MUSTANG, THUNDERBIRD 1983-86 LTD 1984-93 TEMPO 1986-93 TAURUS 1988-93 FESTIVA 1989-93 PROBE LINCOLN-MERCURY: 1980-93 GRAND MARQUIS, TOWN CAR 1981-87 LYNX 1982-83 LN7, ZEPHYR 1982-86 CAPRI 1982-93 CONTINENTAL, COUGAR 1983-86 MARQUIS 1984-92 MARK VII 1984-93 TOPAZ 1986-93 SABLE 1991-93 CAPRI, TRACER MERKUR: 1986-89 SCORPIO, XR4TI LIGHT TRUCK: 1980-93 BRONCO, ECONOLINE, F-150-350 SERIES 1983-93 RANGER 1984-90 BRONCO II 1986-93 AEROSTAR 1988-93 F-47 1991-93 EXPLORER 1992-94 F-53 1993 VILLAGER MEDIUM/HEAVY TRUCK: 1954-90 C SERIES 1970-94 L SERIES 1979-90 CL-9000, CL-CLT-9000 SERIES 1980-94 F SERIES 1986-94 CARGO SERIES This TSB is being republished in its entirety to include Heavy Truck models. ISSUE: A number of manufacturers are producing refrigerant products which are described as being direct replacements for refrigerant R-12. The use of any unauthorized substitute refrigerant may severely damage the A/C system components. ACTION: If service is required, use only NEW or RECYCLED refrigerant R-12. Ford Motor Company has not tested or approved any R-12 refrigerant substitute at this time. R-134a is approved only for systems which specify R-134a, Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > Page 6076 and is not compatible with R-12 systems. R-22 likewise, is not compatible with R-12 systems. CAUTION: USING ANY UNAUTHORIZED SUBSTITUTE REFRIGERANT FOR R-12 MAY RESULT IN SEVERE DAMAGE TO THE A/C SYSTEM COMPONENTS. OTHER APPLICABLE ARTICLES: 91-9-7 SUPERSEDES: 93-23-11 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 208000, 208999, 290000 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Capacity Specifications Refrigerant: Capacity Specifications MAKE, YEAR & MODEL Kg. Oz. FORD TRUCKS 1992 Bronco, F-Series pickup 1.3 44 1992-89 Aerostar 1.5 56 1992-83 Bronco II, Explorer, Ranger 0.9 32 E-Series van: Main unit 1.6 54 Auxiliary unit 2.0 70 1991-84 Bronco, F-Series pickup 1.4 48 1988-86 Aerostar 1.4 54 1983 Bronco, F-Series pickup 1.6 54 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Capacity Specifications > Page 6079 Refrigerant: Fluid Type Specifications Type ..................................................................................................................................................... ............................................... Refrigerant 12 (R-12) Ford Part Number ............................................. ........................................................................................................................................ D4AZ-19B519-A Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Filter > Component Information > Technical Service Bulletins > A/C - Filtering Refrigerant After Compressor Replacement Technical Service Bulletin # 98-12-5 Date: 980622 A/C - Filtering Refrigerant After Compressor Replacement Article No. 98-12-5 06/22/98 AIR CONDITIONING - FILTERING REFRIGERANT AFTER A/C COMPRESSOR REPLACEMENT - SERVICE TIPS FORD: 1980-98 CROWN VICTORIA 1981-98 ESCORT 1982-83 FAIRMONT 1982-88 EXP 1982-97 THUNDERBIRD 1982-98 MUSTANG 1983-86 LTD 1984-94 TEMPO 1986-98 TAURUS 1988-93 FESTIVA 1989-97 PROBE 1994-98 ASPIRE 1995-98 CONTOUR LINCOLN-MERCURY: 1980-98 GRAND MARQUIS, TOWN CAR 1982-83 ZEPHYR 1982-86 CAPRI 1982-87 LN7 1982-97 COUGAR 1982-98 CONTINENTAL 1983-86 MARQUIS 1984-92 MARK VII 1984-94 TOPAZ 1986-98 SABLE 1991-94 CAPRI 1991-98 TRACER 1993-98 MARK VIII 1995-98-MYSTIQUE 1999 COUGAR LIGHT TRUCK: 1980-96 BRONCO 1980-97 F SUPER DUTY 1980-98 ECONOLINE, F-150, F-150, F-350 1983-98 RANGER 1984-90 BRONCO II 1986-97 AEROSTAR 1988-97 F-47 1991-98 EXPLORER 1993-98 VILLAGER 1995-98 WINDSTAR 1997-98 EXPEDITION, MOUNTAINEER 1999 SUPER DUTY F SERIES This TSB article is being republished in its entirety to revise the Service Procedure and to update the model years. ISSUE Vehicles that have and inoperative A/C compressor, due to internal causes, MUST have the refrigerant system cleaned to remove any debris or contaminants that may be present to prevent damage to the replacement compressor. ACTION Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Filter > Component Information > Technical Service Bulletins > A/C - Filtering Refrigerant After Compressor Replacement > Page 6084 Install a Service Filter Kit in the refrigerant system prior to installing the replacement compressor. Refer to the following Service Procedure for details. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 96-15-5 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 1992-99 Models And 1991 Lincolns, Basic Warranty Coverage For All Other Models And Major Component Warranty Coverage For All Other Lincoins OPERATION DESCRIPTION TIME 981205A Kit Installation 1.2 Hrs. 981205B Extra Time For Refrigerant 0.4 Hr. (R-12) Recovery DEALER CODING CONDITION BASIC PART NO. CODE 19703 49 OASIS CODES: 208000, 208999 Service Procedure THIS PROCEDURE IS OPTIONAL IF THE SYSTEM IS FLUSHED USING THE ROTUNDA A/C FLUSHER. CAUTION THIS FILTERING PROCEDURE MAY BE USED FOR EITHER R-12 OR R-134a REFRIGERANT SYSTEMS. BECAUSE THE TWO (2) SYSTEMS USE DIFFERENT REFRIGERANT OILS AND BECAUSE THE COMPRESSOR COULD BE DAMAGED IF THE WRONG OIL IS USED, SYSTEM IDENTIFICATION IS VERY IMPORTANT. BE SURE SYSTEM IS CORRECTLY IDENTIFIED BEFORE STARTING THE FILTERING PROCEDURE. Each Service Filter Kit includes the following items: ^ One (1) Pancake Filter (to be installed in the liquid line between the condenser and the orifice tube) ^ One (1) Instruction Sheet NOTE ON 1993-94 RANGER/EXPLORER VEHICLES, TECHNICIANS MAY EXPERIENCE DIFFICULTY WHEN CONNECTING THE PANCAKE FILTER HOSE FITTINGS TO THE EVAPORATOR INLET WITH THE ORIFICE TUBE INSTALLED. REMOVE THE OFFICE TUBE AND RUN THE SYSTEM FOR 1 HOUR AS DESCRIBED IN THE FILTERING PROCEDURE. REINSTALL THE ORIFICE TUBE AFTER FILTERING IS COMPLETE. CAUTION FOLLOW ALL REFRIGERANT SYSTEM SAFETY AND SERVICE PRECAUTIONS OUTLINED IN THE APPROPRIATE SERVICE OR WORKSHOP MANUAL. 1. Before removing any refrigerant system components, recover the refrigerant from the system following the recycling methods outlined In the appropriate Service/Workshop Manual. 2. Remove the suction accumulator/drier assembly and drain the oil into a calibrated container. 3. Install a new suction accumulator/drier and add new refrigerant oil to replace the old oil. The quantity of the new oil to be added is the amount to match that drained from the old accumulator plus 60 mL (2 oz). Refer to the Dealer Master Parts Catalog for the correct suction accumulator/drier part number. CAUTION REMEMBER TO USE MOTORCRAFT YN-9-A REFRIGERANT COMPRESSOR OIL WITH R-12 SYSTEMS AND MOTORCRAFT YN-12-C REFRIGERANT COMPRESSOR OIL WITH R-134a SYSTEMS. FAILURE TO USE THE CORRECT REFRIGERANT OIL MAY RESULT IN DAMAGE TO SYSTEM COMPONENTS. 4. Install a new orifice tube. Refer to the Dealer Master Parts Catalog for the correct orifice tube part number. If the orifice tube in the vehicle is located in the liquid line between the condenser and the evaporator, replace the liquid line assembly. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Filter > Component Information > Technical Service Bulletins > A/C - Filtering Refrigerant After Compressor Replacement > Page 6085 5. Install pancake filter in the liquid line between the condenser and the orifice tube, Figure 1. a. Be sure orifice inlet is toward the condenser. b. Connections can be made using Test Adapter Set D93L-19703-B, or equivalent, and flexible refrigerant hose of 2500 psi burst rating. Individual fittings are also available. 6. Remove the old compressor following Service/Workshop Manual procedures. Drain the oil into a calibrated container. 7. Drain the oil from the replacement compressor into a clean calibrated container. NOTE: IT WILL BE NECESSARY TO TRANSFER THE MAGNET CLUTCH FROM THE OLD COMPRESSOR TO THE REPLACEMENT COMPRESSOR. FOLLOW SERVICE/WORKSHOP MANUAL PROCEDURES. 8. A new FX-15 service compressor contains 207 mL (7 oz.) of R-12 refrigerant oil. A new FS-10 service compressor does not contain any oil and can be used with an R-12 or an R-134a system. CAUTION REMEMBER TO USE YN-9-A (MINERAL) OIL WITH R-12 SYSTEMS AND YN-12-C (PAG) OIL WITH R-134a SYSTEMS. FAILURE TO USE THE CORRECT REFRIGERANT OIL MAY RESULT IN DAMAGE TO SYSTEM COMPONENTS. ^ If the amount of oil drained from the removed compressor is between 90 and 148 mL (3-5 oz), pour the same amount of clean refrigerant oil into the new compressor. ^ If the amount of oil drained from the old compressor is greater than 90 mL (3 oz), pour 90 mL (3 oz) of clean refrigerant oil into the new compressor. 9. Install the new compressor following Service/Workshop Manual procedures. Make sure all mounting bolts are tightened properly. Check the tension of the compressor drive belt. Adjust if necessary. 10. Evacuate, charge and leak test the system, following Service/Workshop Manual procedures. 11. Check all refrigerant system hoses, lines and the position of the newly-installed filters to make sure they do not interfere with other engine compartment components. If necessary, use tie straps to make adjustments. 12. Set the A/C control on Max A/C, high blower and temperature control at full cold. a. Start engine and let idle briefly. b. Be sure A/C system is operating properly. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Filter > Component Information > Technical Service Bulletins > A/C - Filtering Refrigerant After Compressor Replacement > Page 6086 13. Gradually bring the engine up to 1200 rpm by running it at lower rpms for short periods (first at 800 rpm, then at 1000 rpm). Set the engine at 1200 rpm and run it for an hour with the A/C system operating. 14. Stop the engine. NOTE: IT WILL BE NECESSARY TO RECOVER THE SYSTEM REFRIGERANT CHARGE BEFORE PROCEEDING. 15. Allow the engine to cool sufficiently to remove the fittings, flexible hoses and pancake filter from the liquid line. 16. Discard the filter. It can be used one (1) tie only. 17. Reconnect the liquid line back into the system. 18. Evacuate, charge and leak test the system. Make any necessary adjustments. 19. Check the operation of the system in all models. PART NUMBER PART NAME F8VZ-19E773-AA Filter Kit F73Z-19577-AA Refrigerant Oil - Motorcraft YN-9-A (For R-12 Refrigerant Systems Only) F7AZ-19589-DA Refrigerant Oil - Motorcraft YN-12-C (PAG-Type Oil For R-134a Refrigerant Systems Only) NOTE THE TOTAL REPAIR TIME IS FOR INSTALLING SERVICE FILTER KIT PER INSTRUCTIONS THIS INCLUDES INSTALLATION OF AND DISCARD OF FILTER. REFER TO SERVICE LABOR TIME STANDARDS MANUALS IF ADDITIONAL LABOR OPERATIONS ARE REQUIRED. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications > Capacity Specifications Refrigerant Oil: Capacity Specifications Air Conditioning Specifications Compressor Ford does not specify a given amount of oil for the compressor. When a compressor is replaced, drain the old compressor oil into a measuring cup. Then record the amound removed from the compressor. This is the amount to be added to the new compressor. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications > Capacity Specifications > Page 6091 Refrigerant Oil: Fluid Type Specifications Compressor ................................................................................................................... 500 viscosity (C9AZ-19557-B or Motorcraft VN-2 or equivalent) Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Technical Service Bulletins > Customer Interest: > 91155 > Jul > 91 > A/C System - Chemical/Refrigerator Type Odor Refrigerant Pressure Sensor / Switch: Customer Interest A/C System - Chemical/Refrigerator Type Odor Article No. 91-15-5 07/24/91 AIR CONDITIONING - "REFRIGERATOR TYPE SMELL" OR "CHEMICAL TYPE ODOR" A/C SYSTEM - VEHICLES BUILT BEFORE 10/15/90 FORD: 1980-91 CROWN VICTORIA 1981-91 ESCORT 1982-83 FAIRMONT 1982-88 EXP 1982-91 MUSTANG, THUNDERBIRD 1983-86 LTD 1984-91 TEMPO 1986-91 TAURUS 1989-91 PROBE LINCOLN-MERCURY: 1980-91 GRAND MARQUIS, MARK VII, TOWN CAR 1981-87 LYNX 1982-83 LN7, ZEPHYR 1982-86 CAPRI 1982-91 CONTINENTAL, COUGAR 1983-86 MARQUIS 1984-91 TOPAZ 1986-91 SABLE LIGHT TRUCK: 1980-91 BRONCO, F-150-350 SERIES 1982-91 RANGER 1983-90 BRONCO II 1986-91 AEROSTAR 1988-91 ECONOLINE, F SUPER DUTY, F-47 1991 EXPLORER This TSB article is being republished in its entirety to include Labor Standards for the Taurus, Sable and Probe vehicle models. ISSUE: A "refrigerator type smell" or "chemical type" odor may come from some A/C systems. As the calibration of the clutch cycling pressure switch drifts downward, the evaporator core temperature may drop too low. This results in a "refrigerator type smell" or "chemical type" odor as the system cycles on and off. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Technical Service Bulletins > Customer Interest: > 91155 > Jul > 91 > A/C System - Chemical/Refrigerator Type Odor > Page 6100 Figure 1 ACTION: Install a new recalibrated clutch cycling pressure switch or adjust the existing/non-recalibrated clutch cycling pressure switch. The recalibrated switch can be identified by a specific supplier date code stamped near the fitting end of the switch, Figure 1. ^ Recalibrated switches built in the 1990 calendar year begin with the supplier date code 9041 and run through 9052. ^ Recalibrated switches built in the 1991 calendar year start with the supplier date code 9101 and run through 9152. ADJUSTMENT PROCEDURE Adjust the existing/non-recalibrated A/C cycling pressure switch by using the following service procedure. 1. Disconnect the body wiring harness. 2. Turn the set screw located between the two electrical terminals 3/4 turn clockwise (looking into the electrical connection) Figure 1. 3. Reconnect the body wiring harness. PART NUMBER PART NAME CLASS E35Y-19E561-A A/C Cycling Pressure Switch AM OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 91-11-8 WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION DESCRIPTION TIME 911505A Install A/C Cycling 0.3 Hr. Pressure Switch - Town Car, Escort, Lynx, EXP And LN7. 911505B Install A/C Cycling 0.4 Hr. Pressure Switch - Tempo/ Topaz, Taurus/Sable, Probe. 911505C Install A/C Cycling 0.5 Hr. Pressure Switch - Crown Victoria, Grand Marquis, Mark VII, Continental, Thunderbird, Cougar, Fairmont, Zephyr, Mustang, Capri, LTD And Marquis. 911505D Install A/C Cycling 0.4 Hr. Pressure Switch - All Light Trucks. 911505E Adjust A/C Cycling Switch - 0.2 Hr. All DEALER CODING BASIC PART NO. CONDITION CODE 19E661 53 OASIS CODES: 208000, 208999 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Refrigerant Pressure Sensor / Switch: > 91155 > Jul > 91 > A/C System - Chemical/Refrigerator Type Odor Refrigerant Pressure Sensor / Switch: All Technical Service Bulletins A/C System Chemical/Refrigerator Type Odor Article No. 91-15-5 07/24/91 AIR CONDITIONING - "REFRIGERATOR TYPE SMELL" OR "CHEMICAL TYPE ODOR" A/C SYSTEM - VEHICLES BUILT BEFORE 10/15/90 FORD: 1980-91 CROWN VICTORIA 1981-91 ESCORT 1982-83 FAIRMONT 1982-88 EXP 1982-91 MUSTANG, THUNDERBIRD 1983-86 LTD 1984-91 TEMPO 1986-91 TAURUS 1989-91 PROBE LINCOLN-MERCURY: 1980-91 GRAND MARQUIS, MARK VII, TOWN CAR 1981-87 LYNX 1982-83 LN7, ZEPHYR 1982-86 CAPRI 1982-91 CONTINENTAL, COUGAR 1983-86 MARQUIS 1984-91 TOPAZ 1986-91 SABLE LIGHT TRUCK: 1980-91 BRONCO, F-150-350 SERIES 1982-91 RANGER 1983-90 BRONCO II 1986-91 AEROSTAR 1988-91 ECONOLINE, F SUPER DUTY, F-47 1991 EXPLORER This TSB article is being republished in its entirety to include Labor Standards for the Taurus, Sable and Probe vehicle models. ISSUE: A "refrigerator type smell" or "chemical type" odor may come from some A/C systems. As the calibration of the clutch cycling pressure switch drifts downward, the evaporator core temperature may drop too low. This results in a "refrigerator type smell" or "chemical type" odor as the system cycles on and off. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Refrigerant Pressure Sensor / Switch: > 91155 > Jul > 91 > A/C System - Chemical/Refrigerator Type Odor > Page 6106 Figure 1 ACTION: Install a new recalibrated clutch cycling pressure switch or adjust the existing/non-recalibrated clutch cycling pressure switch. The recalibrated switch can be identified by a specific supplier date code stamped near the fitting end of the switch, Figure 1. ^ Recalibrated switches built in the 1990 calendar year begin with the supplier date code 9041 and run through 9052. ^ Recalibrated switches built in the 1991 calendar year start with the supplier date code 9101 and run through 9152. ADJUSTMENT PROCEDURE Adjust the existing/non-recalibrated A/C cycling pressure switch by using the following service procedure. 1. Disconnect the body wiring harness. 2. Turn the set screw located between the two electrical terminals 3/4 turn clockwise (looking into the electrical connection) Figure 1. 3. Reconnect the body wiring harness. PART NUMBER PART NAME CLASS E35Y-19E561-A A/C Cycling Pressure Switch AM OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 91-11-8 WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION DESCRIPTION TIME 911505A Install A/C Cycling 0.3 Hr. Pressure Switch - Town Car, Escort, Lynx, EXP And LN7. 911505B Install A/C Cycling 0.4 Hr. Pressure Switch - Tempo/ Topaz, Taurus/Sable, Probe. 911505C Install A/C Cycling 0.5 Hr. Pressure Switch - Crown Victoria, Grand Marquis, Mark VII, Continental, Thunderbird, Cougar, Fairmont, Zephyr, Mustang, Capri, LTD And Marquis. 911505D Install A/C Cycling 0.4 Hr. Pressure Switch - All Light Trucks. 911505E Adjust A/C Cycling Switch - 0.2 Hr. All DEALER CODING BASIC PART NO. CONDITION CODE 19E661 53 OASIS CODES: 208000, 208999 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Refrigerant Pressure Sensor / Switch: > 891410 > Jul > 89 > A/C - Pressure Cycling Switch Diagnostic Procedure Refrigerant Pressure Sensor / Switch: All Technical Service Bulletins A/C - Pressure Cycling Switch Diagnostic Procedure AIR CONDITIONING-CLUTCH PRESSURE CYCLING SWITCH DIAGNOSTIC PROCEDURE Article No. 89-14-10 FORD: 1980-89 CROWN VICTORIA 1981-89 ESCORT 1982-88 EXP 1982-89 MUSTANG, THUNDERBIRD 1983-86 LTD 1984-89 TEMPO 1986-89 TAURUS LINCOLN-MERCURY: 1980-89 GRAND MARQUIS, MARK VI, MARK VII, TOWN CAR 1981-87 LYNX 1982-86 CAPRI 1982-89 CONTINENTAL, COUGAR 1983-86 MARQUIS 1984-89 TOPAZ 1986-89 SABLE LIGHT TRUCK: 1980-89 BRONCO, F SERIES 1983-89 RANGER 1984-89 BRONCO II 1986-89 AEROSTAR 1988-89 ECONOLINE ISSUE: Poor air conditioning cooling caused by low or no refrigerant charge often results in unnecessary replacement of the clutch cycling pressure switch. The switch is designed to work on system pressure. It closes at about 46 psi and opens at about 24.5 psi. It has a normal cycle (on and off) rate of 2 to 5 cycles per minute. ACTION: If an inoperative or fast cycling pressure switch is found, use the following diagnostic charts before replacing the pressure switch. DIAGNOSTIC PROCEDURE: 1. Connect a manifold gauge set to the service ports and check the system pressures. They should be above the closing pressure of the switch (46 psi). 2. If the A/C system pressures are above 46 psi and the clutch will not engage, proceed as follows: ^ Check the pressure switch harness connector and harness wires for a continuous open condition. ^ Check for an intermittent open or a poor connection between the connector and the pressure switch terminals. a. If the harness connector and wires are OK, by-pass the pressure switch by jumping the two terminals of the connector. If the clutch still does not engage, THE PRESSURE SWITCH IS NOT DEFECTIVE. Refer to the respective EVTM for the clutch circuit schematic and circuit diagnosis. Repair as necessary. 3. Check the ambient temperature. If the ambient temperature is below 48~ F (9~ C), the system pressure will not be high enough to close the pressure switch (46 psi). 4. If the system does not contain refrigerant, the pressure will not be high enough to close the switch for compressor operation. Leak test, repair, evacuate and charge the system. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Refrigerant Pressure Sensor / Switch: > 891410 > Jul > 89 > A/C - Pressure Cycling Switch Diagnostic Procedure > Page 6111 Figure 1 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Refrigerant Pressure Sensor / Switch: > 891410 > Jul > 89 > A/C - Pressure Cycling Switch Diagnostic Procedure > Page 6112 Figure 2 5. If the pressures are above 46 psi and the clutch cycle rate is faster than the normal rate of 2 to 5 cycles per minute, the system is probably low on refrigerant. Check that the system contains the correct refrigerant charge by following the correct diagnostic chart (Figures 1 or 2). WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 2600, 2610 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Technical Service Bulletins > All Other Service Bulletins for Refrigerant Pressure Sensor / Switch: > 891410 > Jul > 89 > A/C - Pressure Cycling Switch Diagnostic Procedure Refrigerant Pressure Sensor / Switch: All Technical Service Bulletins A/C - Pressure Cycling Switch Diagnostic Procedure AIR CONDITIONING-CLUTCH PRESSURE CYCLING SWITCH DIAGNOSTIC PROCEDURE Article No. 89-14-10 FORD: 1980-89 CROWN VICTORIA 1981-89 ESCORT 1982-88 EXP 1982-89 MUSTANG, THUNDERBIRD 1983-86 LTD 1984-89 TEMPO 1986-89 TAURUS LINCOLN-MERCURY: 1980-89 GRAND MARQUIS, MARK VI, MARK VII, TOWN CAR 1981-87 LYNX 1982-86 CAPRI 1982-89 CONTINENTAL, COUGAR 1983-86 MARQUIS 1984-89 TOPAZ 1986-89 SABLE LIGHT TRUCK: 1980-89 BRONCO, F SERIES 1983-89 RANGER 1984-89 BRONCO II 1986-89 AEROSTAR 1988-89 ECONOLINE ISSUE: Poor air conditioning cooling caused by low or no refrigerant charge often results in unnecessary replacement of the clutch cycling pressure switch. The switch is designed to work on system pressure. It closes at about 46 psi and opens at about 24.5 psi. It has a normal cycle (on and off) rate of 2 to 5 cycles per minute. ACTION: If an inoperative or fast cycling pressure switch is found, use the following diagnostic charts before replacing the pressure switch. DIAGNOSTIC PROCEDURE: 1. Connect a manifold gauge set to the service ports and check the system pressures. They should be above the closing pressure of the switch (46 psi). 2. If the A/C system pressures are above 46 psi and the clutch will not engage, proceed as follows: ^ Check the pressure switch harness connector and harness wires for a continuous open condition. ^ Check for an intermittent open or a poor connection between the connector and the pressure switch terminals. a. If the harness connector and wires are OK, by-pass the pressure switch by jumping the two terminals of the connector. If the clutch still does not engage, THE PRESSURE SWITCH IS NOT DEFECTIVE. Refer to the respective EVTM for the clutch circuit schematic and circuit diagnosis. Repair as necessary. 3. Check the ambient temperature. If the ambient temperature is below 48~ F (9~ C), the system pressure will not be high enough to close the pressure switch (46 psi). 4. If the system does not contain refrigerant, the pressure will not be high enough to close the switch for compressor operation. Leak test, repair, evacuate and charge the system. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Technical Service Bulletins > All Other Service Bulletins for Refrigerant Pressure Sensor / Switch: > 891410 > Jul > 89 > A/C - Pressure Cycling Switch Diagnostic Procedure > Page 6118 Figure 1 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Technical Service Bulletins > All Other Service Bulletins for Refrigerant Pressure Sensor / Switch: > 891410 > Jul > 89 > A/C - Pressure Cycling Switch Diagnostic Procedure > Page 6119 Figure 2 5. If the pressures are above 46 psi and the clutch cycle rate is faster than the normal rate of 2 to 5 cycles per minute, the system is probably low on refrigerant. Check that the system contains the correct refrigerant charge by following the correct diagnostic chart (Figures 1 or 2). WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 2600, 2610 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Technical Service Bulletins > Page 6120 Refrigerant Pressure Sensor / Switch: Locations Rear RH Side Of Engine Compartment On Accumulator/Drier Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Technical Service Bulletins > Customer Interest: > 91155 > Jul > 91 > A/C System - Chemical/Refrigerator Type Odor Refrigerant Pressure Sensor / Switch: Customer Interest A/C System - Chemical/Refrigerator Type Odor Article No. 91-15-5 07/24/91 AIR CONDITIONING - "REFRIGERATOR TYPE SMELL" OR "CHEMICAL TYPE ODOR" A/C SYSTEM - VEHICLES BUILT BEFORE 10/15/90 FORD: 1980-91 CROWN VICTORIA 1981-91 ESCORT 1982-83 FAIRMONT 1982-88 EXP 1982-91 MUSTANG, THUNDERBIRD 1983-86 LTD 1984-91 TEMPO 1986-91 TAURUS 1989-91 PROBE LINCOLN-MERCURY: 1980-91 GRAND MARQUIS, MARK VII, TOWN CAR 1981-87 LYNX 1982-83 LN7, ZEPHYR 1982-86 CAPRI 1982-91 CONTINENTAL, COUGAR 1983-86 MARQUIS 1984-91 TOPAZ 1986-91 SABLE LIGHT TRUCK: 1980-91 BRONCO, F-150-350 SERIES 1982-91 RANGER 1983-90 BRONCO II 1986-91 AEROSTAR 1988-91 ECONOLINE, F SUPER DUTY, F-47 1991 EXPLORER This TSB article is being republished in its entirety to include Labor Standards for the Taurus, Sable and Probe vehicle models. ISSUE: A "refrigerator type smell" or "chemical type" odor may come from some A/C systems. As the calibration of the clutch cycling pressure switch drifts downward, the evaporator core temperature may drop too low. This results in a "refrigerator type smell" or "chemical type" odor as the system cycles on and off. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Technical Service Bulletins > Customer Interest: > 91155 > Jul > 91 > A/C System - Chemical/Refrigerator Type Odor > Page 6130 Figure 1 ACTION: Install a new recalibrated clutch cycling pressure switch or adjust the existing/non-recalibrated clutch cycling pressure switch. The recalibrated switch can be identified by a specific supplier date code stamped near the fitting end of the switch, Figure 1. ^ Recalibrated switches built in the 1990 calendar year begin with the supplier date code 9041 and run through 9052. ^ Recalibrated switches built in the 1991 calendar year start with the supplier date code 9101 and run through 9152. ADJUSTMENT PROCEDURE Adjust the existing/non-recalibrated A/C cycling pressure switch by using the following service procedure. 1. Disconnect the body wiring harness. 2. Turn the set screw located between the two electrical terminals 3/4 turn clockwise (looking into the electrical connection) Figure 1. 3. Reconnect the body wiring harness. PART NUMBER PART NAME CLASS E35Y-19E561-A A/C Cycling Pressure Switch AM OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 91-11-8 WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION DESCRIPTION TIME 911505A Install A/C Cycling 0.3 Hr. Pressure Switch - Town Car, Escort, Lynx, EXP And LN7. 911505B Install A/C Cycling 0.4 Hr. Pressure Switch - Tempo/ Topaz, Taurus/Sable, Probe. 911505C Install A/C Cycling 0.5 Hr. Pressure Switch - Crown Victoria, Grand Marquis, Mark VII, Continental, Thunderbird, Cougar, Fairmont, Zephyr, Mustang, Capri, LTD And Marquis. 911505D Install A/C Cycling 0.4 Hr. Pressure Switch - All Light Trucks. 911505E Adjust A/C Cycling Switch - 0.2 Hr. All DEALER CODING BASIC PART NO. CONDITION CODE 19E661 53 OASIS CODES: 208000, 208999 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Refrigerant Pressure Sensor / Switch: > 91155 > Jul > 91 > A/C System - Chemical/Refrigerator Type Odor Refrigerant Pressure Sensor / Switch: All Technical Service Bulletins A/C System Chemical/Refrigerator Type Odor Article No. 91-15-5 07/24/91 AIR CONDITIONING - "REFRIGERATOR TYPE SMELL" OR "CHEMICAL TYPE ODOR" A/C SYSTEM - VEHICLES BUILT BEFORE 10/15/90 FORD: 1980-91 CROWN VICTORIA 1981-91 ESCORT 1982-83 FAIRMONT 1982-88 EXP 1982-91 MUSTANG, THUNDERBIRD 1983-86 LTD 1984-91 TEMPO 1986-91 TAURUS 1989-91 PROBE LINCOLN-MERCURY: 1980-91 GRAND MARQUIS, MARK VII, TOWN CAR 1981-87 LYNX 1982-83 LN7, ZEPHYR 1982-86 CAPRI 1982-91 CONTINENTAL, COUGAR 1983-86 MARQUIS 1984-91 TOPAZ 1986-91 SABLE LIGHT TRUCK: 1980-91 BRONCO, F-150-350 SERIES 1982-91 RANGER 1983-90 BRONCO II 1986-91 AEROSTAR 1988-91 ECONOLINE, F SUPER DUTY, F-47 1991 EXPLORER This TSB article is being republished in its entirety to include Labor Standards for the Taurus, Sable and Probe vehicle models. ISSUE: A "refrigerator type smell" or "chemical type" odor may come from some A/C systems. As the calibration of the clutch cycling pressure switch drifts downward, the evaporator core temperature may drop too low. This results in a "refrigerator type smell" or "chemical type" odor as the system cycles on and off. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Refrigerant Pressure Sensor / Switch: > 91155 > Jul > 91 > A/C System - Chemical/Refrigerator Type Odor > Page 6136 Figure 1 ACTION: Install a new recalibrated clutch cycling pressure switch or adjust the existing/non-recalibrated clutch cycling pressure switch. The recalibrated switch can be identified by a specific supplier date code stamped near the fitting end of the switch, Figure 1. ^ Recalibrated switches built in the 1990 calendar year begin with the supplier date code 9041 and run through 9052. ^ Recalibrated switches built in the 1991 calendar year start with the supplier date code 9101 and run through 9152. ADJUSTMENT PROCEDURE Adjust the existing/non-recalibrated A/C cycling pressure switch by using the following service procedure. 1. Disconnect the body wiring harness. 2. Turn the set screw located between the two electrical terminals 3/4 turn clockwise (looking into the electrical connection) Figure 1. 3. Reconnect the body wiring harness. PART NUMBER PART NAME CLASS E35Y-19E561-A A/C Cycling Pressure Switch AM OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 91-11-8 WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION DESCRIPTION TIME 911505A Install A/C Cycling 0.3 Hr. Pressure Switch - Town Car, Escort, Lynx, EXP And LN7. 911505B Install A/C Cycling 0.4 Hr. Pressure Switch - Tempo/ Topaz, Taurus/Sable, Probe. 911505C Install A/C Cycling 0.5 Hr. Pressure Switch - Crown Victoria, Grand Marquis, Mark VII, Continental, Thunderbird, Cougar, Fairmont, Zephyr, Mustang, Capri, LTD And Marquis. 911505D Install A/C Cycling 0.4 Hr. Pressure Switch - All Light Trucks. 911505E Adjust A/C Cycling Switch - 0.2 Hr. All DEALER CODING BASIC PART NO. CONDITION CODE 19E661 53 OASIS CODES: 208000, 208999 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Refrigerant Pressure Sensor / Switch: > 891410 > Jul > 89 > A/C - Pressure Cycling Switch Diagnostic Procedure Refrigerant Pressure Sensor / Switch: All Technical Service Bulletins A/C - Pressure Cycling Switch Diagnostic Procedure AIR CONDITIONING-CLUTCH PRESSURE CYCLING SWITCH DIAGNOSTIC PROCEDURE Article No. 89-14-10 FORD: 1980-89 CROWN VICTORIA 1981-89 ESCORT 1982-88 EXP 1982-89 MUSTANG, THUNDERBIRD 1983-86 LTD 1984-89 TEMPO 1986-89 TAURUS LINCOLN-MERCURY: 1980-89 GRAND MARQUIS, MARK VI, MARK VII, TOWN CAR 1981-87 LYNX 1982-86 CAPRI 1982-89 CONTINENTAL, COUGAR 1983-86 MARQUIS 1984-89 TOPAZ 1986-89 SABLE LIGHT TRUCK: 1980-89 BRONCO, F SERIES 1983-89 RANGER 1984-89 BRONCO II 1986-89 AEROSTAR 1988-89 ECONOLINE ISSUE: Poor air conditioning cooling caused by low or no refrigerant charge often results in unnecessary replacement of the clutch cycling pressure switch. The switch is designed to work on system pressure. It closes at about 46 psi and opens at about 24.5 psi. It has a normal cycle (on and off) rate of 2 to 5 cycles per minute. ACTION: If an inoperative or fast cycling pressure switch is found, use the following diagnostic charts before replacing the pressure switch. DIAGNOSTIC PROCEDURE: 1. Connect a manifold gauge set to the service ports and check the system pressures. They should be above the closing pressure of the switch (46 psi). 2. If the A/C system pressures are above 46 psi and the clutch will not engage, proceed as follows: ^ Check the pressure switch harness connector and harness wires for a continuous open condition. ^ Check for an intermittent open or a poor connection between the connector and the pressure switch terminals. a. If the harness connector and wires are OK, by-pass the pressure switch by jumping the two terminals of the connector. If the clutch still does not engage, THE PRESSURE SWITCH IS NOT DEFECTIVE. Refer to the respective EVTM for the clutch circuit schematic and circuit diagnosis. Repair as necessary. 3. Check the ambient temperature. If the ambient temperature is below 48~ F (9~ C), the system pressure will not be high enough to close the pressure switch (46 psi). 4. If the system does not contain refrigerant, the pressure will not be high enough to close the switch for compressor operation. Leak test, repair, evacuate and charge the system. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Refrigerant Pressure Sensor / Switch: > 891410 > Jul > 89 > A/C - Pressure Cycling Switch Diagnostic Procedure > Page 6141 Figure 1 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Refrigerant Pressure Sensor / Switch: > 891410 > Jul > 89 > A/C - Pressure Cycling Switch Diagnostic Procedure > Page 6142 Figure 2 5. If the pressures are above 46 psi and the clutch cycle rate is faster than the normal rate of 2 to 5 cycles per minute, the system is probably low on refrigerant. Check that the system contains the correct refrigerant charge by following the correct diagnostic chart (Figures 1 or 2). WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 2600, 2610 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Technical Service Bulletins > All Other Service Bulletins for Refrigerant Pressure Sensor / Switch: > 891410 > Jul > 89 > A/C - Pressure Cycling Switch Diagnostic Procedure Refrigerant Pressure Sensor / Switch: All Technical Service Bulletins A/C - Pressure Cycling Switch Diagnostic Procedure AIR CONDITIONING-CLUTCH PRESSURE CYCLING SWITCH DIAGNOSTIC PROCEDURE Article No. 89-14-10 FORD: 1980-89 CROWN VICTORIA 1981-89 ESCORT 1982-88 EXP 1982-89 MUSTANG, THUNDERBIRD 1983-86 LTD 1984-89 TEMPO 1986-89 TAURUS LINCOLN-MERCURY: 1980-89 GRAND MARQUIS, MARK VI, MARK VII, TOWN CAR 1981-87 LYNX 1982-86 CAPRI 1982-89 CONTINENTAL, COUGAR 1983-86 MARQUIS 1984-89 TOPAZ 1986-89 SABLE LIGHT TRUCK: 1980-89 BRONCO, F SERIES 1983-89 RANGER 1984-89 BRONCO II 1986-89 AEROSTAR 1988-89 ECONOLINE ISSUE: Poor air conditioning cooling caused by low or no refrigerant charge often results in unnecessary replacement of the clutch cycling pressure switch. The switch is designed to work on system pressure. It closes at about 46 psi and opens at about 24.5 psi. It has a normal cycle (on and off) rate of 2 to 5 cycles per minute. ACTION: If an inoperative or fast cycling pressure switch is found, use the following diagnostic charts before replacing the pressure switch. DIAGNOSTIC PROCEDURE: 1. Connect a manifold gauge set to the service ports and check the system pressures. They should be above the closing pressure of the switch (46 psi). 2. If the A/C system pressures are above 46 psi and the clutch will not engage, proceed as follows: ^ Check the pressure switch harness connector and harness wires for a continuous open condition. ^ Check for an intermittent open or a poor connection between the connector and the pressure switch terminals. a. If the harness connector and wires are OK, by-pass the pressure switch by jumping the two terminals of the connector. If the clutch still does not engage, THE PRESSURE SWITCH IS NOT DEFECTIVE. Refer to the respective EVTM for the clutch circuit schematic and circuit diagnosis. Repair as necessary. 3. Check the ambient temperature. If the ambient temperature is below 48~ F (9~ C), the system pressure will not be high enough to close the pressure switch (46 psi). 4. If the system does not contain refrigerant, the pressure will not be high enough to close the switch for compressor operation. Leak test, repair, evacuate and charge the system. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Technical Service Bulletins > All Other Service Bulletins for Refrigerant Pressure Sensor / Switch: > 891410 > Jul > 89 > A/C - Pressure Cycling Switch Diagnostic Procedure > Page 6148 Figure 1 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Technical Service Bulletins > All Other Service Bulletins for Refrigerant Pressure Sensor / Switch: > 891410 > Jul > 89 > A/C - Pressure Cycling Switch Diagnostic Procedure > Page 6149 Figure 2 5. If the pressures are above 46 psi and the clutch cycle rate is faster than the normal rate of 2 to 5 cycles per minute, the system is probably low on refrigerant. Check that the system contains the correct refrigerant charge by following the correct diagnostic chart (Figures 1 or 2). WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 2600, 2610 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Technical Service Bulletins > Page 6150 Refrigerant Pressure Sensor / Switch: Locations Rear RH Side Of Engine Compartment On Accumulator/Drier Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Throttle Full Open Switch HVAC > Component Information > Description and Operation Throttle Full Open Switch HVAC: Description and Operation A switch assembly, Figure 1 is mounted on the carburetor on some gasoline engines and on the fuel injector pump on the 2.0L Diesel engine to sense a wide open throttle condition. When maximum engine power is required, this switch assembly cuts off the air conditioning compressor to reduce engine loading. Switch closed at throttle opening less than wide open throttle. Switch open at wide open throttle condition. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Heating and Air Conditioning > Vacuum Harness HVAC > Component Information > Description and Operation Vacuum Harness HVAC: Description and Operation Engine vacuum systems a pre-assembled harness which features colored nylon vacuum lines. The color is a visual aid both in production and in service. The emission decal on the engine provides a colored schematic of the vacuum hookup which corresponds with the pre-assembled harness. Vacuum hose harnesses consist of nylon hoses a .150 inch outer diameter and a .090 inch inner diameter bonded to nylon or rubber connectors. Occasionally a rubber hose may be connected to the harness. The nylon connectors have rubber inserts to provide a seal between the nylon connector and the component connection. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Heating and Air Conditioning > Vacuum Tank <--> [Vacuum Reservoir HVAC] > Component Information > Description and Operation Vacuum Tank: Description and Operation Fig. 37 Vacuum reservoirs The vacuum reservoir, Fig. 37, used on some vehicles, acts as an accumulator and prevents sudden drops or rapid fluctuations in a vacuum signal during acceleration. If vacuum in the reservoir leaks more than 1/2 inch Hg in 1 minute, the reservoir is defective and must be replaced. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Heating and Air Conditioning > Vacuum Tank <--> [Vacuum Reservoir HVAC] > Component Information > Description and Operation > Page 6160 Vacuum Tank: Service and Repair 1983-87 Models Exc. 1983-87 Ranger, 1984-87 Bronco II & 1986-87 Aerostar 1. Disconnect the two vacuum lines connected to the reservoir ports. 2. Remove reservoir retaining nuts from the underside of the left hand apron, then the reservoir. 3. Reverse procedure to install. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle Switch > Component Information > Locations Seat Belt Buckle Switch: Locations In Driver's Seatbelt Buckle Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Latch > Component Information > Technical Service Bulletins > Safety Belt - Tongue Cover Now Available Seat Belt Latch: Technical Service Bulletins Safety Belt - Tongue Cover Now Available SAFETY BELT - TONGUE COVER SERVICE PART AVAILABILITY Article No. 88-25-2 FORD: 1974-88 ALL LINCOLN-MERCURY: 1974-88 ALL LIGHT-TRUCK: 1974-88 ALL MEDIUM/HEAVY: 1974-88 ISSUE: The safety belt tongue cover is now available for service. It is no longer necessary to replace the entire safety belt assembly in the event a buckle and tongue cover requires service. ACTION: No corrective action is required. Refer to the following application chart for the correct service part number. NOTE: THE SAFETY BELT TONGUE COVERS ARE SERVICED IN A NEUTRAL COLOR AND MUST BE PAINTED TO MATCH. SAFETY BELT TONGUE COVER APPLICATION CHART MODEL YEAR VEHICLE SERVICE PART NO. 1986-88 Taurus/Sable E7DZ-54612A64-A 1974-88 All Other Vehicles E7FZ-61612A64-A PART NUMBER PART NAME CLASS E7DZ-54612A64-A Safety Belt Tongue Cover Package of 4 BM E7FZ-61612A64-A Safety Belt Tongue Cover Package of 4 B OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" OASIS CODES: 1050, 1051, 1800 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Locations Seat Belt Buckle Switch: Locations In Driver's Seatbelt Buckle Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > System Information > Technical Service Bulletins > Antitheft Devices - Installation Precautions Antitheft and Alarm Systems: Technical Service Bulletins Antitheft Devices - Installation Precautions Article No. 86-3-9 ANTI-THEFT DEVICES (AFTER MARKET) - INSTALLATION/ OPERATING PRECAUTIONS ON VEHICLES EQUIPPED WITH ELECTRONIC ENGINE CONTROLS (EEC) FORD 1978-86 ALL LINCOLN-MERCURY 1978-86 ALL LIGHT TRUCK 1981-86 ALL NOTE: This article is being republished in its entirety to include 1986 models. Installation of "AfterMarket" anti-theft devices such as fuel shutoff and ignition defeating devices may cause no starts, hard starting, stalls, or damage to vehicle components on Ford vehicles equipped with electronic engine controls. Possible damage caused by these devices can result from the following situations: 1. Fuel shutoff devices - Attempting to start the vehicle without disarming this device may cause the fuel injectors to run dry and overheat, which will lead to failure of the injectors. 2. Ignition defeating devices which ground the ignition/tachometer lead - Attempting to start the vehicle without disarming may result in ignition coil failure. Figure 13 In addition, care must be taken when routing underhood after market wiring (see Figure 13 for proper precautions), in order to avoid electromagnetic interference with electronic engine controls. The following precautions must be observed: Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > System Information > Technical Service Bulletins > Antitheft Devices - Installation Precautions > Page 6179 1. Ignition tach signal wiring must not be randomly routed through the engine compartment. 2. Add-on wiring must not run parallel to secondary (plug) ignition wires. 3. EEC wiring harness (12A581) must not be altered or cut or rerouted. Failure to observe these warnings may result in damage to vehicle components or drive deterioration. OTHER APPLICABLE ARTICLES: Supersedes 85-7-8 WARRANTY STATUS: "INFORMATION ONLY" Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Accessories and Optional Equipment > Citizens Band Radio (CB) > Component Information > Technical Service Bulletins > Customer Interest for Citizens Band Radio (CB): > 91175 > Aug > 91 > Radio/Two-Way Communications - Whine/Buzz Citizens Band Radio (CB): Customer Interest Radio/Two-Way Communications - Whine/Buzz Article No. 91-17-5 08/21/91 ^ FUEL SYSTEM - FUEL PUMP "WHINE/BUZZ" NOISE COMES THROUGH ENTERTAINMENT OR TWO-WAY COMMUNICATION RADIO ^ RADIO - ENTERTAINMENT OR TWO-WAY COMMUNICATION - "WHINE/BUZZ" NOISE CAUSED BY FUEL PUMP ^ NOISE - "WHINE/BUZZ" - COMES THROUGH ENTERTAINMENT OR TWO-WAY COMMUNICATION RADIO FORD: 1984 THUNDERBIRD 1984-85 MUSTANG 1984-86 LTD 1985-87 TEMPO 1986-89 TAURUS 1987 EXP 1987-90 ESCORT LINCOLN-MERCURY: 1984 CONTINENTAL, COUGAR, MARK VII 1984-85 CAPRI 1984-86 MARQUIS 1985-87 TOPAZ 1986-89 SABLE 1987 LYNX LIGHT TRUCK: 1985-87 RANGER 1985-88 BRONCO, F-150-350 SERIES 1986 AEROSTAR 1986-87 BRONCO II 1986-91 ECONOLINE ISSUE: A "whining/buzzing" noise may come from the entertainment or two-way communication radio on vehicles with an in-tank electric fuel pump. This occurs because of electrical interference from the fuel pump. ACTION: Install a noise filter kit (E7PZ-9B357-A) consisting of an RFI noise filter, electrical terminals and a piece of shrink tubing. Refer to the following service procedure. 1. Remove the fuel pump/sender unit from the fuel tank. Refer to the appropriate Shop Manual for removal procedure. 2. Disconnect the heavy red and black wires from the pump terminals. 3. Inspect the fuel pump electrical terminals. ^ If the fuel pump has threaded terminals, go to Step 4. ^ If the fuel pump has spade terminals, go to Step 7. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Accessories and Optional Equipment > Citizens Band Radio (CB) > Component Information > Technical Service Bulletins > Customer Interest for Citizens Band Radio (CB): > 91175 > Aug > 91 > Radio/Two-Way Communications - Whine/Buzz > Page 6188 Figure 1 4. For Threaded Terminals - Insert RFI noise filter into the pump collar and onto the threaded terminals, Figure 1. a. Observe polarity marking on fuel pump and RFI noise filter. b. Install nuts and tighten securely. 5. Cut the ring terminals from the red and black wire ends and discard. CAUTION: BE SURE NOT TO CUT THE WIRE TOO SHORT. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Accessories and Optional Equipment > Citizens Band Radio (CB) > Component Information > Technical Service Bulletins > Customer Interest for Citizens Band Radio (CB): > 91175 > Aug > 91 > Radio/Two-Way Communications - Whine/Buzz > Page 6189 a. Install a 1" (25.4 mm) piece of heat shrink tubing over each end of wire. b. Install the small female spade terminal onto the red wire and the large female spade terminal onto the black wire. c. Crimp and solder new terminals onto the wires. d. Put shrink tubing over the new crimp and solder connection. 6. Install wires on the RFI noise filter terminals. NOTE: BE SURE TO OBSERVE POLARITY MARKINGS. Go to Step 12. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Accessories and Optional Equipment > Citizens Band Radio (CB) > Component Information > Technical Service Bulletins > Customer Interest for Citizens Band Radio (CB): > 91175 > Aug > 91 > Radio/Two-Way Communications - Whine/Buzz > Page 6190 Figure 2 7. For Spade Terminals - Measure from fuel pump electrical connectors toward the mounting flange and cut two (2) two inch jumper wires from the pump wires, Figure 2. a. Install a 1" (25.4 mm) piece of heat shrink tubing over each end of wire. b. Install the small female spade terminal onto the red wire end and the large female spade terminal onto the black wire end. c. Crimp and solder new terminals onto the wires. d. Put shrink tubing over the new crimp and solder connection. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Accessories and Optional Equipment > Citizens Band Radio (CB) > Component Information > Technical Service Bulletins > Customer Interest for Citizens Band Radio (CB): > 91175 > Aug > 91 > Radio/Two-Way Communications - Whine/Buzz > Page 6191 8. Strip 3/8" (9.525 mm) of insulation from each end of the wires attached to the mounting flange. a. Slide a 1" (25.4 mm) piece of heat shrink tubing over each end of wire. b. Wrap and solder the wires to the ring terminals of the RFI noise filter (red wire to positive terminal, black wire to negative terminals). c. Push heat shrink tubing over soldered wire ends and shrink. 9. Attach jumper wires to the RFI noise filter spade terminals. NOTE: BE SURE TO OBSERVE POLARITY MARKINGS. 10. Attach the jumper wires to the electrical fuel pump terminals. NOTE: BE SURE TO OBSERVE POLARITY MARKINGS. 11. Use tie straps to attach the RFI noise filter to the pick-up/return tubing of the pump/sender unit. NOTE: MAKE SURE WIRES ARE SECURELY ATTACHED. 12. Reinstall the fuel pump/sender in the vehicle. Refer to the appropriate service manual for service details and required parts. PART NUMBER PART NAME CLASS E7PZ-9B357-A Noise Filter Kit C OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 87-20-13 WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION DESCRIPTION TIME 911705A Aerostar, Ranger And 1.5 Hr. Econoline With Mid-Ship Fuel Tank. 911705B F-Series With Mid-Ship Fuel 1.3 Hr. Tank Or Ranger With Aft Of Axle Fuel Tank. 911705C Bronco II, F-Series And 1.6 Hr. Bronco With Aft Of Axle Fuel Tank. 911705D Econoline With Aft Of Axle 1.2 Hr. Fuel Tank. 911705E Additional Time - F-Series 0.2 Hr. Equipped With Spare Tire Carrier. 911705F All Cars 1.3 Hr. DEALER CODING BASIC PART NO. CONDITION CODE 9H307 56 OASIS CODES: 205000, 207000, 404000, 702000 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Accessories and Optional Equipment > Citizens Band Radio (CB) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Citizens Band Radio (CB): > 91175 > Aug > 91 > Radio/Two-Way Communications - Whine/Buzz Citizens Band Radio (CB): All Technical Service Bulletins Radio/Two-Way Communications Whine/Buzz Article No. 91-17-5 08/21/91 ^ FUEL SYSTEM - FUEL PUMP "WHINE/BUZZ" NOISE COMES THROUGH ENTERTAINMENT OR TWO-WAY COMMUNICATION RADIO ^ RADIO - ENTERTAINMENT OR TWO-WAY COMMUNICATION - "WHINE/BUZZ" NOISE CAUSED BY FUEL PUMP ^ NOISE - "WHINE/BUZZ" - COMES THROUGH ENTERTAINMENT OR TWO-WAY COMMUNICATION RADIO FORD: 1984 THUNDERBIRD 1984-85 MUSTANG 1984-86 LTD 1985-87 TEMPO 1986-89 TAURUS 1987 EXP 1987-90 ESCORT LINCOLN-MERCURY: 1984 CONTINENTAL, COUGAR, MARK VII 1984-85 CAPRI 1984-86 MARQUIS 1985-87 TOPAZ 1986-89 SABLE 1987 LYNX LIGHT TRUCK: 1985-87 RANGER 1985-88 BRONCO, F-150-350 SERIES 1986 AEROSTAR 1986-87 BRONCO II 1986-91 ECONOLINE ISSUE: A "whining/buzzing" noise may come from the entertainment or two-way communication radio on vehicles with an in-tank electric fuel pump. This occurs because of electrical interference from the fuel pump. ACTION: Install a noise filter kit (E7PZ-9B357-A) consisting of an RFI noise filter, electrical terminals and a piece of shrink tubing. Refer to the following service procedure. 1. Remove the fuel pump/sender unit from the fuel tank. Refer to the appropriate Shop Manual for removal procedure. 2. Disconnect the heavy red and black wires from the pump terminals. 3. Inspect the fuel pump electrical terminals. ^ If the fuel pump has threaded terminals, go to Step 4. ^ If the fuel pump has spade terminals, go to Step 7. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Accessories and Optional Equipment > Citizens Band Radio (CB) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Citizens Band Radio (CB): > 91175 > Aug > 91 > Radio/Two-Way Communications - Whine/Buzz > Page 6197 Figure 1 4. For Threaded Terminals - Insert RFI noise filter into the pump collar and onto the threaded terminals, Figure 1. a. Observe polarity marking on fuel pump and RFI noise filter. b. Install nuts and tighten securely. 5. Cut the ring terminals from the red and black wire ends and discard. CAUTION: BE SURE NOT TO CUT THE WIRE TOO SHORT. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Accessories and Optional Equipment > Citizens Band Radio (CB) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Citizens Band Radio (CB): > 91175 > Aug > 91 > Radio/Two-Way Communications - Whine/Buzz > Page 6198 a. Install a 1" (25.4 mm) piece of heat shrink tubing over each end of wire. b. Install the small female spade terminal onto the red wire and the large female spade terminal onto the black wire. c. Crimp and solder new terminals onto the wires. d. Put shrink tubing over the new crimp and solder connection. 6. Install wires on the RFI noise filter terminals. NOTE: BE SURE TO OBSERVE POLARITY MARKINGS. Go to Step 12. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Accessories and Optional Equipment > Citizens Band Radio (CB) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Citizens Band Radio (CB): > 91175 > Aug > 91 > Radio/Two-Way Communications - Whine/Buzz > Page 6199 Figure 2 7. For Spade Terminals - Measure from fuel pump electrical connectors toward the mounting flange and cut two (2) two inch jumper wires from the pump wires, Figure 2. a. Install a 1" (25.4 mm) piece of heat shrink tubing over each end of wire. b. Install the small female spade terminal onto the red wire end and the large female spade terminal onto the black wire end. c. Crimp and solder new terminals onto the wires. d. Put shrink tubing over the new crimp and solder connection. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Accessories and Optional Equipment > Citizens Band Radio (CB) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Citizens Band Radio (CB): > 91175 > Aug > 91 > Radio/Two-Way Communications - Whine/Buzz > Page 6200 8. Strip 3/8" (9.525 mm) of insulation from each end of the wires attached to the mounting flange. a. Slide a 1" (25.4 mm) piece of heat shrink tubing over each end of wire. b. Wrap and solder the wires to the ring terminals of the RFI noise filter (red wire to positive terminal, black wire to negative terminals). c. Push heat shrink tubing over soldered wire ends and shrink. 9. Attach jumper wires to the RFI noise filter spade terminals. NOTE: BE SURE TO OBSERVE POLARITY MARKINGS. 10. Attach the jumper wires to the electrical fuel pump terminals. NOTE: BE SURE TO OBSERVE POLARITY MARKINGS. 11. Use tie straps to attach the RFI noise filter to the pick-up/return tubing of the pump/sender unit. NOTE: MAKE SURE WIRES ARE SECURELY ATTACHED. 12. Reinstall the fuel pump/sender in the vehicle. Refer to the appropriate service manual for service details and required parts. PART NUMBER PART NAME CLASS E7PZ-9B357-A Noise Filter Kit C OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 87-20-13 WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION DESCRIPTION TIME 911705A Aerostar, Ranger And 1.5 Hr. Econoline With Mid-Ship Fuel Tank. 911705B F-Series With Mid-Ship Fuel 1.3 Hr. Tank Or Ranger With Aft Of Axle Fuel Tank. 911705C Bronco II, F-Series And 1.6 Hr. Bronco With Aft Of Axle Fuel Tank. 911705D Econoline With Aft Of Axle 1.2 Hr. Fuel Tank. 911705E Additional Time - F-Series 0.2 Hr. Equipped With Spare Tire Carrier. 911705F All Cars 1.3 Hr. DEALER CODING BASIC PART NO. CONDITION CODE 9H307 56 OASIS CODES: 205000, 207000, 404000, 702000 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > Customer Interest for Radio/Stereo Noise Filter: > 91175 > Aug > 91 > Radio/Two-Way Communications - Whine/Buzz Radio/Stereo Noise Filter: Customer Interest Radio/Two-Way Communications - Whine/Buzz Article No. 91-17-5 08/21/91 ^ FUEL SYSTEM - FUEL PUMP "WHINE/BUZZ" NOISE COMES THROUGH ENTERTAINMENT OR TWO-WAY COMMUNICATION RADIO ^ RADIO - ENTERTAINMENT OR TWO-WAY COMMUNICATION - "WHINE/BUZZ" NOISE CAUSED BY FUEL PUMP ^ NOISE - "WHINE/BUZZ" - COMES THROUGH ENTERTAINMENT OR TWO-WAY COMMUNICATION RADIO FORD: 1984 THUNDERBIRD 1984-85 MUSTANG 1984-86 LTD 1985-87 TEMPO 1986-89 TAURUS 1987 EXP 1987-90 ESCORT LINCOLN-MERCURY: 1984 CONTINENTAL, COUGAR, MARK VII 1984-85 CAPRI 1984-86 MARQUIS 1985-87 TOPAZ 1986-89 SABLE 1987 LYNX LIGHT TRUCK: 1985-87 RANGER 1985-88 BRONCO, F-150-350 SERIES 1986 AEROSTAR 1986-87 BRONCO II 1986-91 ECONOLINE ISSUE: A "whining/buzzing" noise may come from the entertainment or two-way communication radio on vehicles with an in-tank electric fuel pump. This occurs because of electrical interference from the fuel pump. ACTION: Install a noise filter kit (E7PZ-9B357-A) consisting of an RFI noise filter, electrical terminals and a piece of shrink tubing. Refer to the following service procedure. 1. Remove the fuel pump/sender unit from the fuel tank. Refer to the appropriate Shop Manual for removal procedure. 2. Disconnect the heavy red and black wires from the pump terminals. 3. Inspect the fuel pump electrical terminals. ^ If the fuel pump has threaded terminals, go to Step 4. ^ If the fuel pump has spade terminals, go to Step 7. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > Customer Interest for Radio/Stereo Noise Filter: > 91175 > Aug > 91 > Radio/Two-Way Communications - Whine/Buzz > Page 6211 Figure 1 4. For Threaded Terminals - Insert RFI noise filter into the pump collar and onto the threaded terminals, Figure 1. a. Observe polarity marking on fuel pump and RFI noise filter. b. Install nuts and tighten securely. 5. Cut the ring terminals from the red and black wire ends and discard. CAUTION: BE SURE NOT TO CUT THE WIRE TOO SHORT. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > Customer Interest for Radio/Stereo Noise Filter: > 91175 > Aug > 91 > Radio/Two-Way Communications - Whine/Buzz > Page 6212 a. Install a 1" (25.4 mm) piece of heat shrink tubing over each end of wire. b. Install the small female spade terminal onto the red wire and the large female spade terminal onto the black wire. c. Crimp and solder new terminals onto the wires. d. Put shrink tubing over the new crimp and solder connection. 6. Install wires on the RFI noise filter terminals. NOTE: BE SURE TO OBSERVE POLARITY MARKINGS. Go to Step 12. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > Customer Interest for Radio/Stereo Noise Filter: > 91175 > Aug > 91 > Radio/Two-Way Communications - Whine/Buzz > Page 6213 Figure 2 7. For Spade Terminals - Measure from fuel pump electrical connectors toward the mounting flange and cut two (2) two inch jumper wires from the pump wires, Figure 2. a. Install a 1" (25.4 mm) piece of heat shrink tubing over each end of wire. b. Install the small female spade terminal onto the red wire end and the large female spade terminal onto the black wire end. c. Crimp and solder new terminals onto the wires. d. Put shrink tubing over the new crimp and solder connection. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > Customer Interest for Radio/Stereo Noise Filter: > 91175 > Aug > 91 > Radio/Two-Way Communications - Whine/Buzz > Page 6214 8. Strip 3/8" (9.525 mm) of insulation from each end of the wires attached to the mounting flange. a. Slide a 1" (25.4 mm) piece of heat shrink tubing over each end of wire. b. Wrap and solder the wires to the ring terminals of the RFI noise filter (red wire to positive terminal, black wire to negative terminals). c. Push heat shrink tubing over soldered wire ends and shrink. 9. Attach jumper wires to the RFI noise filter spade terminals. NOTE: BE SURE TO OBSERVE POLARITY MARKINGS. 10. Attach the jumper wires to the electrical fuel pump terminals. NOTE: BE SURE TO OBSERVE POLARITY MARKINGS. 11. Use tie straps to attach the RFI noise filter to the pick-up/return tubing of the pump/sender unit. NOTE: MAKE SURE WIRES ARE SECURELY ATTACHED. 12. Reinstall the fuel pump/sender in the vehicle. Refer to the appropriate service manual for service details and required parts. PART NUMBER PART NAME CLASS E7PZ-9B357-A Noise Filter Kit C OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 87-20-13 WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION DESCRIPTION TIME 911705A Aerostar, Ranger And 1.5 Hr. Econoline With Mid-Ship Fuel Tank. 911705B F-Series With Mid-Ship Fuel 1.3 Hr. Tank Or Ranger With Aft Of Axle Fuel Tank. 911705C Bronco II, F-Series And 1.6 Hr. Bronco With Aft Of Axle Fuel Tank. 911705D Econoline With Aft Of Axle 1.2 Hr. Fuel Tank. 911705E Additional Time - F-Series 0.2 Hr. Equipped With Spare Tire Carrier. 911705F All Cars 1.3 Hr. DEALER CODING BASIC PART NO. CONDITION CODE 9H307 56 OASIS CODES: 205000, 207000, 404000, 702000 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radio/Stereo Noise Filter: > 91175 > Aug > 91 > Radio/Two-Way Communications - Whine/Buzz Radio/Stereo Noise Filter: All Technical Service Bulletins Radio/Two-Way Communications Whine/Buzz Article No. 91-17-5 08/21/91 ^ FUEL SYSTEM - FUEL PUMP "WHINE/BUZZ" NOISE COMES THROUGH ENTERTAINMENT OR TWO-WAY COMMUNICATION RADIO ^ RADIO - ENTERTAINMENT OR TWO-WAY COMMUNICATION - "WHINE/BUZZ" NOISE CAUSED BY FUEL PUMP ^ NOISE - "WHINE/BUZZ" - COMES THROUGH ENTERTAINMENT OR TWO-WAY COMMUNICATION RADIO FORD: 1984 THUNDERBIRD 1984-85 MUSTANG 1984-86 LTD 1985-87 TEMPO 1986-89 TAURUS 1987 EXP 1987-90 ESCORT LINCOLN-MERCURY: 1984 CONTINENTAL, COUGAR, MARK VII 1984-85 CAPRI 1984-86 MARQUIS 1985-87 TOPAZ 1986-89 SABLE 1987 LYNX LIGHT TRUCK: 1985-87 RANGER 1985-88 BRONCO, F-150-350 SERIES 1986 AEROSTAR 1986-87 BRONCO II 1986-91 ECONOLINE ISSUE: A "whining/buzzing" noise may come from the entertainment or two-way communication radio on vehicles with an in-tank electric fuel pump. This occurs because of electrical interference from the fuel pump. ACTION: Install a noise filter kit (E7PZ-9B357-A) consisting of an RFI noise filter, electrical terminals and a piece of shrink tubing. Refer to the following service procedure. 1. Remove the fuel pump/sender unit from the fuel tank. Refer to the appropriate Shop Manual for removal procedure. 2. Disconnect the heavy red and black wires from the pump terminals. 3. Inspect the fuel pump electrical terminals. ^ If the fuel pump has threaded terminals, go to Step 4. ^ If the fuel pump has spade terminals, go to Step 7. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radio/Stereo Noise Filter: > 91175 > Aug > 91 > Radio/Two-Way Communications - Whine/Buzz > Page 6220 Figure 1 4. For Threaded Terminals - Insert RFI noise filter into the pump collar and onto the threaded terminals, Figure 1. a. Observe polarity marking on fuel pump and RFI noise filter. b. Install nuts and tighten securely. 5. Cut the ring terminals from the red and black wire ends and discard. CAUTION: BE SURE NOT TO CUT THE WIRE TOO SHORT. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radio/Stereo Noise Filter: > 91175 > Aug > 91 > Radio/Two-Way Communications - Whine/Buzz > Page 6221 a. Install a 1" (25.4 mm) piece of heat shrink tubing over each end of wire. b. Install the small female spade terminal onto the red wire and the large female spade terminal onto the black wire. c. Crimp and solder new terminals onto the wires. d. Put shrink tubing over the new crimp and solder connection. 6. Install wires on the RFI noise filter terminals. NOTE: BE SURE TO OBSERVE POLARITY MARKINGS. Go to Step 12. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radio/Stereo Noise Filter: > 91175 > Aug > 91 > Radio/Two-Way Communications - Whine/Buzz > Page 6222 Figure 2 7. For Spade Terminals - Measure from fuel pump electrical connectors toward the mounting flange and cut two (2) two inch jumper wires from the pump wires, Figure 2. a. Install a 1" (25.4 mm) piece of heat shrink tubing over each end of wire. b. Install the small female spade terminal onto the red wire end and the large female spade terminal onto the black wire end. c. Crimp and solder new terminals onto the wires. d. Put shrink tubing over the new crimp and solder connection. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radio/Stereo Noise Filter: > 91175 > Aug > 91 > Radio/Two-Way Communications - Whine/Buzz > Page 6223 8. Strip 3/8" (9.525 mm) of insulation from each end of the wires attached to the mounting flange. a. Slide a 1" (25.4 mm) piece of heat shrink tubing over each end of wire. b. Wrap and solder the wires to the ring terminals of the RFI noise filter (red wire to positive terminal, black wire to negative terminals). c. Push heat shrink tubing over soldered wire ends and shrink. 9. Attach jumper wires to the RFI noise filter spade terminals. NOTE: BE SURE TO OBSERVE POLARITY MARKINGS. 10. Attach the jumper wires to the electrical fuel pump terminals. NOTE: BE SURE TO OBSERVE POLARITY MARKINGS. 11. Use tie straps to attach the RFI noise filter to the pick-up/return tubing of the pump/sender unit. NOTE: MAKE SURE WIRES ARE SECURELY ATTACHED. 12. Reinstall the fuel pump/sender in the vehicle. Refer to the appropriate service manual for service details and required parts. PART NUMBER PART NAME CLASS E7PZ-9B357-A Noise Filter Kit C OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 87-20-13 WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION DESCRIPTION TIME 911705A Aerostar, Ranger And 1.5 Hr. Econoline With Mid-Ship Fuel Tank. 911705B F-Series With Mid-Ship Fuel 1.3 Hr. Tank Or Ranger With Aft Of Axle Fuel Tank. 911705C Bronco II, F-Series And 1.6 Hr. Bronco With Aft Of Axle Fuel Tank. 911705D Econoline With Aft Of Axle 1.2 Hr. Fuel Tank. 911705E Additional Time - F-Series 0.2 Hr. Equipped With Spare Tire Carrier. 911705F All Cars 1.3 Hr. DEALER CODING BASIC PART NO. CONDITION CODE 9H307 56 OASIS CODES: 205000, 207000, 404000, 702000 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > Page 6224 Radio/Stereo Noise Filter: Locations Near Or On Voltage Regulator Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Tape Player > Component Information > Technical Service Bulletins > Customer Interest for Tape Player: > 862426 > Dec > 86 > Stereo Cassette - Ignition Noise/Alternator Whine Tape Player: Customer Interest Stereo Cassette - Ignition Noise/Alternator Whine Article No. 86-24-26 RADIO - STEREO CASSETTE - IGNITION NOISE/ALTERNATOR WHINE AT MINIMUM VOLUME LIGHT TRUCK 1983-86 F-SERIES, BRONCO Figure 18 Figure 19 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Tape Player > Component Information > Technical Service Bulletins > Customer Interest for Tape Player: > 862426 > Dec > 86 > Stereo Cassette - Ignition Noise/Alternator Whine > Page 6233 Figure 20 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Tape Player > Component Information > Technical Service Bulletins > Customer Interest for Tape Player: > 862426 > Dec > 86 > Stereo Cassette - Ignition Noise/Alternator Whine > Page 6234 Figure 21 Figure 22 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Tape Player > Component Information > Technical Service Bulletins > Customer Interest for Tape Player: > 862426 > Dec > 86 > Stereo Cassette - Ignition Noise/Alternator Whine > Page 6235 Figure 23 Figure 24 RPM related ignition noise/alternator whine heard with the radio's volume control set at minimum sound can be corrected by cutting, taping back and rerouting the #37 (yellow wire) circuit (part of the 14401 main wiring assembly). The wire should be rerouted from entering the interior of the vehicle through the passenger's side of the dash panel, across the dash panel and connected to either the junction block or the auxiliary battery relay (if so equipped) located on the driver's side of the dash panel. If the unit isn't equipped with either a battery relay or a junction block, the feed wire should be connected to the existing (unused) take-out (yellow wire/blue one-way connector) in the 14401 wiring assembly entering the engine compartment through the driver's side of the dash panel. Refer to Figures 18 through 24. PROCEDURE FOR REROUTING THE #37 BATTERY TO ACCESSORY FEED (YELLOW WIRE) CIRCUIT General Instructions Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Tape Player > Component Information > Technical Service Bulletins > Customer Interest for Tape Player: > 862426 > Dec > 86 > Stereo Cassette - Ignition Noise/Alternator Whine > Page 6236 Figure 18 Figure 19 1. Disconnect the battery ground cable. 2. Locate the 14401 wire harness which runs from the starter relay along the fender apron and through the dash panel into the passenger compartment. Refer to Figures 18 (1986 units) and 19 (1983-85 units). Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Tape Player > Component Information > Technical Service Bulletins > Customer Interest for Tape Player: > 862426 > Dec > 86 > Stereo Cassette - Ignition Noise/Alternator Whine > Page 6237 Figure 18 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Tape Player > Component Information > Technical Service Bulletins > Customer Interest for Tape Player: > 862426 > Dec > 86 > Stereo Cassette - Ignition Noise/Alternator Whine > Page 6238 Figure 20 1986 Units (With Fuse Links): 1. Refer to Figures 18 and 20 (View A) and locate the two fuse links in the 14401 wiring assembly near the starter relay (one is 14 gauge green, the other is 16 gauge orange). NOTE: The 14 gauge green fuse link is the #37 circuit wire. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Tape Player > Component Information > Technical Service Bulletins > Customer Interest for Tape Player: > 862426 > Dec > 86 > Stereo Cassette - Ignition Noise/Alternator Whine > Page 6239 Figure 20 2. Cut the green wire two inches past (toward the dash panel) the fuse links to terminate the feed circuit at this point. Fold back the cut end of the wire which goes inside the vehicle and tape wrap with (D6AZ-19627-A) pressure-sensitive waterproof tape, Figure 20. 3. Tape wrap the entire area to prevent unraveling. 4. At the remaining cut end of the Green wire, which connects to the starter relay, strip away 3/8 inch of insulation followed by installing a butt splice connector (E6FZ-14488-C), using a standard crimp tool and a heat gun, Figure 20. 5. Strip away 3/8 inch of insulation from one end of the roll of 10 gauge (Black) wire and install into the other end of the butt splice connector and crimp in place, Figure 20, View A. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Tape Player > Component Information > Technical Service Bulletins > Customer Interest for Tape Player: > 862426 > Dec > 86 > Stereo Cassette - Ignition Noise/Alternator Whine > Page 6240 Figure 21 6. Route the 10 gauge wire along the dash panel over to the 14401 main wiring assembly entering the engine compartment through the driver's side of the dash panel, as shown in Figure 21. Secure the rerouted wire to the dash panel and surrounding hardware, wiring and vacuum hoses, as required, using adjustable binding straps (95874-S). Figure 22 7. At the driver's side of the vehicle, locate either of these items: a. Junction block mounted on the dash panel, Figure 22. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Tape Player > Component Information > Technical Service Bulletins > Customer Interest for Tape Player: > 862426 > Dec > 86 > Stereo Cassette - Ignition Noise/Alternator Whine > Page 6241 Figure 23 b. Auxiliary battery relay mounted on the dash panel, Figure 23. Figure 24 c. One-way hardshell wiring connector, Figure 24. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Tape Player > Component Information > Technical Service Bulletins > Customer Interest for Tape Player: > 862426 > Dec > 86 > Stereo Cassette - Ignition Noise/Alternator Whine > Page 6242 Figure 22 Figure 23 8. At this point, join the rerouted feed circuit to one of the above items as shown in the appropriate illustration. NOTE: To complete the connection at EITHER the junction block OR the auxiliary battery relay, install a (B9A-14294-H) Yellow eyelet on the remaining end of the (new) rerouted 10 gauge wire and attach the wire to the junction block, as shown in Figure 22, or to the left side of the relay, as shown in Figure 23. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Tape Player > Component Information > Technical Service Bulletins > Customer Interest for Tape Player: > 862426 > Dec > 86 > Stereo Cassette - Ignition Noise/Alternator Whine > Page 6243 Figure 24 NOTE: To complete the connection when NEITHER a junction block NOR an auxiliary battery relay is present, assemble a Blue (D6TZ-14489-A) hardshell wiring connector and a (D20Z-14474-B) wire terminal and install onto the remaining end of the (new) rerouted 10 gauge wire and connector the wire and connector assembly to the existing (previously unused Blue) take-out (pan of the #37 (Yellow) circuit), as shown in Figure 24. 9. Reconnect the battery and verify the condition has been corrected. 1983-85 Units (Without Fuse Links): 1. Repeat Steps 1 and 2 under "General Instructions". Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Tape Player > Component Information > Technical Service Bulletins > Customer Interest for Tape Player: > 862426 > Dec > 86 > Stereo Cassette - Ignition Noise/Alternator Whine > Page 6244 Figure 20 2. Moving toward the front of the vehicle, approximately 17 inches from the existing dash panel grommet, carefully cut away about 3 inches of wiring wrap to expose the Yellow 10 gauge wire (#37 circuit). Cut the Yellow 10 gauge (#37 circuit) wire at this point to terminate the feed circuit. Fold back the cut end of the wire which goes inside the vehicle and tape wrap with pressure-sensitive waterproof tape (D6AZ-19627-A), as shown in Figure 20, View B. 3. Repeat Steps 3 through 9 of the procedure for 1986 model units. PART NUMBER PART NAME CLASS WB-310-B 10 Gauge Wire (Black) C E6FZ-14488-C Butt Splice Connector B Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Tape Player > Component Information > Technical Service Bulletins > Customer Interest for Tape Player: > 862426 > Dec > 86 > Stereo Cassette - Ignition Noise/Alternator Whine > Page 6245 (Yellow) B9A-14294-H Straight Eyelet (Yellow) R D6TZ-14489-A One-Way Hardshell C Connector D20Z-14474-B Wire Terminal C 95874-S Strap - Adjustable, AG Binding D6AZ-19627-A Pressure-Sensitive BG Electrical Tape OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION: SP14401E86 TIME: 0.6 Hr. DLR. CODING: Basic Part No. 14401 - Code: 43 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Tape Player > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tape Player: > 862426 > Dec > 86 > Stereo Cassette - Ignition Noise/Alternator Whine Tape Player: All Technical Service Bulletins Stereo Cassette - Ignition Noise/Alternator Whine Article No. 86-24-26 RADIO - STEREO CASSETTE - IGNITION NOISE/ALTERNATOR WHINE AT MINIMUM VOLUME LIGHT TRUCK 1983-86 F-SERIES, BRONCO Figure 18 Figure 19 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Tape Player > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tape Player: > 862426 > Dec > 86 > Stereo Cassette - Ignition Noise/Alternator Whine > Page 6251 Figure 20 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Tape Player > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tape Player: > 862426 > Dec > 86 > Stereo Cassette - Ignition Noise/Alternator Whine > Page 6252 Figure 21 Figure 22 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Tape Player > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tape Player: > 862426 > Dec > 86 > Stereo Cassette - Ignition Noise/Alternator Whine > Page 6253 Figure 23 Figure 24 RPM related ignition noise/alternator whine heard with the radio's volume control set at minimum sound can be corrected by cutting, taping back and rerouting the #37 (yellow wire) circuit (part of the 14401 main wiring assembly). The wire should be rerouted from entering the interior of the vehicle through the passenger's side of the dash panel, across the dash panel and connected to either the junction block or the auxiliary battery relay (if so equipped) located on the driver's side of the dash panel. If the unit isn't equipped with either a battery relay or a junction block, the feed wire should be connected to the existing (unused) take-out (yellow wire/blue one-way connector) in the 14401 wiring assembly entering the engine compartment through the driver's side of the dash panel. Refer to Figures 18 through 24. PROCEDURE FOR REROUTING THE #37 BATTERY TO ACCESSORY FEED (YELLOW WIRE) CIRCUIT General Instructions Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Tape Player > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tape Player: > 862426 > Dec > 86 > Stereo Cassette - Ignition Noise/Alternator Whine > Page 6254 Figure 18 Figure 19 1. Disconnect the battery ground cable. 2. Locate the 14401 wire harness which runs from the starter relay along the fender apron and through the dash panel into the passenger compartment. Refer to Figures 18 (1986 units) and 19 (1983-85 units). Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Tape Player > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tape Player: > 862426 > Dec > 86 > Stereo Cassette - Ignition Noise/Alternator Whine > Page 6255 Figure 18 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Tape Player > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tape Player: > 862426 > Dec > 86 > Stereo Cassette - Ignition Noise/Alternator Whine > Page 6256 Figure 20 1986 Units (With Fuse Links): 1. Refer to Figures 18 and 20 (View A) and locate the two fuse links in the 14401 wiring assembly near the starter relay (one is 14 gauge green, the other is 16 gauge orange). NOTE: The 14 gauge green fuse link is the #37 circuit wire. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Tape Player > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tape Player: > 862426 > Dec > 86 > Stereo Cassette - Ignition Noise/Alternator Whine > Page 6257 Figure 20 2. Cut the green wire two inches past (toward the dash panel) the fuse links to terminate the feed circuit at this point. Fold back the cut end of the wire which goes inside the vehicle and tape wrap with (D6AZ-19627-A) pressure-sensitive waterproof tape, Figure 20. 3. Tape wrap the entire area to prevent unraveling. 4. At the remaining cut end of the Green wire, which connects to the starter relay, strip away 3/8 inch of insulation followed by installing a butt splice connector (E6FZ-14488-C), using a standard crimp tool and a heat gun, Figure 20. 5. Strip away 3/8 inch of insulation from one end of the roll of 10 gauge (Black) wire and install into the other end of the butt splice connector and crimp in place, Figure 20, View A. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Tape Player > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tape Player: > 862426 > Dec > 86 > Stereo Cassette - Ignition Noise/Alternator Whine > Page 6258 Figure 21 6. Route the 10 gauge wire along the dash panel over to the 14401 main wiring assembly entering the engine compartment through the driver's side of the dash panel, as shown in Figure 21. Secure the rerouted wire to the dash panel and surrounding hardware, wiring and vacuum hoses, as required, using adjustable binding straps (95874-S). Figure 22 7. At the driver's side of the vehicle, locate either of these items: a. Junction block mounted on the dash panel, Figure 22. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Tape Player > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tape Player: > 862426 > Dec > 86 > Stereo Cassette - Ignition Noise/Alternator Whine > Page 6259 Figure 23 b. Auxiliary battery relay mounted on the dash panel, Figure 23. Figure 24 c. One-way hardshell wiring connector, Figure 24. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Tape Player > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tape Player: > 862426 > Dec > 86 > Stereo Cassette - Ignition Noise/Alternator Whine > Page 6260 Figure 22 Figure 23 8. At this point, join the rerouted feed circuit to one of the above items as shown in the appropriate illustration. NOTE: To complete the connection at EITHER the junction block OR the auxiliary battery relay, install a (B9A-14294-H) Yellow eyelet on the remaining end of the (new) rerouted 10 gauge wire and attach the wire to the junction block, as shown in Figure 22, or to the left side of the relay, as shown in Figure 23. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Tape Player > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tape Player: > 862426 > Dec > 86 > Stereo Cassette - Ignition Noise/Alternator Whine > Page 6261 Figure 24 NOTE: To complete the connection when NEITHER a junction block NOR an auxiliary battery relay is present, assemble a Blue (D6TZ-14489-A) hardshell wiring connector and a (D20Z-14474-B) wire terminal and install onto the remaining end of the (new) rerouted 10 gauge wire and connector the wire and connector assembly to the existing (previously unused Blue) take-out (pan of the #37 (Yellow) circuit), as shown in Figure 24. 9. Reconnect the battery and verify the condition has been corrected. 1983-85 Units (Without Fuse Links): 1. Repeat Steps 1 and 2 under "General Instructions". Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Tape Player > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tape Player: > 862426 > Dec > 86 > Stereo Cassette - Ignition Noise/Alternator Whine > Page 6262 Figure 20 2. Moving toward the front of the vehicle, approximately 17 inches from the existing dash panel grommet, carefully cut away about 3 inches of wiring wrap to expose the Yellow 10 gauge wire (#37 circuit). Cut the Yellow 10 gauge (#37 circuit) wire at this point to terminate the feed circuit. Fold back the cut end of the wire which goes inside the vehicle and tape wrap with pressure-sensitive waterproof tape (D6AZ-19627-A), as shown in Figure 20, View B. 3. Repeat Steps 3 through 9 of the procedure for 1986 model units. PART NUMBER PART NAME CLASS WB-310-B 10 Gauge Wire (Black) C E6FZ-14488-C Butt Splice Connector B Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Tape Player > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tape Player: > 862426 > Dec > 86 > Stereo Cassette - Ignition Noise/Alternator Whine > Page 6263 (Yellow) B9A-14294-H Straight Eyelet (Yellow) R D6TZ-14489-A One-Way Hardshell C Connector D20Z-14474-B Wire Terminal C 95874-S Strap - Adjustable, AG Binding D6AZ-19627-A Pressure-Sensitive BG Electrical Tape OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION: SP14401E86 TIME: 0.6 Hr. DLR. CODING: Basic Part No. 14401 - Code: 43 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions Trailer Connector: Diagram Information and Instructions Symbol Identification Wire Color Code Identification Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6269 NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6270 Trailer Connector: Electrical Diagrams Fig. 6 Camper & Trailer Option Wiring Circuit Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6271 Fig. 22 Exterior Lamp (Body Markers, License, Parking & Trailer) Wiring Circuit (Part 1 of 2). F150-350 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lighting Module > Component Information > Locations Trailer Lighting Module: Locations Attached To Brake Pedal Assembly Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lighting Relay > Component Information > Locations Trailer Lighting Relay: Locations Attached To Dash Panel, Below Junction Block Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions Trailer Connector: Diagram Information and Instructions Symbol Identification Wire Color Code Identification Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6282 NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6283 Trailer Connector: Electrical Diagrams Fig. 6 Camper & Trailer Option Wiring Circuit Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6284 Fig. 22 Exterior Lamp (Body Markers, License, Parking & Trailer) Wiring Circuit (Part 1 of 2). F150-350 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System Information > Technical Service Bulletins > Door Latches - Adjustment/Modification Prohibition Front Door Latch: Technical Service Bulletins Door Latches - Adjustment/Modification Prohibition Article No. 91-8-4 04/17/91 LATCHES - DOOR - REPLACEMENT REQUIRED FORD: 1985-88 EXP 1985-91 CROWN VICTORIA, ESCORT, MUSTANG, TEMPO, THUNDERBIRD 1986 LTD 1986-91 TAURUS 1988-91 FESTIVA 1989-91 PROBE LINCOLN-MERCURY: 1985-87 LYNX 1985-91 CAPRI, CONTINENTAL, COUGAR, GRAND MARQUIS, MARK VII, TOPAZ, TOWN CAR 1986-91 SABLE 1987-91 TRACER MERKUR: 1985-89 XR4TI 1988-89 SCORPIO LIGHT TRUCK: 1985-90 BRONCO II 1985-91 AEROSTAR, BRONCO, ECONOLINE, F-150-350 SERIES, RANGER 1989-91 F SUPER DUTY 1991 EXPLORER MEDIUM/HEAVY TRUCK:1985-90 C SERIES 1985-91 CL-9000, F & B SERIES, L SERIES 1986-91 CARGO SERIES ISSUE: Rework of door latches has been reported from Service Investigation Reports. This is unacceptable as it may affect proper latch function. ACTION: Replace latches which function improperly and can not be adjusted. WARNING: NEVER REWORK OR MODIFY A LATCH ASSEMBLY, ALWAYS REPLACE THE LATCH ASSEMBLY. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch > System Information > Technical Service Bulletins > Door Latches - Adjustment/Modification Prohibition Rear Door Latch: Technical Service Bulletins Door Latches - Adjustment/Modification Prohibition Article No. 91-8-4 04/17/91 LATCHES - DOOR - REPLACEMENT REQUIRED FORD: 1985-88 EXP 1985-91 CROWN VICTORIA, ESCORT, MUSTANG, TEMPO, THUNDERBIRD 1986 LTD 1986-91 TAURUS 1988-91 FESTIVA 1989-91 PROBE LINCOLN-MERCURY: 1985-87 LYNX 1985-91 CAPRI, CONTINENTAL, COUGAR, GRAND MARQUIS, MARK VII, TOPAZ, TOWN CAR 1986-91 SABLE 1987-91 TRACER MERKUR: 1985-89 XR4TI 1988-89 SCORPIO LIGHT TRUCK: 1985-90 BRONCO II 1985-91 AEROSTAR, BRONCO, ECONOLINE, F-150-350 SERIES, RANGER 1989-91 F SUPER DUTY 1991 EXPLORER MEDIUM/HEAVY TRUCK:1985-90 C SERIES 1985-91 CL-9000, F & B SERIES, L SERIES 1986-91 CARGO SERIES ISSUE: Rework of door latches has been reported from Service Investigation Reports. This is unacceptable as it may affect proper latch function. ACTION: Replace latches which function improperly and can not be adjusted. WARNING: NEVER REWORK OR MODIFY A LATCH ASSEMBLY, ALWAYS REPLACE THE LATCH ASSEMBLY. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Body and Frame > Firewall > Component Information > Technical Service Bulletins > Customer Interest: > 90167 > Aug > 90 > M/T - Clutch Fluid Leaks/Incomplete Release Technical Service Bulletin # 90167 Date: 900801 M/T - Clutch Fluid Leaks/Incomplete Release Article No. 90-16-7 ^ CRACKS - DASH (ENGINE COMPARTMENT BULKHEAD) - CLUTCH MASTER CYLINDER AREA - VEHICLES BUILT BEFORE 6/15/90 ^ CLUTCH - HIGH EFFORT - DASH CRACKED IN CLUTCH MASTER CYLINDER AREA VEHICLES BUILT BEFORE 6/15/90 LIGHT TRUCK: 1984-90 BRONCO, F-150, F-250, F-350 1988-90 F SUPER DUTY ISSUE: Incomplete clutch release and/or hydraulic fluid leaking into the cab from the clutch master cylinder may be caused by the reinforcement plate on the clutch master cylinder separating from the dash panel. The separation of the reinforcement plate reduces the clutch master cylinder pushrod travel. Reinforcement plate separation can also cause deflection of the clutch master cylinder that results in a misalignment of the pushrod to the clutch master cylinder. Misalignment causes the "O" ring in front of the secondary seal to leak hydraulic fluid. ACTION: Inspect the truck and, if necessary, use the following service procedure to install a reinforcement kit. Inspection Procedure 1. If the truck is a 1988 or later model, confirm that the starter interlock switch operates (the engine can be started) with the clutch pedal at least 0.5" (12.7 mm) from the floor. 2. Test drive the truck and check for good clutch release. There should be no grinding of the gears, particularly when shifting from neutral to reverse gear. 3. If the truck passes these tests, go to the Small Reinforcement Installation Procedure Section of this article. 4. If either of the above conditions are not met, check the hydraulic system for air. Refer to the Suggested Bleeding Procedure at the end of this article. 5. Test drive the truck and check for improved clutch release. 6. If there is no improvement, proceed as follows: a. Remove the clutch master cylinder pushrod from the release lever pin on the release lever. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Body and Frame > Firewall > Component Information > Technical Service Bulletins > Customer Interest: > 90167 > Aug > 90 > M/T - Clutch Fluid Leaks/Incomplete Release > Page 6306 Figure 1 b. Make sure the hole in the pushrod lines up with the pin, for those units requiring a minimal force for installation, Figure 1. c. If it does not line up correctly, install an adjustable pushrod (except 1988 and later models) or replace the clutch release lever (required on 1988 and later models), cutting a new seat on the cross shaft splines. 7. Test drive the truck again, checking for improved clutch release. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Body and Frame > Firewall > Component Information > Technical Service Bulletins > Customer Interest: > 90167 > Aug > 90 > M/T - Clutch Fluid Leaks/Incomplete Release > Page 6307 Figure 2 8. If there is no improvement, inspect the truck for adequate release bearing travel. ^ It should be 11 mm or greater for full pedal travel. ^ Pedal travel at the center of the pedal pad should be 6.75" (171 mm minimum) or more, Figure 2. 9. Release bearing travel and gear grinding noise may indicate the following concerns. ^ If the release bearing is 11 mm or greater and there is grinding of one or two gears only, the concern is probably with the transmission. ^ If all gears grind, the concern may be with the clutch and/or pilot bearing which will need replacing. ^ If the release travel is less than 11 mm, check the clutch hydraulic system for air and bleed as necessary. 10. If the release travel is still less than 11 mm, with all of the above items eliminated, proceed as follows: a. Raise the hood, while an assistant operates the clutch pedal. b. Watch the clutch master cylinder for significant deflection. Figure 3 c. Look for the dash reinforcement moving away from the dash, Figure 3. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Body and Frame > Firewall > Component Information > Technical Service Bulletins > Customer Interest: > 90167 > Aug > 90 > M/T - Clutch Fluid Leaks/Incomplete Release > Page 6308 d. On 1987 and earlier models, look down inside the cowl cover at the cowl where it is attached to the dash reinforcement. Check for pulled spot welds. 11. If there is significant movement of the dash or clutch master cylinder, proceed as follows: a. Remove the steering column and its dash toe plate and seal. Refer to the appropriate Light Truck Shop Manual, Section 13-07 for service details. b. Inspect the dash inside the cab and look for: ^ Pulled spotwelds and cracked or torn sheet metal. ^ Cracks in the brake and clutch pedal support Figure 4 ^ Missing Y-brace fasteners and a broken or detached Y-brace, Figure 4. 12. Check the cross shaft bushings for wear if the brake pedal moves when the clutch is depressed and vise versa. Replace them as required. NOTE: GENERALLY, TRUCKS WITH SIGNIFICANTLY LESS THAN 11 MM CLUTCH RELEASE BEARING TRAVEL (AFTER COMPLETING THE INSPECTION PROCEDURE AND CORRECTING WHERE NECESSARY) WILL HAVE SIGNIFICANT DASH DAMAGE FROM PULLED SPOTWELDS AND TORN METAL. THESE TRUCKS WILL REQUIRE EXTENSIVE REPAIR. THEREFORE, GO TO THE LARGE REINFORCEMENT INSTALLATION PROCEDURE. Small Reinforcement Installation Procedure Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Body and Frame > Firewall > Component Information > Technical Service Bulletins > Customer Interest: > 90167 > Aug > 90 > M/T - Clutch Fluid Leaks/Incomplete Release > Page 6309 Figure 5 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Body and Frame > Firewall > Component Information > Technical Service Bulletins > Customer Interest: > 90167 > Aug > 90 > M/T - Clutch Fluid Leaks/Incomplete Release > Page 6310 Figure 6 There are two small reinforcement kits. One for 1988 and later models and one for 1987 and prior models. This is necessary because a new hydraulic clutch master cylinder mounting pattern was introduced for 1988 models. 1987 And Prior Trucks Use reinforcement kit E3TZ-7K509-A on these trucks, Figure 5. Comprehensive installation instructions are included in this kit. 1988 And Later Trucks Use reinforcement kit E8TZ-7K509-A on these trucks. The only part in this kit is the special reinforcement for these trucks. To install it, proceed as follows: 1. Remove the two clutch master cylinder attaching nuts (13 mm) from inside the truck. 2. Position the reinforcement in place over the clutch master cylinder studs. 3. Re-install the two master cylinder nuts, Figure 6. Tighten to 9.5 - 14.9 N-m. Large Reinforcement Installation Procedure Figure 7 Use reinforcement kit E3TZ-7K509-B on all 1983-1991 Bronco/F-Series trucks with hydraulic clutch controls. The kit consists of the following items: ^ A main reinforcement or doubler, with a plate having two studs to clamp the doubler through the cowl inner ^ Two additional pieces with three threaded holes: Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Body and Frame > Firewall > Component Information > Technical Service Bulletins > Customer Interest: > 90167 > Aug > 90 > M/T - Clutch Fluid Leaks/Incomplete Release > Page 6311 One plate helps attach the main doubler through the dash inner tunnel. The other large piece is placed inside the front of the cowl, with bolts driven through from the engine compartment side of the dash reinforcement, see Figure 7. Installation Figure 1 1. Remove the insulating material. a. On earlier models, remove the instrument panel lower sound insulator assembly. b. For later diesel powered trucks, remove the fasteners holding the engine compartment dash insulation in place. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Body and Frame > Firewall > Component Information > Technical Service Bulletins > Customer Interest: > 90167 > Aug > 90 > M/T - Clutch Fluid Leaks/Incomplete Release > Page 6312 c. Pull the dash insulation back out of the way. d. Disconnect the battery ground cable. 2. Disconnect the clutch master cylinder pushrod from the lever, removing the pushrod retention clip on older models, Figure 1. 3. Remove the two nuts attaching the clutch master cylinder to the dash panel. a. Pull the master cylinder into the engine compartment. b. For, 1988 and later trucks, it will be necessary to disconnect the wiring harness connector from the pushrod switch. c. Rotate the master cylinder to get it past the switch through the dash opening. 4. Remove the steering column and dash toe plate by removing the five (5) fasteners. 5. Disconnect the brake master cylinder pushrod from the brake pedal. 6. On F-Super Duty, proceed to Step 7. On all units except F-Super Duty, proceed as follows: a. Remove the four brake booster attaching nuts. b. Move the brake booster to one side. Figure 4 c. Loosen the two (2) fasteners attaching the brake and clutch pedal support to the Y-brace, Figure 4. 7. Check for cracks. a. Pull back the floor covering and dash sound insulator. (it may be helpful to remove the accelerator pedal.) b. Inspect the area for pulled welds and torn dash sheet metal. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Body and Frame > Firewall > Component Information > Technical Service Bulletins > Customer Interest: > 90167 > Aug > 90 > M/T - Clutch Fluid Leaks/Incomplete Release > Page 6313 Figure 8 c. If there are cracks that have not run out, stop them by drilling a 2-3 mm hole at the end, Figure 8. NOTE: WELDING OR BRAZING IS NOT RECOMMENDED, BECAUSE IT COULD BE A SOURCE OF FUTURE BLIND SIDE CORROSION. Figure 4 8. Thoroughly inspect the brake and clutch support again for cracks in the casting and worn bushings. Also, inspect the "Y" brace for cracks and missing fasteners. Replace as necessary, Figure 4. 9. Remove excess body sealer in the area of the clutch master cylinder, inside the dash. 10. Carefully remove the cowl top cover 12 fasteners (7 in front, 5 in rear). NOTE: IT MAY BE NECESSARY TO REMOVE THE RADIO ANTENNA AND REPOSITION THE HOOD TO ACHIEVE THIS. IF THE HOOD IS REMOVED, MARK THE LOCATION OF THE HINGES WITH A WAX PENCIL, PRIOR TO LOOSENING. 11. Place the main reinforcement in position. a. Locate positively, using the lower steering column toe plate fastener and a bolt and nut (8 mm or 5/16") through the upper clutch master Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Body and Frame > Firewall > Component Information > Technical Service Bulletins > Customer Interest: > 90167 > Aug > 90 > M/T - Clutch Fluid Leaks/Incomplete Release > Page 6314 cylinder stud hole. NOTE: THE SHEET METAL VARIES FROM TRUCK TO TRUCK AND IT MAY BE NECESSARY TO BEND THE REINFORCEMENT TO GET A GOOD FIT. b. Tighten the upper nut and bolt securely to compress any distortion in the four sheet metal laminations in this area. 12. Drill the holes for the reinforcement plate. a. Using a 3/8" (9.5 mm) drill bit, with the reinforcement as a template, drill two holes up into the cowl inner and three holes into the inner side of the dash. b. De-burr the outside of the holes as necessary. c. Remove any excess sealant in the area and clean up the drill chips inside the truck and cowl. 13. Attach the smaller plate via the three threaded holes into the engine compartment side of the dash inner panel. a. Use three 8 mm bolts passed through the main reinforcement, from inside the cab. b. Install the rubber cap (N804118) onto the end of the uppermost screw from under the dash. c. Position the plate with the two studs attached inside the cowl, through the two holes drilled from below. d. Attach two 8 mm nuts from the inside of the cab. 14. Using the paper template provided in the kit, proceed as follows: Figure 9 a. Center punch and drill three 3/8" (9.5 mm) holes into the dash reinforcement and through the cowl, from the engine compartment side, Figure 9. NOTE: DRILLING WILL BE EASIER IF THERE ARE NO SPOTWELDS VISIBLE THROUGH THE THREE HOLES. b. If necessary, move the pattern outboard slightly to avoid any visible spotwelds. c. De-burr the holes inside the cowl as necessary and clean up the drill chips inside the cowl. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Body and Frame > Firewall > Component Information > Technical Service Bulletins > Customer Interest: > 90167 > Aug > 90 > M/T - Clutch Fluid Leaks/Incomplete Release > Page 6315 Figure 10 15. Place the larger three holed plate from the kit inside the cowl. Attach it with three 8 mm bolts through the dash reinforcement, from the engine compartment side, Figure 10. 16. Inspect the seam between the cowl inner and outer, inside the cowl, for cracks in the sealant. If necessary, add sealant. 17. Replace the cowl top. a. If the hood was removed, locate the hinges to the wax pencil marks and tighten the fasteners. b. Replace the radio antenna and windshield washer tube. 18. Re-install the brake booster and stoplight switch, if removed. Tighten the brace bolts. 19. Install the clutch master cylinder. a. Inspect the clutch master cylinder for leaks in the area of the pushrod. Replace it if there is evidence of leaking. b. Remove the nut and bolt from the top of the reinforcement. c. Install the clutch master cylinder. d. Inspect the position of the clutch master cylinder pushrod hole. The pushrod hole should go onto the lever pin with no force required while the pedal is against the upstop. NOTE: ALTHOUGH THIS WAS SPECIFIED IN THE INSPECTION PROCEDURE, REPAIR MAY HAVE CHANGED THE SETTING. e. If the pushrod hole is not in position, install and adjust an adjustable clutch master cylinder pushrod (1987 and prior models) or install a new lever (7A554). Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Body and Frame > Firewall > Component Information > Technical Service Bulletins > Customer Interest: > 90167 > Aug > 90 > M/T - Clutch Fluid Leaks/Incomplete Release > Page 6316 Figure 1 NOTE: THE NEW LEVER IS TIGHTENED INTO PLACE WHILE THE MASTER CYLINDER PUSHROD IS ATTACHED, TO SET THE CORRECT POSITION, FIGURE 1. 20. Remove the toe plate fastener from the bottom of the reinforcement and reinstall the steering column and five (5) fasteners. 21. Complete reassembly. a. Re-install the dash sound deadener material and the instrument panel sound insulator. b. Re-install the engine compartment sound insulator on diesel models. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Body and Frame > Firewall > Component Information > Technical Service Bulletins > Customer Interest: > 90167 > Aug > 90 > M/T - Clutch Fluid Leaks/Incomplete Release > Page 6317 c. Connect the battery ground terminal. Final Inspection If the truck has been driven for a long period of time with the broken dash and resulting poor clutch release, the clutch disc could be excessively worn or buckled. Test drive the truck, evaluating the clutch for clean release. If the release is not satisfactory, measure the release bearing travel. ^ If it has the required 12 mm at full clutch pedal stroke, then the clutch may need to be replaced. ^ If the release bearing has less than the required release travel, then the hydraulic system probably needs to be bled. Suggested Bleeding Procedure - External Slave Cylinder Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Body and Frame > Firewall > Component Information > Technical Service Bulletins > Customer Interest: > 90167 > Aug > 90 > M/T - Clutch Fluid Leaks/Incomplete Release > Page 6318 Figure 11 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Body and Frame > Firewall > Component Information > Technical Service Bulletins > Customer Interest: > 90167 > Aug > 90 > M/T - Clutch Fluid Leaks/Incomplete Release > Page 6319 Figure 12 If the truck is a 1987 or prior model, 1988 model with a 7.3L Diesel, 7.5L EFI gas engine or the smaller family of engines with a Warner T-18 four speed transmission, proceed as follows: 1. Remove the master cylinder reservoir cap and diaphragm. 2. Check the fluid level to be sure it is at the step diameter of the reservoir. Do not over fill. 3. From below the truck, push the release lever slowly towards the front of the truck several times. Figures 11 & 12. 4. If it will not move, the master cylinder pushrod is not set correctly. See repair Step # 19. 5. Check the fluid level and replace the diaphragm and cap. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Body and Frame > Firewall > Component Information > Technical Service Bulletins > Customer Interest: > 90167 > Aug > 90 > M/T - Clutch Fluid Leaks/Incomplete Release > Page 6320 Suggested Bleeding Proc - Internal Concentric Slave CYL. Figure 13 If the truck has a concentric slave cylinder, proceed as follows: 1. Operate the clutch pedal at full stroke, 10-20 times. 2. Check the fluid level at the change in diameter part of the reservoir. Do not over fill. 3. Have an assistant depress the clutch pedal slowly and hold it down. 4. Open the slave cylinder bleed screw and watch for escaping air, Figure 13. 5. Close the bleed screw and have the assistant release pedal. 6. Repeat this cycle several times until there is no sign of air. Be sure to keep the reservoir topped to the correct level. 7. Replace the diaphragm and reservoir cover. 8. Operate the clutch pedal at full stroke 10-20 times. Misc. Information OTHER APPLICABLE ARTICLES: 86-20-10 WARRANTY STATUS: Eligible Under Basic Warranty Coverage, Powertrain Warranty Coverage OPERATION DESCRIPTION TIME 901607A Inspect & Adjust 0.5 Hr. 901607B Install Reinforcement 2.9 Hr. DEALER CODING BASIC PART NO. CONDITION CODE 7050 50 OASIS CODES: 111000, 505000, 505200, 506000, 590000 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Body and Frame > Firewall > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 86817 > Apr > 86 > Engine - Rough Idle/Stalls On Cold Start Vacuum Check Valve: All Technical Service Bulletins Engine - Rough Idle/Stalls On Cold Start Article No. 86-8-17 IDLE - ROUGH/STALL (5.8L(W)) DURING COLD START OR A/C OPERATION - 8500 LBS. GVW LIGHT TRUCK 1986 F SERIES, BRONCO CALIBRATIONS: 4-64G-R15 and 4-64Z-R14 WARNING: This modification is authorized only for the listed engines. Performing this modification on other engine calibrations is unauthorized and could create liability under applicable federal or local laws. Rough engine idle and/or stalls, during cold start or air conditioning operation may be caused by an improperly installed vacuum check valve to throttle kicker. To correct the above conditions, the following procedure is recommended. 1. Locate vacuum check valve (part number D9AE- 12A197-AA) connected to throttle kicker vacuum hose. Valve should be installed with blue side connected to hose attached to throttle kicker and black side should be connected to hose attached to vacuum source (remove and re-install, if necessary). 2. If check valve was properly installed, continue engine performance diagnostics as outlined in the 1986 Car/Truck Engine/Emissions Diagnosis Manual, Volume H, to determine the cause of the concern. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION: SP12197A86 TIME: 0.3 Hr. DLR. CODING: Basic Part No. 12A197 - Code: J4, J8 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Body and Frame > Firewall > Component Information > Technical Service Bulletins > All Other Service Bulletins for Firewall: > 86817 > Apr > 86 > Customer Interest for Firewall: > 90167 > Aug > 90 > M/T - Clutch Fluid Leaks/Incomplete Release Technical Service Bulletin # 90167 Date: 900801 M/T - Clutch Fluid Leaks/Incomplete Release Article No. 90-16-7 ^ CRACKS - DASH (ENGINE COMPARTMENT BULKHEAD) - CLUTCH MASTER CYLINDER AREA - VEHICLES BUILT BEFORE 6/15/90 ^ CLUTCH - HIGH EFFORT - DASH CRACKED IN CLUTCH MASTER CYLINDER AREA VEHICLES BUILT BEFORE 6/15/90 LIGHT TRUCK: 1984-90 BRONCO, F-150, F-250, F-350 1988-90 F SUPER DUTY ISSUE: Incomplete clutch release and/or hydraulic fluid leaking into the cab from the clutch master cylinder may be caused by the reinforcement plate on the clutch master cylinder separating from the dash panel. The separation of the reinforcement plate reduces the clutch master cylinder pushrod travel. Reinforcement plate separation can also cause deflection of the clutch master cylinder that results in a misalignment of the pushrod to the clutch master cylinder. Misalignment causes the "O" ring in front of the secondary seal to leak hydraulic fluid. ACTION: Inspect the truck and, if necessary, use the following service procedure to install a reinforcement kit. Inspection Procedure 1. If the truck is a 1988 or later model, confirm that the starter interlock switch operates (the engine can be started) with the clutch pedal at least 0.5" (12.7 mm) from the floor. 2. Test drive the truck and check for good clutch release. There should be no grinding of the gears, particularly when shifting from neutral to reverse gear. 3. If the truck passes these tests, go to the Small Reinforcement Installation Procedure Section of this article. 4. If either of the above conditions are not met, check the hydraulic system for air. Refer to the Suggested Bleeding Procedure at the end of this article. 5. Test drive the truck and check for improved clutch release. 6. If there is no improvement, proceed as follows: a. Remove the clutch master cylinder pushrod from the release lever pin on the release lever. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Body and Frame > Firewall > Component Information > Technical Service Bulletins > All Other Service Bulletins for Firewall: > 86817 > Apr > 86 > Customer Interest for Firewall: > 90167 > Aug > 90 > M/T - Clutch Fluid Leaks/Incomplete Release > Page 6335 Figure 1 b. Make sure the hole in the pushrod lines up with the pin, for those units requiring a minimal force for installation, Figure 1. c. If it does not line up correctly, install an adjustable pushrod (except 1988 and later models) or replace the clutch release lever (required on 1988 and later models), cutting a new seat on the cross shaft splines. 7. Test drive the truck again, checking for improved clutch release. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Body and Frame > Firewall > Component Information > Technical Service Bulletins > All Other Service Bulletins for Firewall: > 86817 > Apr > 86 > Customer Interest for Firewall: > 90167 > Aug > 90 > M/T - Clutch Fluid Leaks/Incomplete Release > Page 6336 Figure 2 8. If there is no improvement, inspect the truck for adequate release bearing travel. ^ It should be 11 mm or greater for full pedal travel. ^ Pedal travel at the center of the pedal pad should be 6.75" (171 mm minimum) or more, Figure 2. 9. Release bearing travel and gear grinding noise may indicate the following concerns. ^ If the release bearing is 11 mm or greater and there is grinding of one or two gears only, the concern is probably with the transmission. ^ If all gears grind, the concern may be with the clutch and/or pilot bearing which will need replacing. ^ If the release travel is less than 11 mm, check the clutch hydraulic system for air and bleed as necessary. 10. If the release travel is still less than 11 mm, with all of the above items eliminated, proceed as follows: a. Raise the hood, while an assistant operates the clutch pedal. b. Watch the clutch master cylinder for significant deflection. Figure 3 c. Look for the dash reinforcement moving away from the dash, Figure 3. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Body and Frame > Firewall > Component Information > Technical Service Bulletins > All Other Service Bulletins for Firewall: > 86817 > Apr > 86 > Customer Interest for Firewall: > 90167 > Aug > 90 > M/T - Clutch Fluid Leaks/Incomplete Release > Page 6337 d. On 1987 and earlier models, look down inside the cowl cover at the cowl where it is attached to the dash reinforcement. Check for pulled spot welds. 11. If there is significant movement of the dash or clutch master cylinder, proceed as follows: a. Remove the steering column and its dash toe plate and seal. Refer to the appropriate Light Truck Shop Manual, Section 13-07 for service details. b. Inspect the dash inside the cab and look for: ^ Pulled spotwelds and cracked or torn sheet metal. ^ Cracks in the brake and clutch pedal support Figure 4 ^ Missing Y-brace fasteners and a broken or detached Y-brace, Figure 4. 12. Check the cross shaft bushings for wear if the brake pedal moves when the clutch is depressed and vise versa. Replace them as required. NOTE: GENERALLY, TRUCKS WITH SIGNIFICANTLY LESS THAN 11 MM CLUTCH RELEASE BEARING TRAVEL (AFTER COMPLETING THE INSPECTION PROCEDURE AND CORRECTING WHERE NECESSARY) WILL HAVE SIGNIFICANT DASH DAMAGE FROM PULLED SPOTWELDS AND TORN METAL. THESE TRUCKS WILL REQUIRE EXTENSIVE REPAIR. THEREFORE, GO TO THE LARGE REINFORCEMENT INSTALLATION PROCEDURE. Small Reinforcement Installation Procedure Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Body and Frame > Firewall > Component Information > Technical Service Bulletins > All Other Service Bulletins for Firewall: > 86817 > Apr > 86 > Customer Interest for Firewall: > 90167 > Aug > 90 > M/T - Clutch Fluid Leaks/Incomplete Release > Page 6338 Figure 5 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Body and Frame > Firewall > Component Information > Technical Service Bulletins > All Other Service Bulletins for Firewall: > 86817 > Apr > 86 > Customer Interest for Firewall: > 90167 > Aug > 90 > M/T - Clutch Fluid Leaks/Incomplete Release > Page 6339 Figure 6 There are two small reinforcement kits. One for 1988 and later models and one for 1987 and prior models. This is necessary because a new hydraulic clutch master cylinder mounting pattern was introduced for 1988 models. 1987 And Prior Trucks Use reinforcement kit E3TZ-7K509-A on these trucks, Figure 5. Comprehensive installation instructions are included in this kit. 1988 And Later Trucks Use reinforcement kit E8TZ-7K509-A on these trucks. The only part in this kit is the special reinforcement for these trucks. To install it, proceed as follows: 1. Remove the two clutch master cylinder attaching nuts (13 mm) from inside the truck. 2. Position the reinforcement in place over the clutch master cylinder studs. 3. Re-install the two master cylinder nuts, Figure 6. Tighten to 9.5 - 14.9 N-m. Large Reinforcement Installation Procedure Figure 7 Use reinforcement kit E3TZ-7K509-B on all 1983-1991 Bronco/F-Series trucks with hydraulic clutch controls. The kit consists of the following items: ^ A main reinforcement or doubler, with a plate having two studs to clamp the doubler through the cowl inner ^ Two additional pieces with three threaded holes: Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Body and Frame > Firewall > Component Information > Technical Service Bulletins > All Other Service Bulletins for Firewall: > 86817 > Apr > 86 > Customer Interest for Firewall: > 90167 > Aug > 90 > M/T - Clutch Fluid Leaks/Incomplete Release > Page 6340 One plate helps attach the main doubler through the dash inner tunnel. The other large piece is placed inside the front of the cowl, with bolts driven through from the engine compartment side of the dash reinforcement, see Figure 7. Installation Figure 1 1. Remove the insulating material. a. On earlier models, remove the instrument panel lower sound insulator assembly. b. For later diesel powered trucks, remove the fasteners holding the engine compartment dash insulation in place. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Body and Frame > Firewall > Component Information > Technical Service Bulletins > All Other Service Bulletins for Firewall: > 86817 > Apr > 86 > Customer Interest for Firewall: > 90167 > Aug > 90 > M/T - Clutch Fluid Leaks/Incomplete Release > Page 6341 c. Pull the dash insulation back out of the way. d. Disconnect the battery ground cable. 2. Disconnect the clutch master cylinder pushrod from the lever, removing the pushrod retention clip on older models, Figure 1. 3. Remove the two nuts attaching the clutch master cylinder to the dash panel. a. Pull the master cylinder into the engine compartment. b. For, 1988 and later trucks, it will be necessary to disconnect the wiring harness connector from the pushrod switch. c. Rotate the master cylinder to get it past the switch through the dash opening. 4. Remove the steering column and dash toe plate by removing the five (5) fasteners. 5. Disconnect the brake master cylinder pushrod from the brake pedal. 6. On F-Super Duty, proceed to Step 7. On all units except F-Super Duty, proceed as follows: a. Remove the four brake booster attaching nuts. b. Move the brake booster to one side. Figure 4 c. Loosen the two (2) fasteners attaching the brake and clutch pedal support to the Y-brace, Figure 4. 7. Check for cracks. a. Pull back the floor covering and dash sound insulator. (it may be helpful to remove the accelerator pedal.) b. Inspect the area for pulled welds and torn dash sheet metal. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Body and Frame > Firewall > Component Information > Technical Service Bulletins > All Other Service Bulletins for Firewall: > 86817 > Apr > 86 > Customer Interest for Firewall: > 90167 > Aug > 90 > M/T - Clutch Fluid Leaks/Incomplete Release > Page 6342 Figure 8 c. If there are cracks that have not run out, stop them by drilling a 2-3 mm hole at the end, Figure 8. NOTE: WELDING OR BRAZING IS NOT RECOMMENDED, BECAUSE IT COULD BE A SOURCE OF FUTURE BLIND SIDE CORROSION. Figure 4 8. Thoroughly inspect the brake and clutch support again for cracks in the casting and worn bushings. Also, inspect the "Y" brace for cracks and missing fasteners. Replace as necessary, Figure 4. 9. Remove excess body sealer in the area of the clutch master cylinder, inside the dash. 10. Carefully remove the cowl top cover 12 fasteners (7 in front, 5 in rear). NOTE: IT MAY BE NECESSARY TO REMOVE THE RADIO ANTENNA AND REPOSITION THE HOOD TO ACHIEVE THIS. IF THE HOOD IS REMOVED, MARK THE LOCATION OF THE HINGES WITH A WAX PENCIL, PRIOR TO LOOSENING. 11. Place the main reinforcement in position. a. Locate positively, using the lower steering column toe plate fastener and a bolt and nut (8 mm or 5/16") through the upper clutch master Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Body and Frame > Firewall > Component Information > Technical Service Bulletins > All Other Service Bulletins for Firewall: > 86817 > Apr > 86 > Customer Interest for Firewall: > 90167 > Aug > 90 > M/T - Clutch Fluid Leaks/Incomplete Release > Page 6343 cylinder stud hole. NOTE: THE SHEET METAL VARIES FROM TRUCK TO TRUCK AND IT MAY BE NECESSARY TO BEND THE REINFORCEMENT TO GET A GOOD FIT. b. Tighten the upper nut and bolt securely to compress any distortion in the four sheet metal laminations in this area. 12. Drill the holes for the reinforcement plate. a. Using a 3/8" (9.5 mm) drill bit, with the reinforcement as a template, drill two holes up into the cowl inner and three holes into the inner side of the dash. b. De-burr the outside of the holes as necessary. c. Remove any excess sealant in the area and clean up the drill chips inside the truck and cowl. 13. Attach the smaller plate via the three threaded holes into the engine compartment side of the dash inner panel. a. Use three 8 mm bolts passed through the main reinforcement, from inside the cab. b. Install the rubber cap (N804118) onto the end of the uppermost screw from under the dash. c. Position the plate with the two studs attached inside the cowl, through the two holes drilled from below. d. Attach two 8 mm nuts from the inside of the cab. 14. Using the paper template provided in the kit, proceed as follows: Figure 9 a. Center punch and drill three 3/8" (9.5 mm) holes into the dash reinforcement and through the cowl, from the engine compartment side, Figure 9. NOTE: DRILLING WILL BE EASIER IF THERE ARE NO SPOTWELDS VISIBLE THROUGH THE THREE HOLES. b. If necessary, move the pattern outboard slightly to avoid any visible spotwelds. c. De-burr the holes inside the cowl as necessary and clean up the drill chips inside the cowl. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Body and Frame > Firewall > Component Information > Technical Service Bulletins > All Other Service Bulletins for Firewall: > 86817 > Apr > 86 > Customer Interest for Firewall: > 90167 > Aug > 90 > M/T - Clutch Fluid Leaks/Incomplete Release > Page 6344 Figure 10 15. Place the larger three holed plate from the kit inside the cowl. Attach it with three 8 mm bolts through the dash reinforcement, from the engine compartment side, Figure 10. 16. Inspect the seam between the cowl inner and outer, inside the cowl, for cracks in the sealant. If necessary, add sealant. 17. Replace the cowl top. a. If the hood was removed, locate the hinges to the wax pencil marks and tighten the fasteners. b. Replace the radio antenna and windshield washer tube. 18. Re-install the brake booster and stoplight switch, if removed. Tighten the brace bolts. 19. Install the clutch master cylinder. a. Inspect the clutch master cylinder for leaks in the area of the pushrod. Replace it if there is evidence of leaking. b. Remove the nut and bolt from the top of the reinforcement. c. Install the clutch master cylinder. d. Inspect the position of the clutch master cylinder pushrod hole. The pushrod hole should go onto the lever pin with no force required while the pedal is against the upstop. NOTE: ALTHOUGH THIS WAS SPECIFIED IN THE INSPECTION PROCEDURE, REPAIR MAY HAVE CHANGED THE SETTING. e. If the pushrod hole is not in position, install and adjust an adjustable clutch master cylinder pushrod (1987 and prior models) or install a new lever (7A554). Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Body and Frame > Firewall > Component Information > Technical Service Bulletins > All Other Service Bulletins for Firewall: > 86817 > Apr > 86 > Customer Interest for Firewall: > 90167 > Aug > 90 > M/T - Clutch Fluid Leaks/Incomplete Release > Page 6345 Figure 1 NOTE: THE NEW LEVER IS TIGHTENED INTO PLACE WHILE THE MASTER CYLINDER PUSHROD IS ATTACHED, TO SET THE CORRECT POSITION, FIGURE 1. 20. Remove the toe plate fastener from the bottom of the reinforcement and reinstall the steering column and five (5) fasteners. 21. Complete reassembly. a. Re-install the dash sound deadener material and the instrument panel sound insulator. b. Re-install the engine compartment sound insulator on diesel models. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Body and Frame > Firewall > Component Information > Technical Service Bulletins > All Other Service Bulletins for Firewall: > 86817 > Apr > 86 > Customer Interest for Firewall: > 90167 > Aug > 90 > M/T - Clutch Fluid Leaks/Incomplete Release > Page 6346 c. Connect the battery ground terminal. Final Inspection If the truck has been driven for a long period of time with the broken dash and resulting poor clutch release, the clutch disc could be excessively worn or buckled. Test drive the truck, evaluating the clutch for clean release. If the release is not satisfactory, measure the release bearing travel. ^ If it has the required 12 mm at full clutch pedal stroke, then the clutch may need to be replaced. ^ If the release bearing has less than the required release travel, then the hydraulic system probably needs to be bled. Suggested Bleeding Procedure - External Slave Cylinder Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Body and Frame > Firewall > Component Information > Technical Service Bulletins > All Other Service Bulletins for Firewall: > 86817 > Apr > 86 > Customer Interest for Firewall: > 90167 > Aug > 90 > M/T - Clutch Fluid Leaks/Incomplete Release > Page 6347 Figure 11 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Body and Frame > Firewall > Component Information > Technical Service Bulletins > All Other Service Bulletins for Firewall: > 86817 > Apr > 86 > Customer Interest for Firewall: > 90167 > Aug > 90 > M/T - Clutch Fluid Leaks/Incomplete Release > Page 6348 Figure 12 If the truck is a 1987 or prior model, 1988 model with a 7.3L Diesel, 7.5L EFI gas engine or the smaller family of engines with a Warner T-18 four speed transmission, proceed as follows: 1. Remove the master cylinder reservoir cap and diaphragm. 2. Check the fluid level to be sure it is at the step diameter of the reservoir. Do not over fill. 3. From below the truck, push the release lever slowly towards the front of the truck several times. Figures 11 & 12. 4. If it will not move, the master cylinder pushrod is not set correctly. See repair Step # 19. 5. Check the fluid level and replace the diaphragm and cap. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Body and Frame > Firewall > Component Information > Technical Service Bulletins > All Other Service Bulletins for Firewall: > 86817 > Apr > 86 > Customer Interest for Firewall: > 90167 > Aug > 90 > M/T - Clutch Fluid Leaks/Incomplete Release > Page 6349 Suggested Bleeding Proc - Internal Concentric Slave CYL. Figure 13 If the truck has a concentric slave cylinder, proceed as follows: 1. Operate the clutch pedal at full stroke, 10-20 times. 2. Check the fluid level at the change in diameter part of the reservoir. Do not over fill. 3. Have an assistant depress the clutch pedal slowly and hold it down. 4. Open the slave cylinder bleed screw and watch for escaping air, Figure 13. 5. Close the bleed screw and have the assistant release pedal. 6. Repeat this cycle several times until there is no sign of air. Be sure to keep the reservoir topped to the correct level. 7. Replace the diaphragm and reservoir cover. 8. Operate the clutch pedal at full stroke 10-20 times. Misc. Information OTHER APPLICABLE ARTICLES: 86-20-10 WARRANTY STATUS: Eligible Under Basic Warranty Coverage, Powertrain Warranty Coverage OPERATION DESCRIPTION TIME 901607A Inspect & Adjust 0.5 Hr. 901607B Install Reinforcement 2.9 Hr. DEALER CODING BASIC PART NO. CONDITION CODE 7050 50 OASIS CODES: 111000, 505000, 505200, 506000, 590000 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Body and Frame > Firewall > Component Information > Technical Service Bulletins > All Other Service Bulletins for Vacuum Check Valve: > 90167 > Aug > 90 > M/T - Clutch Fluid Leaks/Incomplete Release Technical Service Bulletin # 90167 Date: 900801 M/T - Clutch Fluid Leaks/Incomplete Release Article No. 90-16-7 ^ CRACKS - DASH (ENGINE COMPARTMENT BULKHEAD) - CLUTCH MASTER CYLINDER AREA - VEHICLES BUILT BEFORE 6/15/90 ^ CLUTCH - HIGH EFFORT - DASH CRACKED IN CLUTCH MASTER CYLINDER AREA VEHICLES BUILT BEFORE 6/15/90 LIGHT TRUCK: 1984-90 BRONCO, F-150, F-250, F-350 1988-90 F SUPER DUTY ISSUE: Incomplete clutch release and/or hydraulic fluid leaking into the cab from the clutch master cylinder may be caused by the reinforcement plate on the clutch master cylinder separating from the dash panel. The separation of the reinforcement plate reduces the clutch master cylinder pushrod travel. Reinforcement plate separation can also cause deflection of the clutch master cylinder that results in a misalignment of the pushrod to the clutch master cylinder. Misalignment causes the "O" ring in front of the secondary seal to leak hydraulic fluid. ACTION: Inspect the truck and, if necessary, use the following service procedure to install a reinforcement kit. Inspection Procedure 1. If the truck is a 1988 or later model, confirm that the starter interlock switch operates (the engine can be started) with the clutch pedal at least 0.5" (12.7 mm) from the floor. 2. Test drive the truck and check for good clutch release. There should be no grinding of the gears, particularly when shifting from neutral to reverse gear. 3. If the truck passes these tests, go to the Small Reinforcement Installation Procedure Section of this article. 4. If either of the above conditions are not met, check the hydraulic system for air. Refer to the Suggested Bleeding Procedure at the end of this article. 5. Test drive the truck and check for improved clutch release. 6. If there is no improvement, proceed as follows: a. Remove the clutch master cylinder pushrod from the release lever pin on the release lever. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Body and Frame > Firewall > Component Information > Technical Service Bulletins > All Other Service Bulletins for Vacuum Check Valve: > 90167 > Aug > 90 > M/T - Clutch Fluid Leaks/Incomplete Release > Page 6355 Figure 1 b. Make sure the hole in the pushrod lines up with the pin, for those units requiring a minimal force for installation, Figure 1. c. If it does not line up correctly, install an adjustable pushrod (except 1988 and later models) or replace the clutch release lever (required on 1988 and later models), cutting a new seat on the cross shaft splines. 7. Test drive the truck again, checking for improved clutch release. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Body and Frame > Firewall > Component Information > Technical Service Bulletins > All Other Service Bulletins for Vacuum Check Valve: > 90167 > Aug > 90 > M/T - Clutch Fluid Leaks/Incomplete Release > Page 6356 Figure 2 8. If there is no improvement, inspect the truck for adequate release bearing travel. ^ It should be 11 mm or greater for full pedal travel. ^ Pedal travel at the center of the pedal pad should be 6.75" (171 mm minimum) or more, Figure 2. 9. Release bearing travel and gear grinding noise may indicate the following concerns. ^ If the release bearing is 11 mm or greater and there is grinding of one or two gears only, the concern is probably with the transmission. ^ If all gears grind, the concern may be with the clutch and/or pilot bearing which will need replacing. ^ If the release travel is less than 11 mm, check the clutch hydraulic system for air and bleed as necessary. 10. If the release travel is still less than 11 mm, with all of the above items eliminated, proceed as follows: a. Raise the hood, while an assistant operates the clutch pedal. b. Watch the clutch master cylinder for significant deflection. Figure 3 c. Look for the dash reinforcement moving away from the dash, Figure 3. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Body and Frame > Firewall > Component Information > Technical Service Bulletins > All Other Service Bulletins for Vacuum Check Valve: > 90167 > Aug > 90 > M/T - Clutch Fluid Leaks/Incomplete Release > Page 6357 d. On 1987 and earlier models, look down inside the cowl cover at the cowl where it is attached to the dash reinforcement. Check for pulled spot welds. 11. If there is significant movement of the dash or clutch master cylinder, proceed as follows: a. Remove the steering column and its dash toe plate and seal. Refer to the appropriate Light Truck Shop Manual, Section 13-07 for service details. b. Inspect the dash inside the cab and look for: ^ Pulled spotwelds and cracked or torn sheet metal. ^ Cracks in the brake and clutch pedal support Figure 4 ^ Missing Y-brace fasteners and a broken or detached Y-brace, Figure 4. 12. Check the cross shaft bushings for wear if the brake pedal moves when the clutch is depressed and vise versa. Replace them as required. NOTE: GENERALLY, TRUCKS WITH SIGNIFICANTLY LESS THAN 11 MM CLUTCH RELEASE BEARING TRAVEL (AFTER COMPLETING THE INSPECTION PROCEDURE AND CORRECTING WHERE NECESSARY) WILL HAVE SIGNIFICANT DASH DAMAGE FROM PULLED SPOTWELDS AND TORN METAL. THESE TRUCKS WILL REQUIRE EXTENSIVE REPAIR. THEREFORE, GO TO THE LARGE REINFORCEMENT INSTALLATION PROCEDURE. Small Reinforcement Installation Procedure Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Body and Frame > Firewall > Component Information > Technical Service Bulletins > All Other Service Bulletins for Vacuum Check Valve: > 90167 > Aug > 90 > M/T - Clutch Fluid Leaks/Incomplete Release > Page 6358 Figure 5 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Body and Frame > Firewall > Component Information > Technical Service Bulletins > All Other Service Bulletins for Vacuum Check Valve: > 90167 > Aug > 90 > M/T - Clutch Fluid Leaks/Incomplete Release > Page 6359 Figure 6 There are two small reinforcement kits. One for 1988 and later models and one for 1987 and prior models. This is necessary because a new hydraulic clutch master cylinder mounting pattern was introduced for 1988 models. 1987 And Prior Trucks Use reinforcement kit E3TZ-7K509-A on these trucks, Figure 5. Comprehensive installation instructions are included in this kit. 1988 And Later Trucks Use reinforcement kit E8TZ-7K509-A on these trucks. The only part in this kit is the special reinforcement for these trucks. To install it, proceed as follows: 1. Remove the two clutch master cylinder attaching nuts (13 mm) from inside the truck. 2. Position the reinforcement in place over the clutch master cylinder studs. 3. Re-install the two master cylinder nuts, Figure 6. Tighten to 9.5 - 14.9 N-m. Large Reinforcement Installation Procedure Figure 7 Use reinforcement kit E3TZ-7K509-B on all 1983-1991 Bronco/F-Series trucks with hydraulic clutch controls. The kit consists of the following items: ^ A main reinforcement or doubler, with a plate having two studs to clamp the doubler through the cowl inner ^ Two additional pieces with three threaded holes: Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Body and Frame > Firewall > Component Information > Technical Service Bulletins > All Other Service Bulletins for Vacuum Check Valve: > 90167 > Aug > 90 > M/T - Clutch Fluid Leaks/Incomplete Release > Page 6360 One plate helps attach the main doubler through the dash inner tunnel. The other large piece is placed inside the front of the cowl, with bolts driven through from the engine compartment side of the dash reinforcement, see Figure 7. Installation Figure 1 1. Remove the insulating material. a. On earlier models, remove the instrument panel lower sound insulator assembly. b. For later diesel powered trucks, remove the fasteners holding the engine compartment dash insulation in place. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Body and Frame > Firewall > Component Information > Technical Service Bulletins > All Other Service Bulletins for Vacuum Check Valve: > 90167 > Aug > 90 > M/T - Clutch Fluid Leaks/Incomplete Release > Page 6361 c. Pull the dash insulation back out of the way. d. Disconnect the battery ground cable. 2. Disconnect the clutch master cylinder pushrod from the lever, removing the pushrod retention clip on older models, Figure 1. 3. Remove the two nuts attaching the clutch master cylinder to the dash panel. a. Pull the master cylinder into the engine compartment. b. For, 1988 and later trucks, it will be necessary to disconnect the wiring harness connector from the pushrod switch. c. Rotate the master cylinder to get it past the switch through the dash opening. 4. Remove the steering column and dash toe plate by removing the five (5) fasteners. 5. Disconnect the brake master cylinder pushrod from the brake pedal. 6. On F-Super Duty, proceed to Step 7. On all units except F-Super Duty, proceed as follows: a. Remove the four brake booster attaching nuts. b. Move the brake booster to one side. Figure 4 c. Loosen the two (2) fasteners attaching the brake and clutch pedal support to the Y-brace, Figure 4. 7. Check for cracks. a. Pull back the floor covering and dash sound insulator. (it may be helpful to remove the accelerator pedal.) b. Inspect the area for pulled welds and torn dash sheet metal. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Body and Frame > Firewall > Component Information > Technical Service Bulletins > All Other Service Bulletins for Vacuum Check Valve: > 90167 > Aug > 90 > M/T - Clutch Fluid Leaks/Incomplete Release > Page 6362 Figure 8 c. If there are cracks that have not run out, stop them by drilling a 2-3 mm hole at the end, Figure 8. NOTE: WELDING OR BRAZING IS NOT RECOMMENDED, BECAUSE IT COULD BE A SOURCE OF FUTURE BLIND SIDE CORROSION. Figure 4 8. Thoroughly inspect the brake and clutch support again for cracks in the casting and worn bushings. Also, inspect the "Y" brace for cracks and missing fasteners. Replace as necessary, Figure 4. 9. Remove excess body sealer in the area of the clutch master cylinder, inside the dash. 10. Carefully remove the cowl top cover 12 fasteners (7 in front, 5 in rear). NOTE: IT MAY BE NECESSARY TO REMOVE THE RADIO ANTENNA AND REPOSITION THE HOOD TO ACHIEVE THIS. IF THE HOOD IS REMOVED, MARK THE LOCATION OF THE HINGES WITH A WAX PENCIL, PRIOR TO LOOSENING. 11. Place the main reinforcement in position. a. Locate positively, using the lower steering column toe plate fastener and a bolt and nut (8 mm or 5/16") through the upper clutch master Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Body and Frame > Firewall > Component Information > Technical Service Bulletins > All Other Service Bulletins for Vacuum Check Valve: > 90167 > Aug > 90 > M/T - Clutch Fluid Leaks/Incomplete Release > Page 6363 cylinder stud hole. NOTE: THE SHEET METAL VARIES FROM TRUCK TO TRUCK AND IT MAY BE NECESSARY TO BEND THE REINFORCEMENT TO GET A GOOD FIT. b. Tighten the upper nut and bolt securely to compress any distortion in the four sheet metal laminations in this area. 12. Drill the holes for the reinforcement plate. a. Using a 3/8" (9.5 mm) drill bit, with the reinforcement as a template, drill two holes up into the cowl inner and three holes into the inner side of the dash. b. De-burr the outside of the holes as necessary. c. Remove any excess sealant in the area and clean up the drill chips inside the truck and cowl. 13. Attach the smaller plate via the three threaded holes into the engine compartment side of the dash inner panel. a. Use three 8 mm bolts passed through the main reinforcement, from inside the cab. b. Install the rubber cap (N804118) onto the end of the uppermost screw from under the dash. c. Position the plate with the two studs attached inside the cowl, through the two holes drilled from below. d. Attach two 8 mm nuts from the inside of the cab. 14. Using the paper template provided in the kit, proceed as follows: Figure 9 a. Center punch and drill three 3/8" (9.5 mm) holes into the dash reinforcement and through the cowl, from the engine compartment side, Figure 9. NOTE: DRILLING WILL BE EASIER IF THERE ARE NO SPOTWELDS VISIBLE THROUGH THE THREE HOLES. b. If necessary, move the pattern outboard slightly to avoid any visible spotwelds. c. De-burr the holes inside the cowl as necessary and clean up the drill chips inside the cowl. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Body and Frame > Firewall > Component Information > Technical Service Bulletins > All Other Service Bulletins for Vacuum Check Valve: > 90167 > Aug > 90 > M/T - Clutch Fluid Leaks/Incomplete Release > Page 6364 Figure 10 15. Place the larger three holed plate from the kit inside the cowl. Attach it with three 8 mm bolts through the dash reinforcement, from the engine compartment side, Figure 10. 16. Inspect the seam between the cowl inner and outer, inside the cowl, for cracks in the sealant. If necessary, add sealant. 17. Replace the cowl top. a. If the hood was removed, locate the hinges to the wax pencil marks and tighten the fasteners. b. Replace the radio antenna and windshield washer tube. 18. Re-install the brake booster and stoplight switch, if removed. Tighten the brace bolts. 19. Install the clutch master cylinder. a. Inspect the clutch master cylinder for leaks in the area of the pushrod. Replace it if there is evidence of leaking. b. Remove the nut and bolt from the top of the reinforcement. c. Install the clutch master cylinder. d. Inspect the position of the clutch master cylinder pushrod hole. The pushrod hole should go onto the lever pin with no force required while the pedal is against the upstop. NOTE: ALTHOUGH THIS WAS SPECIFIED IN THE INSPECTION PROCEDURE, REPAIR MAY HAVE CHANGED THE SETTING. e. If the pushrod hole is not in position, install and adjust an adjustable clutch master cylinder pushrod (1987 and prior models) or install a new lever (7A554). Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Body and Frame > Firewall > Component Information > Technical Service Bulletins > All Other Service Bulletins for Vacuum Check Valve: > 90167 > Aug > 90 > M/T - Clutch Fluid Leaks/Incomplete Release > Page 6365 Figure 1 NOTE: THE NEW LEVER IS TIGHTENED INTO PLACE WHILE THE MASTER CYLINDER PUSHROD IS ATTACHED, TO SET THE CORRECT POSITION, FIGURE 1. 20. Remove the toe plate fastener from the bottom of the reinforcement and reinstall the steering column and five (5) fasteners. 21. Complete reassembly. a. Re-install the dash sound deadener material and the instrument panel sound insulator. b. Re-install the engine compartment sound insulator on diesel models. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Body and Frame > Firewall > Component Information > Technical Service Bulletins > All Other Service Bulletins for Vacuum Check Valve: > 90167 > Aug > 90 > M/T - Clutch Fluid Leaks/Incomplete Release > Page 6366 c. Connect the battery ground terminal. Final Inspection If the truck has been driven for a long period of time with the broken dash and resulting poor clutch release, the clutch disc could be excessively worn or buckled. Test drive the truck, evaluating the clutch for clean release. If the release is not satisfactory, measure the release bearing travel. ^ If it has the required 12 mm at full clutch pedal stroke, then the clutch may need to be replaced. ^ If the release bearing has less than the required release travel, then the hydraulic system probably needs to be bled. Suggested Bleeding Procedure - External Slave Cylinder Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Body and Frame > Firewall > Component Information > Technical Service Bulletins > All Other Service Bulletins for Vacuum Check Valve: > 90167 > Aug > 90 > M/T - Clutch Fluid Leaks/Incomplete Release > Page 6367 Figure 11 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Body and Frame > Firewall > Component Information > Technical Service Bulletins > All Other Service Bulletins for Vacuum Check Valve: > 90167 > Aug > 90 > M/T - Clutch Fluid Leaks/Incomplete Release > Page 6368 Figure 12 If the truck is a 1987 or prior model, 1988 model with a 7.3L Diesel, 7.5L EFI gas engine or the smaller family of engines with a Warner T-18 four speed transmission, proceed as follows: 1. Remove the master cylinder reservoir cap and diaphragm. 2. Check the fluid level to be sure it is at the step diameter of the reservoir. Do not over fill. 3. From below the truck, push the release lever slowly towards the front of the truck several times. Figures 11 & 12. 4. If it will not move, the master cylinder pushrod is not set correctly. See repair Step # 19. 5. Check the fluid level and replace the diaphragm and cap. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Body and Frame > Firewall > Component Information > Technical Service Bulletins > All Other Service Bulletins for Vacuum Check Valve: > 90167 > Aug > 90 > M/T - Clutch Fluid Leaks/Incomplete Release > Page 6369 Suggested Bleeding Proc - Internal Concentric Slave CYL. Figure 13 If the truck has a concentric slave cylinder, proceed as follows: 1. Operate the clutch pedal at full stroke, 10-20 times. 2. Check the fluid level at the change in diameter part of the reservoir. Do not over fill. 3. Have an assistant depress the clutch pedal slowly and hold it down. 4. Open the slave cylinder bleed screw and watch for escaping air, Figure 13. 5. Close the bleed screw and have the assistant release pedal. 6. Repeat this cycle several times until there is no sign of air. Be sure to keep the reservoir topped to the correct level. 7. Replace the diaphragm and reservoir cover. 8. Operate the clutch pedal at full stroke 10-20 times. Misc. Information OTHER APPLICABLE ARTICLES: 86-20-10 WARRANTY STATUS: Eligible Under Basic Warranty Coverage, Powertrain Warranty Coverage OPERATION DESCRIPTION TIME 901607A Inspect & Adjust 0.5 Hr. 901607B Install Reinforcement 2.9 Hr. DEALER CODING BASIC PART NO. CONDITION CODE 7050 50 OASIS CODES: 111000, 505000, 505200, 506000, 590000 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Body and Frame > Frame > Cross-Member > Component Information > Technical Service Bulletins > Customer Interest for Cross-Member: > 94813 > Apr > 94 > Frame/Crossmember - Snapping/Popping Noise Cross-Member: Customer Interest Frame/Crossmember - Snapping/Popping Noise Article No. 94-8-13 ^ FRAME - # 1 CROSSMEMBER - RIVET REPLACEMENT ^ NOISE - "POPPING/CREAKING" SOUNDS - FRAME # 1 CROSSMEMBER LIGHT TRUCK: 1980-94 BRONCO, F-150-350 SERIES 1988-94 F SUPER DUTY, F-47 This TSB article is being republished in its entirety to add certain 1992/94 model year vehicles, to revise the nut specified in the article and its torque specification, and to expand the diagnostic and repair procedures contained in the article. ISSUE: A "popping/creaking" sound may come from the area of the # 1 crossmember attachment to the left frame rail. This occurs because of a slip/stick motion at a loose rivet in the lower flange of the frame near the steering gear. The rivet could be either a standard cold head rivet in light duty applications or a "huck" rivet, which has the appearance of a large "pop" Civet. ACTION: Use the following diagnostic procedure to determine if the noise is originating in this rivet area. If so, replace the rivet with a nut, bolt and washer assembly. The revised parts increase the clamp load at the joint, minimizing the motion that causes the noise. Refer to the following procedure for service details. SOURCES OF VARIOUS FRONT UNDERBODY NOISES: Various front underbody noises may originate from several different sources. Several noises have been misdiagnosed as # 1 crossmember rivet "pop/creak" because the noise tends to propagate to the shock tower area and the shock tower area acts as an amplifier such that the noises all appear to be coming from that area. Other underbody areas that produce similar noises include: ^ loose or improperly seated shock tower rivets ^ loose or misaligned transmission crossmembers ^ loose radius arm brackets ^ loose axle pivot brackets Other service bulletins have been published to address the proper repair of these concerns. DESCRIPTION OF # 1 CROSSMEMBER NOISES: "Pop/creak" - A metal-to-metal rubbing motion which slip/sticks when a twist is induced into the frame. DIAGNOSTIC PROCEDURE: 1. INTERVIEW THE CUSTOMER: a. Understand the customer's description of the noise and of the conditions under which it is heard. b. Road test the vehicle with the customer to fully understand where, how and when the noise occurs. 2. DUPLICATE THE NOISE CONCERN: a. Drive the vehicle around for at least 15 minutes to warm-up and stress the frame joints, so that any frame noise is more likely to be repeatable in the garage. b. Test the following situations: ^ Can the noise be duplicated while stationary and on dry pavement by repeatedly turning the steering wheel from steering stop to steering stop? Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Body and Frame > Frame > Cross-Member > Component Information > Technical Service Bulletins > Customer Interest for Cross-Member: > 94813 > Apr > 94 > Frame/Crossmember - Snapping/Popping Noise > Page 6379 ^ Can the noise be repeated while on the hoist without the suspension loaded by repeatedly turning the steering wheel from steering stop to steering stop? Typically, the twist in the frame can be induced by turning the steering wheel back and forth from steering stop to steering stop to duplicate the noise at the # 1 crossmember attachment. IF THE NOISE IS NOT DUPLICATED UNDER ONE OF THESE SITUATIONS, INVESTIGATE OTHER AREAS FOR THE NOISE BEFORE PROCEEDING TO REPAIR THE # 1 CROSSMEMBER RIVET. 3. INSPECT FRAME BOLTS FOR PROPER INSTALLATION TORQUE: a. Inspect and tighten all front end components which bolt to the frame to confirm they are at the proper torque. This includes, but is not limited to: ^ Radius arm bracket bolts - 135 +/- 20 N-m (100 +/- 15 lb.ft.) ^ Axle pivot bracket bolts (torques vary by model - refer to the appropriate light truck Service Manual for proper torque specifications) ^ Bumper bracket bolts - (refer to the appropriate light truck Service Manual for proper torque specifications) b. Inspect the transmission crossmember for proper alignment and bolt torques. If misaligned: ^ Loosen all transmission crossmember fasteners (including to the transmission). ^ Lift the transmission to remove any load on the crossmember. ^ Lift and reposition the transmission crossmember to be centered on the frame attachment holes. ^ Tighten all frame fasteners to the 63 +/- 9 N-m (46 +/- 7 lb.ft.). ^ Lower the transmission and tighten fasteners to 95 +/- 15 N-m (70 +/- 11 lb.ft.). 4. TEST DRIVE THE VEHICLE Road test the vehicle again to duplicate the concern. If the noise is still present, continue. 5. INSPECT THE FRAME RIVETS a. Repeat Step 2 to duplicate the noise in the garage. b. Use a stethoscope or chassis ears to isolate the area of the chassis that the noise appears to be originating from. Areas to check include the shock tower rivets and all # 1 crossmember rivets. 6. SERVICE THE VEHICLE a. If the noise appears to be from the lower left-front # 1 crossmember fastener, follow the procedure outlined below. b. If the noise appears to be coming from another rivet (other than the lower left front # 1 crossmember rivet), refer to TSB 93-6-10 for the proper rivet repair procedure. LOWER LEFT FRONT # 1 CROSSMEMBER RIVET REPLACEMENT: NOTE: THIS SERVICE PROCEDURE DOES NOT APPLY TO STEERING GEAR LINER REPLACEMENT. REFER TO TSB 90-11-10 FOR STEERING GEAR LINER REPAIR PROCEDURE. 1. Remove damaged or loose COLD HEAD RIVETS: a. Drill a 1/8" (3.175 mm) hole through the rivet. b. Redrill the same hole through the shank of the rivet with a 3/8" (9.525 mm) drill. c. Remove the rivet head with an air chisel. d. Drive out the rivet with a punch and hammer. 2. Remove damaged or loose "HUCK" RIVETS: Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Body and Frame > Frame > Cross-Member > Component Information > Technical Service Bulletins > Customer Interest for Cross-Member: > 94813 > Apr > 94 > Frame/Crossmember - Snapping/Popping Noise > Page 6380 a. Use a flat chisel and hammer (or air chisel) to split the exposed collar of the huck fastener, Figure 1. b. Knock the rivet pin out of the blind side with a 1/4" (6.35 mm) drift punch and hammer, Figure 2. c. Cut the rivet's head off with a hammer and flat chisel, Figure 3. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Body and Frame > Frame > Cross-Member > Component Information > Technical Service Bulletins > Customer Interest for Cross-Member: > 94813 > Apr > 94 > Frame/Crossmember - Snapping/Popping Noise > Page 6381 d. Knock the sleeve out of the blind side with a 3/8" (9.525 mm) drift punch and hammer, Figure 4. CAUTION: REMOVAL OF THE FASTENER WITH A CUTTING TORCH IS NOT RECOMMENDED BECAUSE OF PROBABLE DAMAGE TO THE FRAME STRUCTURE. 3. Line ream the existing hole through the liner, frame flange and crossmember to 9/16" (14.228 mm), Figure 5. 4. Install a 9/16" Grade 8 nut (34990-S4), bolt (58698-S2) and washer (44880-S2), with nut/washer on the bottom, Figure 6. a. Push the bolt into place using a brazing rod to hold the bolt. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Body and Frame > Frame > Cross-Member > Component Information > Technical Service Bulletins > Customer Interest for Cross-Member: > 94813 > Apr > 94 > Frame/Crossmember - Snapping/Popping Noise > Page 6382 b. Slide the bolt into the opening between the front face of the crossmember and frame liner. c. Tighten the nut to 140 4-3 lb.ft. (190 4-4 N-m) and tack weld the nut to the bolt after tightening. CAUTION: DO NOT WELD THE NUT/WASHER TO THE FRAME. OTHER APPLICABLE ARTICLES: 91-11-10 SUPERSEDES: 91-25-18 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 19 2-94 Models, Basic Warranty Coverage For All Other Models OPERATION DESCRIPTION TIME 940813A Perform Diagnostics And 1.9 Hrs. Replace Rivet DEALER CODING BASIC PART NO. CONDITION CODE 5005 56 OASIS CODES: 305000, 390000, 702000, 702100 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Body and Frame > Frame > Cross-Member > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cross-Member: > 94813 > Apr > 94 > Frame/Crossmember Snapping/Popping Noise Cross-Member: All Technical Service Bulletins Frame/Crossmember - Snapping/Popping Noise Article No. 94-8-13 ^ FRAME - # 1 CROSSMEMBER - RIVET REPLACEMENT ^ NOISE - "POPPING/CREAKING" SOUNDS - FRAME # 1 CROSSMEMBER LIGHT TRUCK: 1980-94 BRONCO, F-150-350 SERIES 1988-94 F SUPER DUTY, F-47 This TSB article is being republished in its entirety to add certain 1992/94 model year vehicles, to revise the nut specified in the article and its torque specification, and to expand the diagnostic and repair procedures contained in the article. ISSUE: A "popping/creaking" sound may come from the area of the # 1 crossmember attachment to the left frame rail. This occurs because of a slip/stick motion at a loose rivet in the lower flange of the frame near the steering gear. The rivet could be either a standard cold head rivet in light duty applications or a "huck" rivet, which has the appearance of a large "pop" Civet. ACTION: Use the following diagnostic procedure to determine if the noise is originating in this rivet area. If so, replace the rivet with a nut, bolt and washer assembly. The revised parts increase the clamp load at the joint, minimizing the motion that causes the noise. Refer to the following procedure for service details. SOURCES OF VARIOUS FRONT UNDERBODY NOISES: Various front underbody noises may originate from several different sources. Several noises have been misdiagnosed as # 1 crossmember rivet "pop/creak" because the noise tends to propagate to the shock tower area and the shock tower area acts as an amplifier such that the noises all appear to be coming from that area. Other underbody areas that produce similar noises include: ^ loose or improperly seated shock tower rivets ^ loose or misaligned transmission crossmembers ^ loose radius arm brackets ^ loose axle pivot brackets Other service bulletins have been published to address the proper repair of these concerns. DESCRIPTION OF # 1 CROSSMEMBER NOISES: "Pop/creak" - A metal-to-metal rubbing motion which slip/sticks when a twist is induced into the frame. DIAGNOSTIC PROCEDURE: 1. INTERVIEW THE CUSTOMER: a. Understand the customer's description of the noise and of the conditions under which it is heard. b. Road test the vehicle with the customer to fully understand where, how and when the noise occurs. 2. DUPLICATE THE NOISE CONCERN: a. Drive the vehicle around for at least 15 minutes to warm-up and stress the frame joints, so that any frame noise is more likely to be repeatable in the garage. b. Test the following situations: ^ Can the noise be duplicated while stationary and on dry pavement by repeatedly turning the steering wheel from steering stop to steering stop? Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Body and Frame > Frame > Cross-Member > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cross-Member: > 94813 > Apr > 94 > Frame/Crossmember Snapping/Popping Noise > Page 6388 ^ Can the noise be repeated while on the hoist without the suspension loaded by repeatedly turning the steering wheel from steering stop to steering stop? Typically, the twist in the frame can be induced by turning the steering wheel back and forth from steering stop to steering stop to duplicate the noise at the # 1 crossmember attachment. IF THE NOISE IS NOT DUPLICATED UNDER ONE OF THESE SITUATIONS, INVESTIGATE OTHER AREAS FOR THE NOISE BEFORE PROCEEDING TO REPAIR THE # 1 CROSSMEMBER RIVET. 3. INSPECT FRAME BOLTS FOR PROPER INSTALLATION TORQUE: a. Inspect and tighten all front end components which bolt to the frame to confirm they are at the proper torque. This includes, but is not limited to: ^ Radius arm bracket bolts - 135 +/- 20 N-m (100 +/- 15 lb.ft.) ^ Axle pivot bracket bolts (torques vary by model - refer to the appropriate light truck Service Manual for proper torque specifications) ^ Bumper bracket bolts - (refer to the appropriate light truck Service Manual for proper torque specifications) b. Inspect the transmission crossmember for proper alignment and bolt torques. If misaligned: ^ Loosen all transmission crossmember fasteners (including to the transmission). ^ Lift the transmission to remove any load on the crossmember. ^ Lift and reposition the transmission crossmember to be centered on the frame attachment holes. ^ Tighten all frame fasteners to the 63 +/- 9 N-m (46 +/- 7 lb.ft.). ^ Lower the transmission and tighten fasteners to 95 +/- 15 N-m (70 +/- 11 lb.ft.). 4. TEST DRIVE THE VEHICLE Road test the vehicle again to duplicate the concern. If the noise is still present, continue. 5. INSPECT THE FRAME RIVETS a. Repeat Step 2 to duplicate the noise in the garage. b. Use a stethoscope or chassis ears to isolate the area of the chassis that the noise appears to be originating from. Areas to check include the shock tower rivets and all # 1 crossmember rivets. 6. SERVICE THE VEHICLE a. If the noise appears to be from the lower left-front # 1 crossmember fastener, follow the procedure outlined below. b. If the noise appears to be coming from another rivet (other than the lower left front # 1 crossmember rivet), refer to TSB 93-6-10 for the proper rivet repair procedure. LOWER LEFT FRONT # 1 CROSSMEMBER RIVET REPLACEMENT: NOTE: THIS SERVICE PROCEDURE DOES NOT APPLY TO STEERING GEAR LINER REPLACEMENT. REFER TO TSB 90-11-10 FOR STEERING GEAR LINER REPAIR PROCEDURE. 1. Remove damaged or loose COLD HEAD RIVETS: a. Drill a 1/8" (3.175 mm) hole through the rivet. b. Redrill the same hole through the shank of the rivet with a 3/8" (9.525 mm) drill. c. Remove the rivet head with an air chisel. d. Drive out the rivet with a punch and hammer. 2. Remove damaged or loose "HUCK" RIVETS: Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Body and Frame > Frame > Cross-Member > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cross-Member: > 94813 > Apr > 94 > Frame/Crossmember Snapping/Popping Noise > Page 6389 a. Use a flat chisel and hammer (or air chisel) to split the exposed collar of the huck fastener, Figure 1. b. Knock the rivet pin out of the blind side with a 1/4" (6.35 mm) drift punch and hammer, Figure 2. c. Cut the rivet's head off with a hammer and flat chisel, Figure 3. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Body and Frame > Frame > Cross-Member > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cross-Member: > 94813 > Apr > 94 > Frame/Crossmember Snapping/Popping Noise > Page 6390 d. Knock the sleeve out of the blind side with a 3/8" (9.525 mm) drift punch and hammer, Figure 4. CAUTION: REMOVAL OF THE FASTENER WITH A CUTTING TORCH IS NOT RECOMMENDED BECAUSE OF PROBABLE DAMAGE TO THE FRAME STRUCTURE. 3. Line ream the existing hole through the liner, frame flange and crossmember to 9/16" (14.228 mm), Figure 5. 4. Install a 9/16" Grade 8 nut (34990-S4), bolt (58698-S2) and washer (44880-S2), with nut/washer on the bottom, Figure 6. a. Push the bolt into place using a brazing rod to hold the bolt. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Body and Frame > Frame > Cross-Member > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cross-Member: > 94813 > Apr > 94 > Frame/Crossmember Snapping/Popping Noise > Page 6391 b. Slide the bolt into the opening between the front face of the crossmember and frame liner. c. Tighten the nut to 140 4-3 lb.ft. (190 4-4 N-m) and tack weld the nut to the bolt after tightening. CAUTION: DO NOT WELD THE NUT/WASHER TO THE FRAME. OTHER APPLICABLE ARTICLES: 91-11-10 SUPERSEDES: 91-25-18 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 19 2-94 Models, Basic Warranty Coverage For All Other Models OPERATION DESCRIPTION TIME 940813A Perform Diagnostics And 1.9 Hrs. Replace Rivet DEALER CODING BASIC PART NO. CONDITION CODE 5005 56 OASIS CODES: 305000, 390000, 702000, 702100 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Component Information > Service and Repair Dashboard / Instrument Panel: Service and Repair Fig. 3 Exploded View Of Instrument Panel, 1986-87 Bronco & F-series. 1. Disconnect negative battery cable. 2. Remove screws from the lefthand and righthand defroster openings. A magnetic screwdriver should be used to avoid dropping the screws through the defroster openings. 3. Remove top instrument cluster finish panel to the instrument panel pad attaching screws. 4. Remove screws from center finish panel to instrument panel pad. 5. Remove instrument panel pad screws from above the glove compartment opening. 6. Lift rear edge of the instrument panel pad, then pull rearward to remove. 7. Reverse procedure to install. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Body and Frame > Locks > Door Locks > Component Information > Technical Service Bulletins > Customer Interest for Door Locks: > 95244 > Dec > 95 > Door Lock Cylinder - Loose in Replacement Door Door Locks: Customer Interest Door Lock Cylinder - Loose in Replacement Door Article No. 95-24-4 12/04/95 ^ DOOR - REPLACEMENT DOOR HAS LOOSE FITTING DOOR LOCK CYLINDER - SERVICE TIP ^ LOCK - LOOSE FITTING DOOR LOCK CYLINDER - SERVICE TIP LIGHT TRUCK: 1981-96 F-150-350 SERIES 1983-96 BRONCO, RANGER 1986-95 AEROSTAR 1988-96 F SUPER DUTY 1992-96 ECONOLINE 1995-96 WINDSTAR MEDIUM/HEAVY TRUCK: 1990-96 F & B SERIES ISSUE: New replacement doors for past model years have a larger lock cylinder hole diameter. A loose fit will occur when installing the door lock cylinder. The lock cylinder mounting hole diameter in new doors has been increased in preparation for a new style lock cylinder. New locks will be phased in for future production. ACTION: Install a spacer for the larger diameter door lock cylinder mounting hole. Refer to the following Service Procedure for details. NOTE: THE DOOR LOCK CYLINDER SPACER HAS BEEN ADDED TO CERTAIN 1996 MODEL YEAR VEHICLES TO ELIMINATE THE LOOSE FIT CONDITION FROM THE SMALLER DOOR LOCK CYLINDER. SOME VEHICLES MAY BE BUILT WITH SPACERS ON ONE SIDE ONLY. THIS IS DUE TO THE BALANCE OF SUPPLIES OF RIGHT AND LEFT DOORS AT THE ASSEMBLY PLANTS AT THE TIME OF MODEL YEAR CHANGEOVER. SERVICE PROCEDURE DOOR LOCK CYLINDER INSTALLATION/REMOVAL 1. Whenever the door lock cylinder is removed, check for presence of lock cylinder spacer in the door in the lock hole. If one is present, check for damage and replace if necessary. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Body and Frame > Locks > Door Locks > Component Information > Technical Service Bulletins > Customer Interest for Door Locks: > 95244 > Dec > 95 > Door Lock Cylinder - Loose in Replacement Door > Page 6405 2. If replacement is necessary, refer to the Lock Spacer Usage Chart (Figure 1) for proper part number application. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Body and Frame > Locks > Door Locks > Component Information > Technical Service Bulletins > Customer Interest for Door Locks: > 95244 > Dec > 95 > Door Lock Cylinder - Loose in Replacement Door > Page 6406 3. Snap a new spacer into the hole from outside the door (Figure 2). DOOR OR LIFTGATE INSTALLATION/REMOVAL When replacing the door of liftgate assembly, the new door or liftgate may have the larger lock cylinder hole. Measure the hole diameter (Figure 2). If dimension "X" is more than 24 mm, then a spacer is required. If it is less than 24 mm, then a spacer cannot be used. NOTE: EVEN IF THE ORIGINAL DOOR HAS A SPACER, ONE IS NOT NEEDED IF THE "X" DIMENSION IS LESS THAN 24 mm IN THE NEW DOOR. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Body and Frame > Locks > Door Locks > Component Information > Technical Service Bulletins > Customer Interest for Door Locks: > 95244 > Dec > 95 > Door Lock Cylinder - Loose in Replacement Door > Page 6407 GENERAL INFORMATION REGARDING SPACER USAGE The purpose of the spacer is to allow the flexibility of phasing in future lock designs without having to coordinate doors and locks in production or having to maintain two unique service doors. In general, the spacers are to be used with new doors (large hole) and old locks. The new doors are being phased in ahead of the new locks. PART NUMBER PART NAME F6TZ-1521890-AA Door Lock cylinder Spacer F6UZ-1521890-AA Door Lock Cylinder Spacer F68Z-1621890-AA Door Lock Cylinder Spacer OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 111000, 112000 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Body and Frame > Locks > Door Locks > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Door Locks: > 95244 > Dec > 95 > Door Lock Cylinder - Loose in Replacement Door Door Locks: All Technical Service Bulletins Door Lock Cylinder - Loose in Replacement Door Article No. 95-24-4 12/04/95 ^ DOOR - REPLACEMENT DOOR HAS LOOSE FITTING DOOR LOCK CYLINDER - SERVICE TIP ^ LOCK - LOOSE FITTING DOOR LOCK CYLINDER - SERVICE TIP LIGHT TRUCK: 1981-96 F-150-350 SERIES 1983-96 BRONCO, RANGER 1986-95 AEROSTAR 1988-96 F SUPER DUTY 1992-96 ECONOLINE 1995-96 WINDSTAR MEDIUM/HEAVY TRUCK: 1990-96 F & B SERIES ISSUE: New replacement doors for past model years have a larger lock cylinder hole diameter. A loose fit will occur when installing the door lock cylinder. The lock cylinder mounting hole diameter in new doors has been increased in preparation for a new style lock cylinder. New locks will be phased in for future production. ACTION: Install a spacer for the larger diameter door lock cylinder mounting hole. Refer to the following Service Procedure for details. NOTE: THE DOOR LOCK CYLINDER SPACER HAS BEEN ADDED TO CERTAIN 1996 MODEL YEAR VEHICLES TO ELIMINATE THE LOOSE FIT CONDITION FROM THE SMALLER DOOR LOCK CYLINDER. SOME VEHICLES MAY BE BUILT WITH SPACERS ON ONE SIDE ONLY. THIS IS DUE TO THE BALANCE OF SUPPLIES OF RIGHT AND LEFT DOORS AT THE ASSEMBLY PLANTS AT THE TIME OF MODEL YEAR CHANGEOVER. SERVICE PROCEDURE DOOR LOCK CYLINDER INSTALLATION/REMOVAL 1. Whenever the door lock cylinder is removed, check for presence of lock cylinder spacer in the door in the lock hole. If one is present, check for damage and replace if necessary. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Body and Frame > Locks > Door Locks > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Door Locks: > 95244 > Dec > 95 > Door Lock Cylinder - Loose in Replacement Door > Page 6413 2. If replacement is necessary, refer to the Lock Spacer Usage Chart (Figure 1) for proper part number application. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Body and Frame > Locks > Door Locks > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Door Locks: > 95244 > Dec > 95 > Door Lock Cylinder - Loose in Replacement Door > Page 6414 3. Snap a new spacer into the hole from outside the door (Figure 2). DOOR OR LIFTGATE INSTALLATION/REMOVAL When replacing the door of liftgate assembly, the new door or liftgate may have the larger lock cylinder hole. Measure the hole diameter (Figure 2). If dimension "X" is more than 24 mm, then a spacer is required. If it is less than 24 mm, then a spacer cannot be used. NOTE: EVEN IF THE ORIGINAL DOOR HAS A SPACER, ONE IS NOT NEEDED IF THE "X" DIMENSION IS LESS THAN 24 mm IN THE NEW DOOR. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Body and Frame > Locks > Door Locks > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Door Locks: > 95244 > Dec > 95 > Door Lock Cylinder - Loose in Replacement Door > Page 6415 GENERAL INFORMATION REGARDING SPACER USAGE The purpose of the spacer is to allow the flexibility of phasing in future lock designs without having to coordinate doors and locks in production or having to maintain two unique service doors. In general, the spacers are to be used with new doors (large hole) and old locks. The new doors are being phased in ahead of the new locks. PART NUMBER PART NAME F6TZ-1521890-AA Door Lock cylinder Spacer F6UZ-1521890-AA Door Lock Cylinder Spacer F68Z-1621890-AA Door Lock Cylinder Spacer OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 111000, 112000 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Body and Frame > Locks > Door Locks > Component Information > Diagrams > Diagram Information and Instructions Door Locks: Diagram Information and Instructions Symbol Identification Wire Color Code Identification Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Body and Frame > Locks > Door Locks > Component Information > Diagrams > Diagram Information and Instructions > Page 6418 NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Body and Frame > Locks > Door Locks > Component Information > Diagrams > Diagram Information and Instructions > Page 6419 Fig. 44 Power Door Lock Wiring Circuit Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Technical Service Bulletins > Customer Interest for Power Door Lock Actuator: > 8871033088 > Mar > 88 > Power Door Locks - Are Inoperative Power Door Lock Actuator: Customer Interest Power Door Locks - Are Inoperative LOCKS - POWER - ROD RETAINER CLIP ASSEMBLY BREAKS OR DISENGAGES POWER DOOR LOCKS - INOPERATIVE - ROD RETAINER CLIP BREAKS OR DISENGAGES Article No. 88-7-1 FORD: 1980-82 GRANADA 1980-83 FAIRMONT 1980-88 MUSTANG, THUNDERBIRD, CROWN VICTORIA 1983-86 LTD 1984-85 ESCORT 1984-88 TEMPO 1986-88 TAURUS LINCOLN-MERCURY: 1980 MONARCH 1980-81 LINCOLN 1980-83 ZEPHYR, MARK VI 1980-86 CAPRI 1980-88 COUGAR, GRAND MARQUIS 1982-88 CONTINENTAL, LINCOLN TOWN CAR 1983-86 MARQUIS 1984-85 LYNX 1984-88 TOPAZ, MARK VII 1986-88 SABLE MERKUR: 1985-88 XR4Ti 1988 SCORPIO LIGHT TRUCK: 1980-88 ECONOLINE 1981-88 F SERIES 1985-86 RANGER, BRONCO II ISSUE: Inoperative power door locks maybe caused by a broken or disengaged lock rod retainer clip assembly. The broken or disengaged retainer clip allows the power lock actuator to disconnect from the actuator rod. ACTION: To correct this, install a new lock rod retainer clip assembly made out of stronger material. Refer to the following removal and installation procedure. 1. Remove door trim panel and water shield. 2. Remove broken or disengaged retainer assembly and replace it with new retainer assembly (E8AZ-5421952-A). NOTE: To prevent damage, make sure the latch assembly is supported from behind before tapping the retainer assembly into the latch assembly. Be careful not to bend the lever of the latch. 3. In some cases, the latch assembly may have to be removed to provide enough space to install the retainer assembly. Refer to Section 44 of the appropriate Shop Manual for latch removal and installation procedures. 4. Reinstall water shield and door trim panel. PART NUMBER PART NAME CLASS E8AZ-5421952-A Retainer Clip Assembly BG OTHER APPLICABLE ARTICLES: 85-12-3 WARRANTY STATUS: "INFORMATION ONLY" Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Door Lock Actuator: > 8871033088 > Mar > 88 > Power Door Locks - Are Inoperative Power Door Lock Actuator: All Technical Service Bulletins Power Door Locks - Are Inoperative LOCKS - POWER - ROD RETAINER CLIP ASSEMBLY BREAKS OR DISENGAGES POWER DOOR LOCKS - INOPERATIVE - ROD RETAINER CLIP BREAKS OR DISENGAGES Article No. 88-7-1 FORD: 1980-82 GRANADA 1980-83 FAIRMONT 1980-88 MUSTANG, THUNDERBIRD, CROWN VICTORIA 1983-86 LTD 1984-85 ESCORT 1984-88 TEMPO 1986-88 TAURUS LINCOLN-MERCURY: 1980 MONARCH 1980-81 LINCOLN 1980-83 ZEPHYR, MARK VI 1980-86 CAPRI 1980-88 COUGAR, GRAND MARQUIS 1982-88 CONTINENTAL, LINCOLN TOWN CAR 1983-86 MARQUIS 1984-85 LYNX 1984-88 TOPAZ, MARK VII 1986-88 SABLE MERKUR: 1985-88 XR4Ti 1988 SCORPIO LIGHT TRUCK: 1980-88 ECONOLINE 1981-88 F SERIES 1985-86 RANGER, BRONCO II ISSUE: Inoperative power door locks maybe caused by a broken or disengaged lock rod retainer clip assembly. The broken or disengaged retainer clip allows the power lock actuator to disconnect from the actuator rod. ACTION: To correct this, install a new lock rod retainer clip assembly made out of stronger material. Refer to the following removal and installation procedure. 1. Remove door trim panel and water shield. 2. Remove broken or disengaged retainer assembly and replace it with new retainer assembly (E8AZ-5421952-A). NOTE: To prevent damage, make sure the latch assembly is supported from behind before tapping the retainer assembly into the latch assembly. Be careful not to bend the lever of the latch. 3. In some cases, the latch assembly may have to be removed to provide enough space to install the retainer assembly. Refer to Section 44 of the appropriate Shop Manual for latch removal and installation procedures. 4. Reinstall water shield and door trim panel. PART NUMBER PART NAME CLASS E8AZ-5421952-A Retainer Clip Assembly BG OTHER APPLICABLE ARTICLES: 85-12-3 WARRANTY STATUS: "INFORMATION ONLY" Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Technical Service Bulletins > Page 6434 Power Door Lock Actuator: Locations Circuit Location Amps Power Door Locks.....................Fuse Panel................30 Power Windows........................Fuse Panel................20 Power Tailgate Window................Fuse Panel................25 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Locations Power Door Lock Switch: Locations In Respective Door Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > By Symptom: > 931910 > Sep > 93 > Paint - Peel Repair Procedures Update Paint: By Symptom Paint - Peel Repair Procedures Update Article No. 93-19-10 09/15/93 PAINT - PEEL REPAIR PROCEDURES - UPDATE LIGHT TRUCK: 1985-91 BRONCO, F-150-350 SERIES 1988-91 F SUPER DUTY, F-47 ISSUE: An updated paint repair procedure TSB has been developed for color peeling caused by ultra violet light penetration. ACTION: If paint repair is required, refer to the following procedure for determining the extent of any repairs and the proper method of performing the required repairs. This procedure must be followed without deviation. Failure to follow procedures will lead to an on-site evaluation, which could result in chargeback of the paint repair. NOTE: READ THE ENTIRE SERVICE PROCEDURE BEFORE BEGINNING REPAIRS. TSB ALLOWANCES INCLUDE: ^ Tape test time ^ Strip to bare metal allowance (0.6 hr. per hour of refinish time) ^ Material allowance for two (2) medium wet coats of prime, three (3) coats of primer/surfacer and three (3) coats of color ^ Use of two-part enamel or urethane materials ^ Allowance for two-tone paint ^ Labor and materials to paint body side insert colors ^ Removal of various trim pieces and/or other components as published TSB ALLOWANCES DO NOT INCLUDE AND CANNOT BE CLAIMED FOR: ^ Strip and refinish of inside of bed ^ Time to repair corrosion (Refer to Warranty Policy Manual.) ^ Time to repair sheet metal damage (owner responsibility) ^ Clearcoat application ^ Bed removal to paint rear of cab ^ Removal of door glass ^ Removal of backlite ^ Painting of door jambs PAINT - EXTERIOR COLOR PEELING CAUSED BY ULTRA VIOLET LIGHT Paint may be damaged because of ultra violet light penetration through the color coat. This damage will cause the color coat to peel to the E-coat. NOTE: THE E-COAT MUST BE COMPLETELY REMOVED BEFORE REFINISHING. WARRANTY OF REFINISH REPAIR Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > By Symptom: > 931910 > Sep > 93 > Paint - Peel Repair Procedures Update > Page 6447 NOTE: USE ONLY ONE PAINT MANUFACTURER'S SYSTEM. DO NOT MIX OR MATCH PAINT PRODUCTS. PAINT MANUFACTURER'S WARRANTY WILL BE VOID IF SYSTEMS ARE COMBINED. DO NOT USE ANY GENERIC PRODUCTS. The aftermarket paint manufacturers are providing a warranty on the paint materials used in the repair of the paint peeling concern. Each company has its own specific warranty time period, and requires that the repair be completed as written in the Technical Service Bulletin article. Any deviation or non-compliance. with this procedure could void the paint manufacturer's material warranty. OUTSIDE LABOR (OSL) REPAIRS The subletting dealer is responsible for ensuring that the outside body shop follows the Paint Comprehensive Peel Repair Procedures described in this TSB article. The outside body shop also should be alerted to the warning information in the TSB article as well as compliance with OSHA requirements. SUBLET REPAIR COSTS Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > By Symptom: > 931910 > Sep > 93 > Paint - Peel Repair Procedures Update > Page 6448 If the cost of the sublet repair is excessive and the dealer cannot resolve the issue with the outside body shop, the Sublet Repair Cost Analysis Form, Figure 6, should be completed by the dealer and faxed to the Customer Assistance Center for review and approval. This form should be attached to the hard copy in the customer's service file and must be retained. INSPECTION PROCEDURE 1. Wash the vehicle with soap and rinse thoroughly. Make sure the vehicle is dry and at room temperature before performing the following test. 2. Verify colorcoat loss of adhesion by applying a 2 inch wide by 15 inch long masking tape strip (3M Automotive 3233 Masking Tape # 06340) on any panel that doesn't exhibit peeling. Do the test above and below the character line. a. Press the tape down firmly and pull the tape up quickly. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > By Symptom: > 931910 > Sep > 93 > Paint - Peel Repair Procedures Update > Page 6449 b. Inspect the adhesive side of the tape for paint removal. c. If paint was removed during the tape test, above and below the character line, repaint the entire vehicle. d. If the paint was removed only from areas above the character line, repaint only the horizontal surfaces of the vehicle (entire area above the character line), Figure 1. 3. No repainting will be completed unless body damage (dings, dents, rust) is repaired prior to refinishing. ^ If the vehicle is within the corrosion and perforation warranty, the vehicle should be handled through that program's provisions. ^ If the vehicle is out of warranty, the customer must agree to pay for the cost of sheetmetal repair of the damaged areas. REPAIR PROCEDURE 1. Mask off all areas on the vehicle which are not going to be painted or will be affected by overspray. 2. Use ONLY the following recommended stripping methods. CAUTION: COMPLETELY STRIP (TO BARE METAL) ALL PANELS TO BE REFINISHED. PAINT STRIPPING INFORMATION WARNING: LEAD CONTAMINATION POTENTIAL - THE ELECTROCOAT PRIMER USED BY FORD MOTOR COMPANY CONTAINS SMALL AMOUNTS OF LEAD FOR CORROSION PROTECTION OF STEEL. READ THE FOLLOWING INFORMATION CAREFULLY AND FORWARD THIS TECHNICAL SERVICE BULLETIN ARTICLE TO ALL EMPLOYEES PERFORMING THE PAINT REMOVAL OPERATION. DEALERS SHOULD CONTACT LEGAL COUNSEL AND/OR LOCAL OSHA AUTHORITIES FOR DIRECTION REGARDING LEAD EXPOSURE REQUIREMENTS. RECOMMENDED SANDING PROCEDURE Ford Motor Company has concluded testing an appropriate method for performing sanding and media blasting in accordance with Federal OSHA Lead Standard CFR 1910.1025. Under this method... Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > By Symptom: > 931910 > Sep > 93 > Paint - Peel Repair Procedures Update > Page 6450 ^ Each technician performing the sanding operation MUST wear an approved respirator with high efficiency particulate filters (HEPA). ^ Technicians should use a dual action sander with vacuum collection equipment. ^ The vacuum equipment MUST be equipped with a HEPA filter on the air exhaust. Dealers are cautioned not to exhaust vacuum air into the atmosphere and operators are cautioned to follow the manufacturer's guidelines for maintenance or replacement of the filters. Remove all paint by sanding the affected areas to clean bare metal. Use 80/180 grit 3M Green Corp. Regalite Dust Free sanding discs or equivalent on a D.A. vacuum sander. RECOMMENDED PLASTIC MEDIA BLASTING PROCEDURE Ford's testing has shown that plastic media blasting meets OSHA lead standard requirements and is efficient when the manufacturer's published procedures are followed. The operator must wear an air supplied hood using compressed air free from carbon monoxide, oil, water, and other contamination when performing this operation. This process is safe to the operator and resists damage to vehicle sheet metal. Plastic is the most popular blasting media for paint removal. Plastic media blasting requires removal of the remaining paint from the masked areas, and a light and fast sanding of the entire vehicle using a dual action sander with 220 grit sandpaper. This surface preparation will provide excellent paint adhesion. Other blast media such as Aluminum Oxide or Sodium Bicarbonate are not recommended. CHEMICAL STRIPPING NOT RECOMMENDED Ford Motor Company does not condone the use of chemical stripping. A majority of the chemical stripping products contain the chemical Methylene Chloride. This chemical is on the Environmental Protection Agency's list of regulated chemicals and is on OSHA's list of chemicals with permissible exposure limits. Injury to employees or the environment could result if proper precautions are not taken during its use. MIL THICKNESS READINGS OF "BARE STEEL" After removing all of the paint from the vehicle, zinc phosphate and galvanized steel coatings are left intact. The following information details the steel coatings systems and body panels which have these systems: ^ (1985-1986) All body panels have Zinc Phosphate metal coating to a thickness of 0.0-0.1 of a mil. ^ (1987-1991) All body panels EXCEPT cowl, fenders, and bed side panels have Zinc Phosphate metal coating to a thickness of 0.0 - 0.1 of a mil. ^ (1987-1991) The cowl, fenders, and bed side panels are Galvanized to a thickness of 0.3-0.5 of a mil. These specifications will effect the overall paint thickness readings. 3. If minor rust is present, remove by sanding or use a small blast and vacuum system. 4. Blow off the entire vehicle to remove loose dust and debris. 5. After stripping, mask all areas on the vehicle that are not to be painted or will be affected by paint overspray (engine compartment, wheels, etc.). Mask all mouldings not removed with Scotch Auto Body Protective Tape # 06945. SURFACE PREPARATION 6. Wipe all affected areas with a fast drying solvent. Wipe dry using a clean, lint-free cloth to remove all residue. CAUTION: KEEP WIPING UNTIL SURFACE IS COMPLETELY DRY. ANY RESIDUE MAY RESULT IN CONTAMINATION OF THE COATINGS TO BE APPLIED FOLLOWING THIS STEP. ^ BASF # 900 ^ PPG # DX-330 ^ S-W # R7-K158 ^ DuPont # 3900S ^ Sikkens # M 600 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > By Symptom: > 931910 > Sep > 93 > Paint - Peel Repair Procedures Update > Page 6451 WARNING: SOME OF THE PRODUCTS SHOWN IN THIS TECHNICAL SERVICE BULLETIN ARTICLE MAY CONTAIN ISOCYANATES. USE A NIOSH/MSHA OR OSHA APPROVED SUPPLIED AIR RESPIRATOR OR AIR SUPPLIED HOOD IN CONFINED AREAS FOR RESPIRATORY PROTECTION. USE APPROPRIATE SKIN AND EYE PROTECTION. ANTI-CORROSION - SELF ETCH PRIMER 7. Tack off the bare metal surface and apply two medium wet coats (.5 mil total) of self-etching, anti-corrosion primer using the manufacturer's label recommendations and flash times. ^ BASF # DE-17 ^ PPG # DX-1791 ^ S-W # E2-G980 ^ DuPont VARIPRIME 615S ^ Sikkens WASHPRIMER CR PRIMER SURFACER 8. Tack off and apply three medium wet coats (2.0 mils total) of acrylic urethane primer/surfacer following the manufacturer's label recommendations and flash times. ^ BASF # DP-20 ^ PPG # K-36 ^ S-W # P6-H49/P6-A48/P6-A47 ^ DuPont 1120S ^ Sikkens AUTOCRYL FILLER 9. Sand the vehicle using one of the following methods: ^ Wet-sand by hand using 400 grit or finer sandpaper. ^ Dry-sand by hand using 320 grit or finer sandpaper. This step will remove approximately .5 mils of material. 10. Blow off the entire vehicle to remove loose dust and debris. PRE-PAINT CLEANING 11. Wipe the entire vehicle with a wax and grease remover type product. ^ BASF # 901 PRE-PAINT CLEANER ^ PPG # DX 220 ^ S-W # R7-K158 ^ DuPont # 3901S FINAL CLEAN ^ Sikkens # M-600 12. Tack off all primed surfaces. TOP COAT APPLICATION 13. Apply three medium wet coats (2.0 mils total) of enamel or urethane single stage following the manufacturer's label recommendations and flash times. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > By Symptom: > 931910 > Sep > 93 > Paint - Peel Repair Procedures Update > Page 6452 ^ BASF # HS SOLO ^ PPG # DELTRON ^ S-W # ULTRA ONE STAGE/TURBO ^ DuPont # CHROMAONE ^ Sikkens # AUTOCRYL NOTE: FORD MOTOR COMPANY WILL NOT PAY FOR CLEARCOAT ON VEHICLES THAT DID NOT HAVE IT AVAILABLE IN PRODUCTION. IF YOUR SHOP ROUTINELY USES BASECOAT/CLEARCOAT, THE APPLICABLE PRODUCTS ARE LISTED IN THE CHART FOR STEP # 13A. 14. After the paint is dry, demask the entire vehicle and clean up any areas which have overspray. 15. Install all trim (mouldings, name plates, striping, etc.) on the vehicle which were removed prior to repainting. Use applicable labor operations. 16. Clean the interior and exterior of the vehicle thoroughly, including air ducts. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > By Symptom: > 931910 > Sep > 93 > Paint - Peel Repair Procedures Update > Page 6453 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > By Symptom: > 931910 > Sep > 93 > Paint - Peel Repair Procedures Update > Page 6454 Labor Time and Material Allowance Chart Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > By Symptom: > 931910 > Sep > 93 > Paint - Peel Repair Procedures Update > Page 6455 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > By Symptom: > 931910 > Sep > 93 > Paint - Peel Repair Procedures Update > Page 6456 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > By Symptom: > 931910 > Sep > 93 > Paint - Peel Repair Procedures Update > Page 6457 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > By Symptom: > 931910 > Sep > 93 > Paint - Peel Repair Procedures Update > Page 6458 The following charts, Figures 2-5, contain all ACCEPTABLE products for refinishing F-Series and Bronco in the Owner Dialogue Program. Acceptable materials are separated into Non-VOC Regulated, VOC Regulated, and Canadian Usage. Any product that is not listed in this TSB article MAY NOT BE USED! OTHER APPLICABLE ARTICLES: 91-18-1 SUPERSEDES: 92-21-8 WARRANTY STATUS: Eligible Under Owner Dialogue Program DEALER CODING BASIC PART NO. CONDITION CODE Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > By Symptom: > 931910 > Sep > 93 > Paint - Peel Repair Procedures Update > Page 6459 ENTRE C1 OASIS CODES: 106000 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 9561 > Mar > 95 > Paint - Iron Particle Removal Paint: All Technical Service Bulletins Paint - Iron Particle Removal Article No. 95-6-1 03/27/95 ^ PAINT - IRON PARTICLE REMOVAL - INDUSTRIAL FALLOUT - ACID RAIN NEUTRALIZATION ^ PAINT - ROUGH TEXTURE/FERROUS METAL CONTAMINATION - ACID RAIN DISCOLORATION OR ETCHING FORD: 1980 and after CROWN VICTORIA, ESCORT, MUSTANG, THUNDERBIRD 1982-88 EXP 1984-94 TEMPO 1986 and after TAURUS 1988-93 FESTIVA 1989 and after PROBE 1994-95 ASPIRE 1995 CONTOUR LINCOLN-MERCURY: 1980 and after CONTINENTAL, COUGAR, GRAND MARQUIS, TOWN CAR 1981-87 LYNX 1984-92 MARK VII 1984-94 TOPAZ 1986 and after SABLE 1987-89 TRACER 1991-94 CAPRI 1991 and after TRACER 1993 and after MARK VIII 1995 MYSTIQUE MERKUR: 1985-89 XR4TI 1988-89 SCORPIO LIGHT TRUCK: 1980 and after F-150-350 SERIES 1981 and after ECONOLINE 1982 and after BRONCO 1983 and after RANGER 1984-90 BRONCO II 1986 and after AEROSTAR 1988 and after F SUPER DUTY 1991 and after EXPLORER 1993 and after VILLAGER 1995 and after WINDSTAR MEDIUM/HEAVY TRUCK: 1980-91 C SERIES, CL-CLT-9000 SERIES 1980 and after F & B SERIES, L SERIES 1986 and after CARGO SERIES ISSUE: Ferrous metal particles (hot iron dust) are generated by manufacturing facilities, rail shipments, combustion engines, jet engines, body shops, etc. These particles mechanically/magnetically bond to vehicles' painted surfaces. Moisture and temperature combine with the particles to create a chemical reaction. The reaction causes the particles to corrode and enter into the physical paint film. ACTION: To remove these particles/contaminants, USE ONLY the following procedure. The procedure must be performed before any buffing, polishing, color sanding or refinishing is attempted. The materials in this procedure are alkaline, acidic and neutral. They must be used in the specified order. CAUTION: ANY CHANGES TO THIS PROCEDURE WILL CAUSE AN INCOMPLETE OR UNSATISFACTORY REPAIR AND MAY RESULT IN Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 9561 > Mar > 95 > Paint - Iron Particle Removal > Page 6465 POSSIBLE DAMAGE TO THE PAINTED SURFACES AND TRIM. WARNING: THE TECHNICIAN MUST WEAR PROTECTIVE CLOTHING AND EYE PROTECTION TO PREVENT SKIN IRRITATION. CAUTION: THE USE OF ANY OTHER PRODUCT OR PROCEDURE MAY CAUSE DAMAGE TO ALUMINUM, FLEXIBLE PAINTED SURFACES OR OTHER PAINTED SURFACES. FOLLOW DIRECTIONS EXACTLY AND RINSE THOROUGHLY AFTER EACH STEP. NOTE: THIS DECONTAMINATION PROCEDURE IS DESIGNED TO REMOVE SURFACE CONTAMINANTS FROM THE PAINT ON VEHICLES THAT HAVE BEEN CONTAMINATED UP TO 120 DAYS. VEHICLES WHICH HAVE EXPERIENCED THE CONDITION LONGER THAN THIS PERIOD MAY REQUIRE AN ADDITIONAL TREATMENT TO REMOVE FERROUS METAL CONTAMINANTS. IDENTIFICATION Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 9561 > Mar > 95 > Paint - Iron Particle Removal > Page 6466 For ease of identifying, the Radio Shack Model 63-851, 30X, lighted, magnifier is recommended. 1. Ferrous Metal ^ Light colored vehicles: Small rust orange dots with black in center of stain. ^ Dark colored vehicles: Small white or silver dots with a "rainbow hue" around the particle. The surface will also feel rough to the touch. 2. Industrial Fallout ^ The surface feels rough to the touch and may exhibit crystalline deposits. ^ Usually ferrous metal is present, as well as water spots. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 9561 > Mar > 95 > Paint - Iron Particle Removal > Page 6467 3. Acid Rain ^ Surface will exhibit irregular discolored spotting. ^ Dark colored vehicles will show cloudy or greying spots where the acids have started to etch away the paint. NOTE: IN EXTREME CASES ETCHING OF THE SURFACE WILL BE VISIBLE OR FELT. DECONTAMINATION Use Finish Kare Inc. products 1119/883/11850 to decontaminate the paint surface. Follow the manufacturer's recommended procedures. NOTE: FORD DOES NOT RECOMMEND THE USE OF OXALIC ACIDS OR OTHER "FALLOUT REMOVERS". 1. Rinse off dust and debris with cold water. Be sure to start at the bottom and work up. 2. Prepare product "1119" by mixing one (1) part "1119" with four (4) parts cold water. 3. Use clean wash mitt and apply mixture to entire car, starting at the bottom and working up to the top surface. Keep car wet with the solution for 5 to 10 minutes. Do not allow product to dry on the car, and do not allow it to streak down the sides. Rewipe with mitt if necessary to avoid streaks. 4. Rinse car with cold water. 5. Dry the flat surfaces of the vehicle hood, roof and deck lid. 6. Apply product "883" directly to the contaminated surfaces using a clean dry sponge, wash mitt, or soft truck brush ("883" is ready to use from the bottle, with no mixing involved). Keep the areas wet with the "883" for 5 to 7 minutes. Do not allow to dry on the car. Wipe down to the body line on the sides. 7. Prepare product "118SC" by mixing 1 oz (0.03 L) with 1 gal (3.785 L) of water. 8. Shampoo the vehicle with "118SC" shampoo mixture using a clean wash mitt and then rinse with cold water. NOTE: DO NOT USE "1185C" MITT WITH "1119" OR "883" SOLUTIONS. USE SEPARATE MITTS AND ALWAYS KEEP THEM SEPARATE. 9. Inspect paint surface to see if rust particles have been removed. If rust particles have been on the vehicle for a long time, it may be necessary to repeat each of the above steps. NOTE: THE NEUTRALIZER CONCENTRATE IS A HEAVY DUTY SHAMPOO AND CAN BE USED IN AN AUTOMATIC CAR WASH SYSTEM. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 9561 > Mar > 95 > Paint - Iron Particle Removal > Page 6468 CORRECTION OF SURFACE FOLLOWING DECONTAMINATION: 1. Visually inspect surface for evidence of removal of ferrous metal particles, crystalline deposits and water spots. Acid rain discoloring or etching will require either buffing, color sanding or refinishing if etching is visible. 2. Use the buffing products from only one (1) manufacturer. Do not intermix products. 3. Always follow the manufacturer's product sequence. Use appropriate pads with each product as recommended by the manufacturer. NOTE: DO NOT REMOVE MORE THAN 0.3 OF A MIL OF PAINT MATERIAL, OR REPAINTING WILL BE REQUIRED. 4. Use a dual action sander (D/A Sander) with a velcro-mount backing plate and appropriate foam pad for final polishing swirl removal. 5. Use an alcohol and water mixture (1:4 ratio) to clean buffed areas to verify removal of scratches and swirls before application of final protective glaze. NOTE: FREQUENT WASHING OF VEHICLES IS IMPORTANT. CONTAMINANTS SETTLE ONTO THE VEHICLE EVERY DAY. USE CLEAN WATER (DEIONIZED, REVERSE OSMOSIS, ETC.) TWICE WEEKLY TO REMOVE HEAVY DUST, AND PARTICULATES. THE USE OF A NEUTRAL pH CAR WASH SOAP EVERY TWO (2) WEEKS IS RECOMMENDED TO NEUTRALIZE VEHICLE CONTAMINATION. Parts Block NOTE: DEALERS SHOULD USE PROGRAM CODE R-23 AND CONDITION CODES C5 AND C6. REFER TO W & P MANUAL, SECTION 5-1, PAGE 3. OTHER APPLICABLE ARTICLES: 91-18-1, 92-6-4 WARRANTY STATUS: Eligible Under The Provisions Of 12 Month/12,000 Mile Basic Warranty Coverage OPERATION DESCRIPTION TIME 950601A Decontaminate And Surface 0.6 Hr. Correction - Aspire 950601B Decontaminate And Surface 0.6 Hr. Correction - Escort/Tracer 950601C Decontaminate And Surface 0.6 Hr. Correction - Probe Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 9561 > Mar > 95 > Paint - Iron Particle Removal > Page 6469 950601D Decontaminate And Surface 0.6 Hr. Correction - Contour/Mystique 950601E Decontaminate And Surface 0.6 Hr. Correction - Mustang 950601F Decontaminate And Surface 0.7 Hr. Correction - Taurus/Sable 950601G Decontaminate And Surface 0.7 Hr. Correction - Thunderbird/Cougar 950601H Decontaminate And Surface 0.7 Hr. Correction - Crown Victoria/Grand Marquis 950601I Decontaminate And Surface 0.7 Hr. Correction - Mark VIII 950601J Decontaminate And Surface 0.7 Hr. Correction - Continental 950601K Decontaminate And Surface 0.6 Hr. Correction - Capri 950601L Decontaminate And Surface 0.8 Hr. Correction - Town Car 950601M Decontaminate And Surface 0.7 Hr. Correction - Villager 950601N Decontaminate And Surface 0.6 Hr. Correction - Windstar 9506010 Decontaminate And Surface 0.7 Hr. Correction - Aerostar 950601P Decontaminate And Surface 0.6 Hr. Correction - Bronco 9506010 Decontaminate And Surface 1.1 Hrs. Correction - Econoline 950601R Decontaminate And Surface 0.9 Hr. Correction - F-Series 950601S Decontaminate And Surface 0.6 Hr. Correction - Explorer 950601T Decontaminate And Surface 0.7 Hr. Correction - Ranger 950601U Decontaminate And Surface 0.5 Hr. Correction - F-Super Duty 950601V Decontaminate And Surface 0.7 Hr. Correction - F/B-Series 950601W Decontaminate And Surface 0.7 Hr. Correction - L-Series 950601X Decontaminate And Surface 0.5 Hr. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 9561 > Mar > 95 > Paint - Iron Particle Removal > Page 6470 Correction - Cargo 950601Y Decontaminate And Surface 0.6 Hr. Correction - Tempo/Topaz DEALER CODING BASIC PART NO. CONDITION CODE ENTRE C5 OR C6 OASIS CODES: 106000 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 94234 > Nov > 94 > Paint - Preparation Procedure And MSDS Information Paint: All Technical Service Bulletins Paint - Preparation Procedure And MSDS Information Article No. 94-23-4 11/14/94 PAINT - PRIMED SHEET METAL - PREP PROCEDURE AND MSDS INFORMATION FORD: 1980 and after CROWN VICTORIA, ESCORT, MUSTANG, THUNDERBIRD 1982-88 EXP 1984 and after TEMPO 1986 and after TAURUS 1988-93 FESTIVA 1989 and after PROBE LINCOLN-MERCURY: 1980 and after CONTINENTAL, COUGAR, GRAND MARQUIS, TOWN CAR 1981-87 LYNX 1984-92 MARK VII 1984 and after TOPAZ 1986 and after SABLE 1987-89 TRACER 1991-94 CAPRI 1993 and after MARK VIII MERKUR: 1985-89 XR4TI 1988-90 SCORPIO LIGHT TRUCK: 1980 and after F-150-350 SERIES 1981 and after ECONOLINE 1982 and after BRONCO 1983 and after RANGER 1984-90 BRONCO II 1986 and after AEROSTAR 1988 and after F SUPER DUTY 1991 and after EXPLORER 1993 and after VILLAGER 1995 WINDSTAR MEDIUM/HEAVY TRUCK: 1980-91 C SERIES, CL-CLT-9000 SERIES 1980 and after F & B SERIES, L SERIES 1986 and after CARGO SERIES ISSUE: This procedure is being published to advise all body and paint technicians about proper procedures for preparation of sheet metal parts coated with electrodeposition primer (E-Coat). ACTION: When prepping a replacement body panel for installation, it is mandatory to leave the E-Coat intact. DO NOT SAND OFF THE E-COAT. Improper preparation with excessive sanding of the E-Coat to bare metal will jeopardize the sheet metal warranty and overall customer satisfaction. In particular, the E-Coat is necessary to protect the parts from rust. Light scuff sanding using a Scotch Brite pad or wet 320 grit sand paper is recommended for minor flaws. If a minor flaw exists, wet sand or scuff out the flaw and prime the repair area. Again, do not remove all of the E-Coat from the panel. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 94234 > Nov > 94 > Paint - Preparation Procedure And MSDS Information > Page 6475 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 94234 > Nov > 94 > Paint - Preparation Procedure And MSDS Information > Page 6476 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 94234 > Nov > 94 > Paint - Preparation Procedure And MSDS Information > Page 6477 WARNING: LEAD CONTAMINATION POTENTIAL: THE ELECTRODEPOSITION PRIMER USED BY FORD MOTOR COMPANY OVER BASE METAL ON SERVICE REPLACEMENT PARTS OR COMPLETED VEHICLES CONTAINS SMALL AMOUNTS OF LEAD FOR CORROSION PROTECTION OF STEEL. EXCESSIVE DUSTS GENERATED BY UNNECESSARY AND IMPROPER SANDING MAY CONTAIN AIRBORNE LEAD CONTAMINATION IN EXCESS OF OSHA STANDARDS. INFORMATION REGARDING THE HAZARDS OF LEAD CAN BE FOUND IN THE CHEMICAL FACT SHEETS IN THE FIGURES IN THIS ARTICLE. NOTE: READ ALL INFORMATION IN THIS TECHNICAL SERVICE BULLETIN CAREFULLY AND FORWARD TO ALL EMPLOYEES PERFORMING PAINT PREPPING OPERATIONS. DEALERS SHOULD CONTACT LEGAL COUNSEL AND/OR LOCAL OSHA Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 94234 > Nov > 94 > Paint - Preparation Procedure And MSDS Information > Page 6478 AUTHORITIES FOR DIRECTION REGARDING OSHA LEAD STANDARD REQUIREMENTS. If a replacement body panel contains more than a minor flaw in the E-coat, it should be returned. Contact your Customer Service representative for instructions. If more extensive sanding, other than that described above, is necessary, (e.g., refinishing original vehicle sheet metal) follow the procedures outlined below: ALTERNATIVE SANDING PROCEDURES WHEN EXTENSIVE SANDING IS REQUIRED The following procedures for sheet metal preparation by sanding or media blasting are based on tests conducted by Ford Motor Company in accordance with requirements set forth in the Federal OSHA Inorganic Lead Standard 29 CFR 1910.1025. SANDING PROCEDURE 1. Each technician performing the sanding operation MUST wear an approved respirator with high efficiency particulate filter (HEPA). 2. Technicians should use dual action sander with vacuum collection. 3. The vacuum equipment MUST be equipped with a HEPA filter on the air exhaust. Dealers are cautioned not to exhaust vacuum air into the atmosphere. Operators are cautioned to follow the manufacturer's guidelines for maintenance and the replacement of filters. MEDIA BLASTING PROCEDURE 1. Testing has shown that plastic media blasting meets OSHA lead standard requirements and is efficient when the manufacturer's published procedures are followed. 2. The operator must wear an air supplied hood using compressed air free from carbon monoxide, oil, water, and other contamination when performing this operation. Specifics of the media blasting procedure for whole body paint removal have been previously published. NOTE: PLEASE READ THE CHEMICAL FACT SHEETS IN THE FIGURES. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 106000 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 931910 > Sep > 93 > Paint - Peel Repair Procedures Update Paint: All Technical Service Bulletins Paint - Peel Repair Procedures Update Article No. 93-19-10 09/15/93 PAINT - PEEL REPAIR PROCEDURES - UPDATE LIGHT TRUCK: 1985-91 BRONCO, F-150-350 SERIES 1988-91 F SUPER DUTY, F-47 ISSUE: An updated paint repair procedure TSB has been developed for color peeling caused by ultra violet light penetration. ACTION: If paint repair is required, refer to the following procedure for determining the extent of any repairs and the proper method of performing the required repairs. This procedure must be followed without deviation. Failure to follow procedures will lead to an on-site evaluation, which could result in chargeback of the paint repair. NOTE: READ THE ENTIRE SERVICE PROCEDURE BEFORE BEGINNING REPAIRS. TSB ALLOWANCES INCLUDE: ^ Tape test time ^ Strip to bare metal allowance (0.6 hr. per hour of refinish time) ^ Material allowance for two (2) medium wet coats of prime, three (3) coats of primer/surfacer and three (3) coats of color ^ Use of two-part enamel or urethane materials ^ Allowance for two-tone paint ^ Labor and materials to paint body side insert colors ^ Removal of various trim pieces and/or other components as published TSB ALLOWANCES DO NOT INCLUDE AND CANNOT BE CLAIMED FOR: ^ Strip and refinish of inside of bed ^ Time to repair corrosion (Refer to Warranty Policy Manual.) ^ Time to repair sheet metal damage (owner responsibility) ^ Clearcoat application ^ Bed removal to paint rear of cab ^ Removal of door glass ^ Removal of backlite ^ Painting of door jambs PAINT - EXTERIOR COLOR PEELING CAUSED BY ULTRA VIOLET LIGHT Paint may be damaged because of ultra violet light penetration through the color coat. This damage will cause the color coat to peel to the E-coat. NOTE: THE E-COAT MUST BE COMPLETELY REMOVED BEFORE REFINISHING. WARRANTY OF REFINISH REPAIR Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 931910 > Sep > 93 > Paint - Peel Repair Procedures Update > Page 6483 NOTE: USE ONLY ONE PAINT MANUFACTURER'S SYSTEM. DO NOT MIX OR MATCH PAINT PRODUCTS. PAINT MANUFACTURER'S WARRANTY WILL BE VOID IF SYSTEMS ARE COMBINED. DO NOT USE ANY GENERIC PRODUCTS. The aftermarket paint manufacturers are providing a warranty on the paint materials used in the repair of the paint peeling concern. Each company has its own specific warranty time period, and requires that the repair be completed as written in the Technical Service Bulletin article. Any deviation or non-compliance. with this procedure could void the paint manufacturer's material warranty. OUTSIDE LABOR (OSL) REPAIRS The subletting dealer is responsible for ensuring that the outside body shop follows the Paint Comprehensive Peel Repair Procedures described in this TSB article. The outside body shop also should be alerted to the warning information in the TSB article as well as compliance with OSHA requirements. SUBLET REPAIR COSTS Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 931910 > Sep > 93 > Paint - Peel Repair Procedures Update > Page 6484 If the cost of the sublet repair is excessive and the dealer cannot resolve the issue with the outside body shop, the Sublet Repair Cost Analysis Form, Figure 6, should be completed by the dealer and faxed to the Customer Assistance Center for review and approval. This form should be attached to the hard copy in the customer's service file and must be retained. INSPECTION PROCEDURE 1. Wash the vehicle with soap and rinse thoroughly. Make sure the vehicle is dry and at room temperature before performing the following test. 2. Verify colorcoat loss of adhesion by applying a 2 inch wide by 15 inch long masking tape strip (3M Automotive 3233 Masking Tape # 06340) on any panel that doesn't exhibit peeling. Do the test above and below the character line. a. Press the tape down firmly and pull the tape up quickly. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 931910 > Sep > 93 > Paint - Peel Repair Procedures Update > Page 6485 b. Inspect the adhesive side of the tape for paint removal. c. If paint was removed during the tape test, above and below the character line, repaint the entire vehicle. d. If the paint was removed only from areas above the character line, repaint only the horizontal surfaces of the vehicle (entire area above the character line), Figure 1. 3. No repainting will be completed unless body damage (dings, dents, rust) is repaired prior to refinishing. ^ If the vehicle is within the corrosion and perforation warranty, the vehicle should be handled through that program's provisions. ^ If the vehicle is out of warranty, the customer must agree to pay for the cost of sheetmetal repair of the damaged areas. REPAIR PROCEDURE 1. Mask off all areas on the vehicle which are not going to be painted or will be affected by overspray. 2. Use ONLY the following recommended stripping methods. CAUTION: COMPLETELY STRIP (TO BARE METAL) ALL PANELS TO BE REFINISHED. PAINT STRIPPING INFORMATION WARNING: LEAD CONTAMINATION POTENTIAL - THE ELECTROCOAT PRIMER USED BY FORD MOTOR COMPANY CONTAINS SMALL AMOUNTS OF LEAD FOR CORROSION PROTECTION OF STEEL. READ THE FOLLOWING INFORMATION CAREFULLY AND FORWARD THIS TECHNICAL SERVICE BULLETIN ARTICLE TO ALL EMPLOYEES PERFORMING THE PAINT REMOVAL OPERATION. DEALERS SHOULD CONTACT LEGAL COUNSEL AND/OR LOCAL OSHA AUTHORITIES FOR DIRECTION REGARDING LEAD EXPOSURE REQUIREMENTS. RECOMMENDED SANDING PROCEDURE Ford Motor Company has concluded testing an appropriate method for performing sanding and media blasting in accordance with Federal OSHA Lead Standard CFR 1910.1025. Under this method... Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 931910 > Sep > 93 > Paint - Peel Repair Procedures Update > Page 6486 ^ Each technician performing the sanding operation MUST wear an approved respirator with high efficiency particulate filters (HEPA). ^ Technicians should use a dual action sander with vacuum collection equipment. ^ The vacuum equipment MUST be equipped with a HEPA filter on the air exhaust. Dealers are cautioned not to exhaust vacuum air into the atmosphere and operators are cautioned to follow the manufacturer's guidelines for maintenance or replacement of the filters. Remove all paint by sanding the affected areas to clean bare metal. Use 80/180 grit 3M Green Corp. Regalite Dust Free sanding discs or equivalent on a D.A. vacuum sander. RECOMMENDED PLASTIC MEDIA BLASTING PROCEDURE Ford's testing has shown that plastic media blasting meets OSHA lead standard requirements and is efficient when the manufacturer's published procedures are followed. The operator must wear an air supplied hood using compressed air free from carbon monoxide, oil, water, and other contamination when performing this operation. This process is safe to the operator and resists damage to vehicle sheet metal. Plastic is the most popular blasting media for paint removal. Plastic media blasting requires removal of the remaining paint from the masked areas, and a light and fast sanding of the entire vehicle using a dual action sander with 220 grit sandpaper. This surface preparation will provide excellent paint adhesion. Other blast media such as Aluminum Oxide or Sodium Bicarbonate are not recommended. CHEMICAL STRIPPING NOT RECOMMENDED Ford Motor Company does not condone the use of chemical stripping. A majority of the chemical stripping products contain the chemical Methylene Chloride. This chemical is on the Environmental Protection Agency's list of regulated chemicals and is on OSHA's list of chemicals with permissible exposure limits. Injury to employees or the environment could result if proper precautions are not taken during its use. MIL THICKNESS READINGS OF "BARE STEEL" After removing all of the paint from the vehicle, zinc phosphate and galvanized steel coatings are left intact. The following information details the steel coatings systems and body panels which have these systems: ^ (1985-1986) All body panels have Zinc Phosphate metal coating to a thickness of 0.0-0.1 of a mil. ^ (1987-1991) All body panels EXCEPT cowl, fenders, and bed side panels have Zinc Phosphate metal coating to a thickness of 0.0 - 0.1 of a mil. ^ (1987-1991) The cowl, fenders, and bed side panels are Galvanized to a thickness of 0.3-0.5 of a mil. These specifications will effect the overall paint thickness readings. 3. If minor rust is present, remove by sanding or use a small blast and vacuum system. 4. Blow off the entire vehicle to remove loose dust and debris. 5. After stripping, mask all areas on the vehicle that are not to be painted or will be affected by paint overspray (engine compartment, wheels, etc.). Mask all mouldings not removed with Scotch Auto Body Protective Tape # 06945. SURFACE PREPARATION 6. Wipe all affected areas with a fast drying solvent. Wipe dry using a clean, lint-free cloth to remove all residue. CAUTION: KEEP WIPING UNTIL SURFACE IS COMPLETELY DRY. ANY RESIDUE MAY RESULT IN CONTAMINATION OF THE COATINGS TO BE APPLIED FOLLOWING THIS STEP. ^ BASF # 900 ^ PPG # DX-330 ^ S-W # R7-K158 ^ DuPont # 3900S ^ Sikkens # M 600 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 931910 > Sep > 93 > Paint - Peel Repair Procedures Update > Page 6487 WARNING: SOME OF THE PRODUCTS SHOWN IN THIS TECHNICAL SERVICE BULLETIN ARTICLE MAY CONTAIN ISOCYANATES. USE A NIOSH/MSHA OR OSHA APPROVED SUPPLIED AIR RESPIRATOR OR AIR SUPPLIED HOOD IN CONFINED AREAS FOR RESPIRATORY PROTECTION. USE APPROPRIATE SKIN AND EYE PROTECTION. ANTI-CORROSION - SELF ETCH PRIMER 7. Tack off the bare metal surface and apply two medium wet coats (.5 mil total) of self-etching, anti-corrosion primer using the manufacturer's label recommendations and flash times. ^ BASF # DE-17 ^ PPG # DX-1791 ^ S-W # E2-G980 ^ DuPont VARIPRIME 615S ^ Sikkens WASHPRIMER CR PRIMER SURFACER 8. Tack off and apply three medium wet coats (2.0 mils total) of acrylic urethane primer/surfacer following the manufacturer's label recommendations and flash times. ^ BASF # DP-20 ^ PPG # K-36 ^ S-W # P6-H49/P6-A48/P6-A47 ^ DuPont 1120S ^ Sikkens AUTOCRYL FILLER 9. Sand the vehicle using one of the following methods: ^ Wet-sand by hand using 400 grit or finer sandpaper. ^ Dry-sand by hand using 320 grit or finer sandpaper. This step will remove approximately .5 mils of material. 10. Blow off the entire vehicle to remove loose dust and debris. PRE-PAINT CLEANING 11. Wipe the entire vehicle with a wax and grease remover type product. ^ BASF # 901 PRE-PAINT CLEANER ^ PPG # DX 220 ^ S-W # R7-K158 ^ DuPont # 3901S FINAL CLEAN ^ Sikkens # M-600 12. Tack off all primed surfaces. TOP COAT APPLICATION 13. Apply three medium wet coats (2.0 mils total) of enamel or urethane single stage following the manufacturer's label recommendations and flash times. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 931910 > Sep > 93 > Paint - Peel Repair Procedures Update > Page 6488 ^ BASF # HS SOLO ^ PPG # DELTRON ^ S-W # ULTRA ONE STAGE/TURBO ^ DuPont # CHROMAONE ^ Sikkens # AUTOCRYL NOTE: FORD MOTOR COMPANY WILL NOT PAY FOR CLEARCOAT ON VEHICLES THAT DID NOT HAVE IT AVAILABLE IN PRODUCTION. IF YOUR SHOP ROUTINELY USES BASECOAT/CLEARCOAT, THE APPLICABLE PRODUCTS ARE LISTED IN THE CHART FOR STEP # 13A. 14. After the paint is dry, demask the entire vehicle and clean up any areas which have overspray. 15. Install all trim (mouldings, name plates, striping, etc.) on the vehicle which were removed prior to repainting. Use applicable labor operations. 16. Clean the interior and exterior of the vehicle thoroughly, including air ducts. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 931910 > Sep > 93 > Paint - Peel Repair Procedures Update > Page 6489 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 931910 > Sep > 93 > Paint - Peel Repair Procedures Update > Page 6490 Labor Time and Material Allowance Chart Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 931910 > Sep > 93 > Paint - Peel Repair Procedures Update > Page 6491 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 931910 > Sep > 93 > Paint - Peel Repair Procedures Update > Page 6492 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 931910 > Sep > 93 > Paint - Peel Repair Procedures Update > Page 6493 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 931910 > Sep > 93 > Paint - Peel Repair Procedures Update > Page 6494 The following charts, Figures 2-5, contain all ACCEPTABLE products for refinishing F-Series and Bronco in the Owner Dialogue Program. Acceptable materials are separated into Non-VOC Regulated, VOC Regulated, and Canadian Usage. Any product that is not listed in this TSB article MAY NOT BE USED! OTHER APPLICABLE ARTICLES: 91-18-1 SUPERSEDES: 92-21-8 WARRANTY STATUS: Eligible Under Owner Dialogue Program DEALER CODING BASIC PART NO. CONDITION CODE Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 931910 > Sep > 93 > Paint - Peel Repair Procedures Update > Page 6495 ENTRE C1 OASIS CODES: 106000 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 9366 > Mar > 93 > Paint to Match Parts - Generic Paint Procedure Paint: All Technical Service Bulletins Paint to Match Parts - Generic Paint Procedure Article No. 93-6-6 03/17/93 PAINT - "DEALER PAINT TO MATCH" PARTS - GENERIC PAINTING PROCEDURE FLARESIDE FENDER AND DUAL REAR WHEEL MODELS WITH PICKUP BOX LIGHT TRUCK: 1980-92 F-150-350 SERIES ISSUE: Ford Motor Company is continuing to supply selected parts in "Dealer Paint To Match" form. These selected parts are not painted and require painting at the dealership. ACTION: Use the following painting procedure as a generic process for preparing SMC (Sheet Moulded Compound) plastic body panels. 1. Wash the panel down with detergent and medium warm water. 2. Scuff the entire panel with a "Scotchbrite" fine pad. 3. Blow off the panel to remove debris. 4. Use a low VOC (Volatile Organic Compound) type wax and grease remover or pre-paint cleaner to clean the part. WARNING: REGULAR WAX AND GREASE REMOVERS CONTAIN LOW FLASH POINT SOLVENTS THAT MAY IGNITE WHEN CLEANING PLASTIC. THIS IS DUE TO STATIC ELECTRICITY BUILD UP. 5. Mix and apply one (1) coat of epoxy primer and let flash per the manufacturer's label instructions. 6. Mix and apply one (1) coat of colored urethane primer/sufacer or primer/sealer per the manufacturer's label instructions. 7. Mix and apply either single stage or basecoat/clearcoat paint system per vehicle requirement. Use manufacturer's label instructions. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 106000, 111000, 190000 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 91181 > Sep > 91 > Exterior Paint - Comprehensive Repair Procedures Technical Service Bulletin # 91181 Date: 910905 Exterior Paint - Comprehensive Repair Procedures Article No. 91-18-1 09/05/91 PAINT-EXTERIOR-COMPREHENSIVE REPAIR PROCEDURES FORD: 1985-86 LTD 1985-92 CROWN VICTORIA, ESCORT, MUSTANG, TEMPO, THUNDERBIRD 1986-92 TAURUS 1988-92 FESTIVA 1989-92 PROBE LINCOLN-MERCURY: 1985-86 CAPRI, MARQUIS 1985-87 LYNX 1985-92 CONTINENTAL, COUGAR, GRAND MARQUIS, MARK VII, TOPAZ, TOWN CAR 1986-92 SABLE 1988-92 TRACER MERKUR: 1985-89 XR4TI 1988-89 SCORPIO LIGHT TRUCK: 1985-90 BRONCO II 1985-92 BRONCO, ECONOLINE, F-150-350 SERIES, RANGER 1986-92 AEROSTAR 1991 EXPLORER ISSUE: A comprehensive paint repair procedure TSB has been developed for service use. It includes the following paint repair topics: Section (A) has been superseded by TSB # 9264, dated 3/92. (B) Exterior Color Peeling From Ultra Violet Light (C) Lower Body Stone Protection Repair Tips (D) Procedures For PVC Body Side Moldings (E) Lower Body-Side Stone Chip Protection Program (F) Surface Defect Removal Without Repainting (G) 1991 Color Matched/Compatible Spray Primer Chart (H) Repair For Tinted Clearcoat (I) Frequently Used And Paintable Plastics (J) 1992 Paint Codes ACTION: If paint repair is required, refer to the following procedures for paint restoration. Section A Has Been Superseded By TSB # 9264, Dated 3/92. CAUTION: FAILURE TO THOROUGHLY RINSE THIS SURFACE COULD RESULT IN CORROSION OF ANODIZED ALUMINUM OR STAINLESS STEEL PARTS PROCEDURE # 2 FINISH KARE FORMULA # 1119 AND # 883 (Buffered solution not as harsh on aluminum parts) WARNING: FOR YOUR SAFETY, USE RUBBER GLOVES, GOGGLES AND PROTECTIVE CLOTHING WHEN HANDLING THESE PRODUCTS. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 91181 > Sep > 91 > Exterior Paint - Comprehensive Repair Procedures > Page 6504 1. Apply hot diluted solution with soft mitt. 2. Agitate to create suds. Suds hold the acid solution in suspension and to the surface creating greater and extended activity. 3. Allow 3 to 5 minutes dwell time. 4. Rinse with COLD WATER. 5. Apply # 883 per label instructions. LIQUID NEUTRALIZER CONCENTRATE 1. Using a mitt, thoroughly go over the entire surface with the diluted solution (50-1) of water and # 118 Liquid Neutralizer Concentrate. Then wipe dry. 2. If the iron particles are not totally removed after 2 washings, use one or both of the following service actions. a. Sand with micro fine sandpaper (1500 Grid or greater) in localized areas. b. Buff with very light compound and polish with wax in localized areas. WARNING: OUR ENVIRONMENT IS PRECIOUS - PLEASE USE PROPER DISPOSAL TECHNIQUES FOR ANY VOLATILE ORGANIC COMPOUNDS (V.O.C.'S) OR EXCESS MATERIALS. (B) Paint Exterior Color Peeling From Ultra Violet Light Paint may be damaged because of ultra violet light absorption through the color coat. This damage will cause the top coat to peel to the E-coat primer. If service is required, use the following procedure to correct the concerns. NOTE: READ THE ENTIRE SERVICE PROCEDURE BEFORE STARTING REPAIRS. WARNING: ALWAYS WEAR A NOISHA/MSHA RECOMMENDED VAPOR/PARTICULATE RESPIRATOR AND USE OTHER RECOMMENDED SAFETY EQUIPMENT. 1. Wash the vehicle with soap and water. 2. Verify topcoat adhesion by applying a 2 inch wide masking tape strip on all body panels above and below the beltline on each panel. a. Pull the tape up quickly. b. Inspect the adhesive side of the tape for paint removal. NOTE: IF PAINT WAS REMOVED DURING THE TAPE TEST, THE ENTIRE PANEL SHOULD BE STRIPPED AND REFINISHED AS NECESSARY. 3. Remove all trim (mouldings, name plates, striping, etc.) from the areas which will be repainted. NOTE: ALL REQUIRED REPLACEMENT MOULDINGS AND STRIPES SHOULD BE ORDERED AND RECEIVED PRIOR TO REPAIRING THE CUSTOMER'S VEHICLE. 4. Wipe the entire vehicle with wax and grease remover. ^ BASF Product # 900 Prekleano ^ PPG Product # DX300 ^ S-W Product # R7-K156 ^ DuPont Product # 3919 S ^ Sikkens Product # M 600 5. Mask off all areas on the vehicle which are not going to be painted or will be affected by overspray (engine compartment, wheels, etc.). Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 91181 > Sep > 91 > Exterior Paint - Comprehensive Repair Procedures > Page 6505 6. Remove the paint to bare metal from all the areas of the vehicle which are going to be repainted. Use one of the following methods. SAND THE AFFECTED AREAS TO BARE METAL USING 40 GRIT 3M GREEN CORPS SANDING DISCS OR EQUIVALENT AND A SOFT PAD ON A 1700 RPM POLISHER. KEEP THE POLISHER MOVING TO AVOID DEVELOPING HOT SPOTS ON THE METAL. NOTE: CHEMICAL STRIPPING IS NOT RECOMMENDED. NOTE: IF AVAILABLE, PAINT MAY BE REMOVED USING A PLASTIC MEDIA BLAST SYSTEM. IF THIS PROCESS IS USED, EXTRA CARE MUST BE TAKEN DURING THE MASKING PROCESS TO PREVENT DAMAGE TO GLASS, MOULDING, ETC. 7. Blow off the entire vehicle to remove loose dust and debris. NOTE: IF RUST IS PRESENT, USE APPROPRIATE METAL CLEANER AND CONDITIONER (PHOSPHATE COATING) OVER BARE METAL AREAS. 8. Wipe all affected areas with a fast dry enamel reducer solvent, followed by a dry wipe using a clean, lint free cloth to remove all residue. CAUTION: KEEP WIPING UNTIL SURFACE IS COMPLETELY DRY. ANY RESIDUE WILL RESULT IN POPPING OF THE COATINGS TO BE APPLIED FOLLOWING THIS STEP. NOTE: THIS STEP WILL REDUCE THE POSSIBILITY OF FLASH RUST. ^ BASF Product # BR 50 ^ PPG Product # DX 300 ^ S-W Product # R7 K156 ^ DuPont Product # 3812 S ^ Sikkens Product # 123 FAST 9. Apply two medium wet coats (1.0 mil total) of self-etching, anti-corrosion primer using the manufacturer's recommendations and flash times. ^ BASF Product # DE-17 ^ PPG Product # DP EPOXY PRIMER ^ S-W Product # E2-6980 ^ DuPont Product # VARIPRIME ^ Sikkens Product # WASH FILLER 580 10. Apply three medium wet coats (2.0 mils total) of acrylic urethane primer surfacer following the manufacturer's recommended procedures. ^ BASF Product # DP-20 PRIMER/SUFACER ^ PPG Product # K-36 ^ S-W Product # P6-M49 OR P6-A48 ^ DuPont Product # URO PRIMERFILLER ^ Sikkens Product # AUTOCRYL 3+1 FILLER 11. Sand the vehicle using one of the following methods: ^ Wet-sand by hand using 400 grit or finer sandpaper. ^ Dry-sand by hand using 320 grit or finer sandpaper. 12. Blow the entire vehicle off to remove loose dust and debris. 13. Demask (remove all paper and tape) as necessary to remove the primer and dirt buildup on the paper and tape. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 91181 > Sep > 91 > Exterior Paint - Comprehensive Repair Procedures > Page 6506 14. Wipe the entire vehicle with wax and grease remover, followed by a dry wipe using a clean, lint free cloth to remove all residue. CAUTION: KEEP WIPING UNTIL SURFACE IS COMPLETELY DRY. ANY RESIDUE WILL RESULT IN POPPING OF THE COATINGS TO BE APPLIED FOLLOWING THIS STEP. ^ BASF Product # 901 PRE-PAINT CLEANER ^ PPG Product # DX 330 ^ S-W Product # R7-K156 ^ DuPont Product # 3812 S ^ Sikkens Product # M 600 15. Mask all areas on the vehicle which are not to be painted or will be affected by paint overspray (engine compartment, wheels, etc.). NOTE: APPLY BASECOAT/CLEAR COAT ONLY TO SURFACES WHICH ORIGINALLY HAD BASECOAT/CLEAR COAT 16. Apply three medium wet coats (enough material to hide primer) of acrylic enamel base coat or acrylic urethane monocoat following the manufacturer's recommended procedure. ^ BASF Product # DIAMONT BASECOAT/Solo ^ PPG Product # DELTRON BASECOAT DBC/Deltron ^ S-W Product # ULTRA BASE/Ultra One Stage ^ DuPont Product # CHROMABASE/Cronar ^ Sikkens Product # AUTO BASE/Autocryl 17. Apply two medium wet coats of 2K acrylic urethane enamel clear coat, following manufacturer's recommended procedure. ^ BASF Product # DIAMONT CLEAR 88/89 ^ PPG Product # CONCEPT 2001 DCU ^ S-W Product # CC-650 OR CC-640 ^ DuPont Product # 1080 S URO CLEAR ^ Sikkens Product # AUTO CLEAR 18. After the paint is dry, demask the entire vehicle and clean up any areas which have overspray. 19. Polish the vehicle as necessary to remove any defects in the paint which may create a customer concern. CAUTION: USE LOW SPEED (1700 RPM MAXIMUM) POLISHER. 20. Install all trim (mouldings, name plates, striping, etc.) on the vehicle which were removed prior to repainting. 21. Clean the exterior and interior of the vehicle thoroughly, including air ducts and other areas which are prone to accumulating dust. This step is essential to ensure customer satisfaction. WARNING: OUR ENVIRONMENT IS PRECIOUS - PLEASE USE PROPER DISPOSAL TECHNIQUES FOR ANY VOLATILE ORGANIC COMPOUNDS (V.O.C.'s) OR EXCESS MATERIALS. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 91181 > Sep > 91 > Exterior Paint - Comprehensive Repair Procedures > Page 6507 Figure 1 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 91181 > Sep > 91 > Exterior Paint - Comprehensive Repair Procedures > Page 6508 Figure 2 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 91181 > Sep > 91 > Exterior Paint - Comprehensive Repair Procedures > Page 6509 Figure 3 STRIP AND REFINISH CLAIMING METHODOLOGY The claiming instructions shown in Figure 1 are applicable to the repair of the EXTERIOR COLOR PEELING FROM ULTRA VIOLET LIGHT concern covered in this TSB only. See the SAMPLE CLAIMS, Figures 2 and 3, for examples. (C) Lower Body Stone Protection Repair Tips Ford has introduced a vinyl anti-stone abrasion material for the lower exterior body surfaces of selected passenger vehicles and light trucks. The anti-stone abrasion material is applied to the lower fenders, rocker panels, lower doors, quarter panel dogleg, and lower rear of quarter panel behind the wheel. The anti-stone abrasion material will usually end at a body character line. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 91181 > Sep > 91 > Exterior Paint - Comprehensive Repair Procedures > Page 6510 While primarily for servicing of factory-applied protective coating, the following provides installation information. If the vehicle has experienced body damage in the factory-applied material protective area, the sheet metal damage must be serviced prior to the application of the new protective coating. SMALL AREAS - MINOR DEFECTS (VEHICLES WITH FACTORY SPRAYED-ON VINYL) A small dent in the sheet metal that did not mar the vinyl surface, can possibly be corrected with proper bumping tools without damage to the vinyl coating. However, noticeable scratches or gouges (not over 1/2 inch in diameter) or dings and dents that when "ironed out" show vinyl damage, can be satisfactorily serviced with the following procedure: 1. Solvent-wipe the damaged area with "Silicone and Wax Remover." 2. Using a heat gun or lamp, soften the vinyl coating of the damaged area until it can be scraped off with a putty knife or a similar tool. If necessary, sand off any hard to remove coating using an orbital disc sander (No. 80 Disc). (The spray-on vinyl protective coatings may not be suitable for "spot" application. See Manufacturer's label for instructions.) 3. Perform necessary servicing to correct the sheet metal damage. 4. Using white bodyfiller, fill the damaged area. Follow the instructions on the label and blend the bodyfiller with the surrounding sheet metal. 5. Allow the bodyfiller to completely cure and then carefully sand the area smooth, removing any high spots. 6. Refer to "Spray Procedure" for restoration of vinyl anti-stone abrasion material. LARGE DAMAGED AREAS - VEHICLE WITH FACTORY SPRAYED ON VINYL Peeling or damage over a large area will necessitate removal of the factory sprayed-on vinyl coating. The following procedure is suggested. NOTE: WHERE SHEET METAL IS DAMAGED TO THE EXTENT THAT A FENDER, DOOR, OR QUARTER PANEL REPLACEMENT IS REQUIRED (OR IN AN INITIAL INSTALLATION), DISREGARD STEPS NO. 1 AND NO. 2. 1. Using a heat gun or lamp, soften the vinyl coating until it is pliable. Scrape coating off with a putty knife or a similar tool. If necessary, sand off any hard to remove coating using an orbital disc sander (No. 80 Disc). (The vinyl material, abrasion resistant coating may not be suitable for "spot" applications. See manufacturer's label for instructions.) 2. Perform necessary servicing to correct the sheet metal damage. 3. Refer to "Spray Procedure" for restoration of vinyl anti-stone abrasion material. COATING APPLICATIONS Approximately two quarts will be required for an initial installation on a passenger car or F-Series. Slightly more will be required for an Econoline. The specified dry film thickness of 15 to 20 mils (.015 to .020 inch) will require at least three, possibly four, applications of coating material, with "flash off" time between coats. Spray coat complete panels only. The coating must be applied with commercial equipment by an experienced automotive painter. The coating must be thoroughly agitated before application. The material is heavy bodied. A pressure cup spray gun or "Rocker Schutz Gun" is recommended. COATING PREPARATION - MASKING VEHICLE Install suitable covers over the wheels. NOTE: IF THE VEHICLE HAS LOWER BODY SIDE MOULDINGS (12-14 INCHES ABOVE THE "TURN UNDER" OF THE ROCKER PANEL), THE MOULDING CAN SERVE AS THE UPPER MARGIN OF THE AREA TO BE COATED. IF THE VEHICLE DOES NOT HAVE SUITABLE MOULDINGS, A SCULPTURE OR BREAK LINE IN THE SHEET METAL CAN BE UTILIZED. THIS LINE SHOULD BE SELECTED TO ENSURE ADEQUATE PROTECTION OF THE PAINTED SURFACES. VEHICLES WITH BODY SIDE MOULDINGS 1. Masking tape should be positioned so that the moulding lower edge is also covered. The adjoining sheet metal should be left uncovered too so anti-stone, abrasion vinyl can be applied. VEHICLES WITHOUT BODY SIDE MOULDINGS 2. If the contour of the body side has a break line, the upper coating margin must be masked off using 3M "Fine Line" Tape. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 91181 > Sep > 91 > Exterior Paint - Comprehensive Repair Procedures > Page 6511 a. The normal masking tape and paper protection for the body side should be applied first and positioned about a quarter inch above the margin line. b. The "Fine Line" tape should then be applied over the regular masking tape with the lower edge at the upper coating margin line. Extend this "Fine Line" tape into the wheel opening, in the absence of wheel opening mouldings, allowing the flange to be coated. c. The anti-stone abrasion coating does not adhere well to flexible plastic parts. If left exposed, they must be masked off. d. It is not necessary to mask off the body door openings in the coating area, as they will be uniformly coated where the door margins allow the coating to enter. NOTE: DOOR OPENING AREAS SHOULD BE CLEANED TO ASSURE COATING ADHERENCE. COATING PREPARATION - SHEET METAL REPAIRED SHEETMETAL 1. Scuff sand (No. 180 Grit Paper) the glossy surface of the painted areas to be coated. 2. Using a clean, lint-free cloth, solvent wipe the area to be coated with wax and grease remover. 3. Remove sanding dust using compressed air and lint-free tack cloth. NEW SHEET METAL 1. Sand off (No. 180 Grit Paper) the prime paint in the area to be coated. 2. Using a lint-free cloth, solvent wipe the area to be coated with wax and grease remover. 3. Remove sanding dust using compressed air and a lint-free tack cloth. NEW INSTALLATION 1. The glossy surface of the paint in the coating area must be sanded with a D/A sander. A 220/240 Grit Disc does a good, fast job. DO NOT sand through the primer. 2. Using a clean, lint-free cloth, solvent wipe the area to be coated with wax and grease remover. 3. Remove sanding dust using compressed air and a lint-free tack cloth. SPRAY PROCEDURE The lower exposed painted fender, rocker, and quarter panel down flanges should be protected. The vehicle must be elevated high enough so that the painter can spray this area effectively. When an initial installation is to be made, a remote two-quart capacity pressure cup makes a much more efficient tool, as the spray gun can be used closer to the floor. The spray gun, fluid hose and/or cup must be cleaned immediately after use. Refer to manufacturer's recommended cleaning procedure. Lacquer thinner can be used when the suggested clean up material is unavailable. WARNING: WEAR A NOISHA/MSHA RECOMMENDED VAPOR/PARTICULATE RESPIRATOR AND USE ALL OTHER RECOMMENDED SAFETY EOUIPMENT. 1. After preparing the new or damaged area(s), mix either Epoxy primer or Self-etch prime, per manufacturer's label instructions, and spray bare metal areas. ^ BASF DE15 or DE17 ^ Sikkens Metalflex CR Primer (1 coat only) ^ DuPont Variprime ^ S-W E2G 980 GBP Etching Filler ^ PPG DP 40 (only) 2. Apply 1-2 light prime coats over the bare metal areas. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 91181 > Sep > 91 > Exterior Paint - Comprehensive Repair Procedures > Page 6512 3. Allow the material to dry for 15-20 minutes before applying the anti-stone abrasion material. 4. Mix and apply anti-stone abrasion material per manufacturer's label instructions over the primed area. NOTE: AN ORANGE PEELED FINISH IS NORMAL WITH THESE PRODUCTS. ^ BASF Glassohyd 1109-1240/6 ^ Sikkens 0TO Bodycoat ^ DuPont 123-5 Vinyl ^ S-W G/W 295 Vinyl Gravel Guard ^ PPG DX 54 Roadguard ^ 3M Rocker Schutz NOTE: SOME ANTI-STONE ABRASION MATERIAL MAY REQUIRE A SLIGHTLY DIFFERENT MIXING PREPARATION, PROCEDURE AND APPLICATION. SOME ANTI-STONE ABRASION MATERIALS CAN NOT BE USED FOR SPOT REPAIR. CHECK WITH THE PAINT MANUFACTURER FOR RECOMMENDATIONS ABOUT THEIR PRODUCT. 5. Allow the stone abrasion material to dry. Heat can be used to accelerate the drying time. Check the manufacturer's instructions. COLOR COAT The complete coated area, as well as the upper raw edge, must be covered with color coat. Mask off the upper margin line using "Fine Line" tape positioned 1/16 inch above the coating edge. Using appropriate service paint and application procedures, the protective coating area can now be finish painted with monocoat or a basecoat/clearcoat urethane system. NOTE: IF DAMAGED SHEET METAL EXTENDS ABOVE THE PROTECTIVE COATING AREA, NORMAL PRIME/COLOR PAINT PROCEDURES SHOULD BE FOLLOWED. CAUTION: OUR ENVIRONMENT IS PRECIOUS - PLEASE USE PROPER DISPOSAL TECHNIQUES FOR ANY VOLATILE ORGANIC COMPOUNDS (V.O.C.'s) OR EXCESS MATERIALS. Figure 4 Refer to the Lower Body Stone Protection Chart, Figure 4, for the material and labor hours involved. (D) Procedure For PVC Body Side Moldings If replacement of the body side molding is necessary, some dealer service kits will be supplied "paint to match." Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 91181 > Sep > 91 > Exterior Paint - Comprehensive Repair Procedures > Page 6513 The painting procedures in the following instructions (also included with the part) address materials from five (5) major aftermarket paint suppliers. Use the paint system materials you are the most familiar with. NOTE: CAREFULLY READ ALL LABEL WARNINGS BEFORE APPLYING THESE PRODUCTS. WARNING: ALWAYS WEAR A NOISHA/MSHA RECOMMENDED VAPOR/PARTICULATE RESPIRATOR AND USE ALL OTHER RECOMMENDED SAFETY EQUIPMENT. SIKKENS PRODUCTS PREPARATION 1. Degrease with M600 wax and grease remover. 2. Scuff with # 320 dry paper or Scotchbrite 7447 (red). 3. Repeat degreasing step. 4. Spray two medium coats of Plastoflex primer. Allow 5 to 10 minutes flash between coats. 5. Allow 20 minutes flash-off at 70~ F before topcoating. TOPCOATING 1. Mix Autocryl color with Elast-O-Actif 50:50 by volume. 2. Mix this material with 1.2.3 hardner and 1.2.3 reducer (use correct reducer for temperature) 100:50:30 by volume. 3. Apply three medium coats, allowing enough flash off to dry to a light touch. 4. Dry one hour at 140~F after 10 minutes flash off or dry 24 hours at 75~F. PPG PRODUCTS PPG MONO-COAT SYSTEMS 1. Solvent wipe with DX330 Acryli-clean. 2. Scuff with red Scotchbrite pad. 3. Repeat solvent wipe. TOPCOATING 1. Mix and apply Deltron topcoat color with DX-369 Flexative per label instructions. 2. Use 40-50 PSI at the gun. PPG BASECOAT/CLEARCOAT SYSTEMS PREPARATION 1. Solvent wipe with SX330 Acryli-clean. 2. Scuff with red Scotchbrite pad. 3. Repeat solvent wipe. TOPCOATING 1. Mix and apply Deltron basecoat color (DBU), with the recommended reducer for the temperature, per label instructions. 2. Mix and apply clearcoat material DBU-88 or DCU-2001, with DX-369 Flexative, per label instructions. SHERWIN-WILLIAMS PRODUCTS Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 91181 > Sep > 91 > Exterior Paint - Comprehensive Repair Procedures > Page 6514 Ultrabase 7 Basecoat/Clearcoat or Ultra One Stage Acrylic Urethane Enamel PREPARATION 1. Wash the material with a mild detergent and wipe dry. 2. Solvent wash with R7 K 156 and wipe dry. 3. Clean with a tack cloth. 4. Apply desired system with correct amount of Multi-flex, V6 V 299. TOPCOATING Prepare topcoating as follows: ^ S-W Ultra One Stage: (Mono-coat) 4 Parts Color 3 Parts SSR 650 Reducer 1 Part V6 V 440 or SSH 520 2 Parts V6 V 299 ^ S-W UB7 Basecoat: 8 Parts Basecoat Color 8 Parts Stabilizer 1 Part V6 V 299 ^ S-W UB7 Clearcoat: 4 Parts T1 C 650 Clearcoat 2 Parts T1 C 650 Reducer 1 Part CCH 690 1 Part V6 V 299 ^ S-W Ultra One Stage: (Mono-coat) Apply 2-3 medium wet coats at 50 PSI ^ UB7 Basecoat: Apply 2-3 medium coats at 45 PSI ^ UB7 Clearcoat: Apply 2-3 medium coats at 50 PSI DUPONT PRODUCTS DUPONT CRONAR POLYOXITHANE MONOCOAT SYSTEM PREPARATION 1. Wash the surface thoroughly with a mild detergent. 2. Clean with Prep Sol. TOPCOATING 1. Add 8 parts of Cronar single stage enamel. 2. Add 1 part Cronar initiator 9404S. 3. Add two parts of (9475S, 9485S, or 9495S,) depending on shop temperature. 4. Add 2 parts flex-additive 9250S. 5. Mix thoroughly. 6. Spray at 45-55 PSI at the gun, 2-3 medium wet coats or until hiding. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 91181 > Sep > 91 > Exterior Paint - Comprehensive Repair Procedures > Page 6515 7. If a clear coat is applied, use 9500S. DUPONT CENTARI MONO-COAT ENAMEL SYSTEMS PREPARATION 1. Wash the surface thoroughly with a mild detergent. 2. Clean with Prep Sol. TOPCOATING (Follow Manufacturer's Recommendation) 1. Add 8 parts of Centari enamel color and 1 part 793S hardener. 2. Add 4 parts of (8022S, 8093S, or 8096S) reducer, depending on shop temperature. 3. Add 355S flex additive per label instructions. 4. Mix thoroughly. 5. Spray 2-3 wet coats, with 5 minutes flash time, at 50-65 PSI. BASF PRODUCTS The following procedure is applicable to 4 paint systems in the BASF paint line. Read individual "system" instructions carefully. PREPARATION 1. Solvent wipe the molding with RM Pre-klean-o 900. 2. Sand with 400 grit sand paper and rinse with 901 pre-paint cleaner. TOPCOATING BASECOAT ^ "Glasurit" 54-line color 2 vol. parts ^ 54-line reducer 1 vol. part ^ "Diamont" basecoat color 2 vol. parts ^ B R Diamont reducer 2 vol. parts ^ "Miracryl" basecoat color 2 vol. parts ^ BCR reducer 2 vol. parts ^ "Supreme Gold" basecoat color 2 vol. parts ^ LBR reducer 2 vol. parts Apply basecoat color until hiding is achieved. Allow 3-5 minutes flash time between coats. NOTE: USE APPROPRIATE REDUCER FOR SHOP CONDITIONS. ALLOW 15 MINUTES FLASH-OFF BEFORE SPRAYING CLEARCOAT. TOPCOATING Apply clearcoat per manufacturer's label instructions: CLEARCOAT REDUCTIONS ^ DC-88 Diamont Clear 4 Vol. Parts ^ DH-44 Diamont Hardener 1 Vol. Part ^ MC-1000 Clear 4 Vol. Parts ^ 894 Hardener 1 Vol. Part ^ LC-1300 Supreme Gold Clear 4 Vol. Parts ^ LH-1301 Hardener 1 Vol. Part Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 91181 > Sep > 91 > Exterior Paint - Comprehensive Repair Procedures > Page 6516 ^ 92354 Glasurit Clear 100 Parts ^ 521-111 Elastifier 20 Parts ^ 929-29 Hardener 60 Parts Apply 2 wet coats with 5 to 10 minutes flash time between coats. Overnight dry or force dry at 140~F for 30 minutes. CAUTION: OUR ENVIRONMENT IS PRECIOUS - PLEASE USE PROPER DISPOSAL TECHNIQUES FOR ANY VOLATILE ORGANIC COMPOUNDS (V.O.C.'s) OR EXCESS MATERIALS. (E) Lower Body-Side Stone Chip Protection Program Ford Motor Company has recently initiated a program to provide improved stone-chip protection on some vehicles and to increase the corrosion protection on cars and trucks. Some customers are unaware of body side anti-stone chip protection which appears as wavy orange peel texture on the lower body areas. Ford is increasing the use of PVC (poly vinyl chloride) material which is applied in a thicker coating on the lower body-side. This material has been in use on vehicles destined for the Canadian market for many years. This PVC material is now applied at the following plants on ALL vehicles. ^ Edison - Ranger ^ Hermosillo - Escort/Tracer ^ Louisville - Ranger and Explorer ^ Ohio Truck - Econoline ^ Wayne - Escort/Tracer This process is also planned for Kansas City, Oakville, Twin Cities and Wixom. This material can be identified by the "orange peel" appearance and a visible "break-line" between protected and unprotected areas in the lower body areas. CAUTION: THIS PROTECTION MUST NOT BE REMOVED IF VEHICLE IS EXPECTED TO MAINTAIN THE CORROSION PROTECTION. Some customers have expressed concerns due to the appearance of the treated areas. These customers did not know about the extra protection this material provides their vehicle. Once explained, customers were pleased with the added protection and accepted the orange peel finish. NOTE: DEALERS SHOULD ADVISE THEIR SALES PEOPLE, SERVICE PEOPLE, AND CUSTOMERS, OF THE REASONS AND BENEFITS OF THIS PROTECTION. CANADIAN DEALERS STRESS THIS AS A SELLING POINT WITH THEIR SALES PEOPLE. IT IS CONSIDERED A COMPETITIVE ADVANTAGE. (F) Surface Defect Removal Without Repainting Exterior paint surface damage or imperfections, where the primer coat does not show through, should be restored without repainting. The restoration of gloss and luster, after the condition has been repaired, is possible with new techniques and improved materials. The following procedure is applicable to surface conditions such as dirt particles, orange peel, runs, sags, industrial fallout stains, swirl marks, light scratches and other minor surface imperfections. For dirt particles or scratches in several localized areas, the entire panel should be refinished to maintain a uniform appearance. PREPARATION To repair the affected surface it must be clean and dry. Mask off adjacent panels, mouldings, stripe and character lines as required. CAUTION: EYE PROTECTION, AND FACE MASK SHOULD BE WORN. RINGS, BRACELETS, WATCHES AND BELT BUCKLES MUST BE REMOVED TO PREVENT ACCIDENTAL DAMAGE TO PAINT FINISH. SERVICE PROCEDURE 1. Remove sanding marks with rubbing compound. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 91181 > Sep > 91 > Exterior Paint - Comprehensive Repair Procedures > Page 6517 2. Swirl marks, evident after buffing, are removed by polishing. 3. Remove light scratches and small dirt particles with a power buffer and medium buffing compound followed with polishing. 4. Remove deeper scratches and heavy dirt particles or orange peel, by wet sanding. 5. Buff with compound to remove the sanding marks and then polish to remove the swirl marks from the buffing operation. NOTE: PERFORM A TRIAL REPAIR WITH A SMALL AREA. FIRST, TRY POLISHING; IF THIS IS NOT SUCCESSFUL, TRY BUFFING AND, FINALLY, USE WET SANDING TO REMOVE THE CONDITION. USE MOST EFFECTIVE TECHNIQUE ON REMAINDER OF AREAS. AN OUTLINE OF THE COMPLETE PROCEDURE AND REQUIRED MATERIALS FOLLOWS. POLISHING - VERY MINOR SCRATCHES OR SWIRL MARKS AND/OR RESTORING A DULL FINISH 1. Apply a small amount of Meguiar's Mirror Glaze, or equivalent, to the affected panel (or pad). 2. Use a suitable electric or air powered polish/buffing wheel (1750 max. RPM) and a Meguiar's Finesse Polishing Pad, or equivalent, to polish the affected area until all swirl marks are gone and desired luster is obtained. 3. When polishing, keep the pad flat against the surface. Do not bear down. The weight of the buffer is sufficient. CAUTION: DO NOT MIX PRODUCTS! USE A SEPARATE, DEDICATED BUFFING PAD FOR EACH PRODUCT TO ACHIEVE DESIRED RESULTS. Variable speed buffers are available in a variety of buffing speeds. The recommended speed range is 1200-1750 RPM. COMPOUNDING - LIGHT SCRATCHES, SMALL DIRT PARTICLES, MINOR GRIND MARKS, AND SANDING MARKS 1. Apply Meguiar's Rubbing Compound (medium) or equivalent to the panel with a clean compound pad on the wheel. 2. Spread the compound evenly and continue buffing until the condition is removed. 3. Keep the wheel flat to the surface and use light to moderate pressure and long strokes. 4. Periodically check the finish and add compound as required. 5. When buffing is complete, polish the panel as described previously. Twisted wool cutting pads are the most effective compounding pads to use with Glaze Machine Cleaner for removing paint defects and heavy oxidation. Following the use of a wool compounding pad, it may be necessary to polish the finish with No. 2 Mirror Glaze Hi-Tech Cleaner using a Mirror Glaze Finesse Polishing Pad to remove the deep swirl marks. GENERAL TECHNIQUES AND HINTS ^ "Foam" buffing pads create added gloss and depth of color on all types of paint finishes without creating buffer swirl marks. ^ When "buffing out" oxidation or other paint defects with a cleaning material, use a liberal amount of material, slower buffing motion and added downward pressure to increase cutting action. ^ Always apply cleaner to buffing pad, not directly on the oxidized paint surface. Dry paint absorbs material into pores upon contact. ^ Always keep the face of the buffing pad completely flat to the surface, reducing the risk of buffer swirl marks. Watch your pad, especially on angled surfaces, to be certain that it stays flat. ^ Avoid short rapid strokes. Move the buffer slowly across the surface using long straight motions and overlap by 50% the buffing pattern left by the previous pass. This insures uniform coverage and allows both material and buffer to perform at maximum efficiency. ^ Avoid buffing directly on raised character lines. The reduced paint film on these surfaces increases the risk of paint burn through. It is best to buff up to them from each side. ^ Always use a "wet buff" technique on a basecoat/clearcoat finish. This is a precaution against buffer swirls. Stop buffing just after the product begins to break down and before an overall dry, glossy finish appears. After "wet buffing", use a towel to wipe off the excess material. ^ Always use a "dry buff" technique on light colored, conventional paint finishes. Continue buffing until the material breaks down and only a slight film remains for final wipe off. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 91181 > Sep > 91 > Exterior Paint - Comprehensive Repair Procedures > Page 6518 ^ If a paint blemish remains after buffing, reapply a small amount of material over the blemish. Confine your buffing strokes to the immediate area of the blemish while applying additional downward pressure and keeping the pad flat. NOTE: ALWAYS KEEP THE PAD MOVING AND LIMIT YOUR STROKES OVER THE BLEMISH TO PREVENT EXCESSIVE HEAT BUILD-UP AND POSSIBLE BURN THROUGH. STOP IMMEDIATELY IF THE SURFACE BECOMES TOO HOT TO LAY THE PALM OF YOUR HAND ON IT. NOTE: HEAT BUILD-UP: WHEN BUFFING CREATES EXCESSIVE HEAT, HAZING MAY APPEAR ACROSS THE SURFACE BEING BUFFED AND THE PRODUCT MAY DRY LIKE A FILM AND REFUSE TO BUFF OUT. TO REMEDY, WIPE THE AREA DOWN WITH COOL WATER, DRY THE SURFACE AND RESUME BUFFING ... AT A LOWER RPM IF POSSIBLE. NOTE: STATIC: STATIC ELECTRICITY MAY BE PRESENT ON PAINTED FIBERGLASS/PLASTIC SURFACE BEING BUFFED, THE MATERIAL MAY DRY LIKE A FILM OR TURN "GUMMY" AND BEGIN TO BALL UP. TO REMEDY, GROUND THE SURFACE BEING BUFFED TO METAL. WET SANDING Paint defects and sanding marks must be completely removed without using compounds and abrasive cleaners that scar the finish. Mirror Glaze Hi-Tech Finesse Sanding Papers provide uniformity in grit particle size and distribution. Using these precision made sanding papers, water sanding marks can be removed with Meguiar's cleaner and finesse polishing pads. ^ Typical paint defects that are repaired with this system include: dirt-in paint, solvent pop, cratering, orange peel, drips, scratches, water spots, and acid rain. ^ Always use the least abrasive (highest grit) sanding products possible to do this job. The following wet sanding procedure utilizes light grit sand paper or sanding blocks for removal of surface damage. These materials cut quickly leaving a uniform finish requiring a minimum of buffing to restore gloss. PROCEDURE 1. Squeeze water to flush the area to be sanded. Continue to flush water to the surface during sanding for maximum lubrication. 2. Use small circular motions to contain the abrasion to the immediate area of the defect. Keep the blocks in water when not in use. 3. If the sanding block is cutting too slow, switch to a lower grade block and resume sanding. When 90% of the defect is removed, switch to a 2000 grade Finesse Sanding Paper or Sanding Block to finish smoothing and prepare the surface for buffing. 4. Finesse Sanding Blocks can be shaped to work on any angle. When the block is wet, rub it against a dry sanding block for shaping. 5. When using Finesse Sanding Papers, wrap the paper tightly around a E-7200 Backing Pad. This pad evenly distributes pressure over the entire surface of the sanding paper. This creates a uniform sanding pattern. 6. Plan your strokes to limit the abrasion to the smallest area possible. NOTE: ALWAYS SAND IN ONE DIRECTION AND KEEP YOUR STROKES STRAIGHT. 7. Always finish sanding with 2000 Grit Finesse Sanding Paper. This eliminates the need for compounding. 8. Buff out sanding marks by applying Meguiar's Cleaner with a Finesse "Foam" Polishing Pad. Follow with a Mirror Glaze Polish for swirl-free gloss. WARNING: OUR ENVIRONMENT IS PRECIOUS - PLEASE USE PROPER DISPOSAL TECHNIQUES FOR ANY VOLATILE ORGANIC COMPOUNDS (V.O.C.'s) OR EXCESS MATERIALS RUNS AND SAGS REMOVAL This procedure consists of shaving the run or sag flush with a commercial single edge razor blade, shaving file or sanding with a hard block and then compounding. NOTE: IF IT IS NECESSARY TO SHAVE RUNS AND SAGS WITH A RAZOR BLADE, FIRST DULL THE CORNERS WITH SANDPAPER TO AVOID SCRATCHING THE ADJACENT PANEL FINISH. MEGUIAR'S PRODUCTS Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 91181 > Sep > 91 > Exterior Paint - Comprehensive Repair Procedures > Page 6519 PART NUMBER GRADE PART NAME S-1005 1000 Mirror Glaze Hi-Tech Finesse Sanding Papers - Half Sheets S-1205 1200 S-1505 1600 S-2005 2000 S-1000 1000 Mirror Glaze Hi-Tech Finesse Sanding Papers - Full Sheets 8-1200 1200 8-1500 1500 S-2000 2000 E-7200 - Mirror Glaze Hi-Tech Finesse Backing Pad E-2000 - Mirror Glaze Hi-Tech Tach Sponge K-400 400 Mirror Glaze Hi-Tech Finesse Sanding Blocks K-1000 1000 K-1500 1500 K-2000 2000 K-3000 3000 Other Applicable Articles: 82-3-3 (G) Color Compatible Spray Primer Chart Ford has released color compatible spray primers for exterior and some interior surfaces. Colored sprayed primers are being used by our "Best-in-Class" competition and are now being implemented at Ford in order to improve process capability and to help in minimizing unsightly paint chipping from stone abrasion. Color keyed (matched) spray primer for exterior body colors is being used in an effort to help in the elimination of unsightly paint chipping from stone abrasion. As with "Best-In-Class" competition, the engine compartment will be left with color compatible primer only and not be topcoated as per past practice. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 91181 > Sep > 91 > Exterior Paint - Comprehensive Repair Procedures > Page 6520 Figure 5 When any paint repair is required, remember that the vehicle may have a colored primer. Refer to the Spray Primer Chart, Figure 5. This information may be of help in correction of exterior paint color match concerns. (H) Paint Repair For Tinted Clear Coat Ford introduced (Early Spring, 1991) a new paint color using a tinted clearcoat. The first color to use this new system is Rio Red. If a paint repair is necessary, refer to the following procedure for repair instructions. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 91181 > Sep > 91 > Exterior Paint - Comprehensive Repair Procedures > Page 6521 BACKGROUND The Probe production paint system for Rio Red includes a Medium Green E-Coat primer, a Light Gray spray primer, bright Rio Red (E4) basecoat and a slightly Red tinted clearcoat topcoat. NOTE: BEFORE ANY REPAIRS ARE BEGUN, IT IS CRITICAL THAT PRIMER, RED BASECOAT AND TINTED CLEARCOAT BE SPRAYED ON A TEST PANEL. THE COLOR MATCH IN EACH STEP IS VERY IMPORTANT FOR A SUCCESSFUL REPAIR. WARNING: ALWAYS WEAR A NOISHA/MSHA RECOMMENDED VAPOR/PARTICULATE RESPIRATOR AND USE ALL OTHER RECOMMENDED SAFETY EQUIPMENT. SMALL SPOT REPAIR PROCEDURE 1 Wash the vehicle with detergent soap and water. 2 Wipe the vehicle down with wax and grease remover. 3. Sand the spot using 400 grit paper. Do not sand through the E-coat. 4. Wipe the sanded surface again with wax and grease remover/pre-cleaner. ^ BASF Product # 90 Pre-Kleano ^ PPG Product # DX 330 ^ S-W Product # R7-K156 ^ DuPont Product # 3919 S ^ Sikkens Product # M 600 5. Mix and apply tintable (Light Gray) self-etching or epoxy primer per manufacturer's label instructions. NOTE: COLOR MATCH OF PRIME COAT IS KEY IN COLOR MATCH OF REPAIRED AREA. ^ BASF Product # DE 17 ^ PPG Product # DP 40 ^ S-W Product # E2-G973 ^ DuPont Product # 615S ^ Sikkens Product # 1016 6. Mix and apply bright Rio Red base coat material per manufacturer's label instructions. NOTE: COLOR MATCH OF BASE CLEAR COAT IS KEY IN COLOR MATCH OF REPAIRED AREA. 7. Mix and apply red tinted clearcoat material per manufacturer's label instructions. NOTE: COLOR MATCH OF TINTED CLEAR COAT IS KEY IN COLOR MATCH OF REPAIRED AREA. FULL PANEL REPAIR PROCEDURE 1. Wash the vehicle with detergent soap and water. 2. Wipe the vehicle down with wax and grease remover. 3. Sand the complete panel and feather edge into the next panel using 400 grit paper. Do not sand through the E-Coat primer. 4. Wipe the sanded surface with wax and grease remover. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 91181 > Sep > 91 > Exterior Paint - Comprehensive Repair Procedures > Page 6522 5. Mix and apply tintable (light gray) primer per manufacturer's label instructions. 6. Mix and apply Rio Red basecoat per manufacturer's label instructions. 7. Mix and apply Red tinted clearcoat per manufacturer's label instructions. 8. Mix and apply one coat of non-tinted clearcoat per manufacturer's label instructions. NOTE: COLOR MATCH OF EACH COAT ARE KEY TO COLOR MATCH OF FINISH REPAIR. WARNING: OUR ENVIRONMENT IS PRECIOUS - PLEASE USE PROPER DISPOSAL TECHNIQUES FOR ANY VOLATILE ORGANIC COMPOUNDS (V.O.C's) OR EXCESS MATERIALS. (I) Paintable Plastics Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 91181 > Sep > 91 > Exterior Paint - Comprehensive Repair Procedures > Page 6523 Figure 6 The Paintable Plastics Chart, Figure 6, is a summary of widely used plastics in our industry. The standard symbol should be located on the part for ease of material identification. If painting or repair of these plastics is necessary, the following chart identifies those materials which can be painted. Refer to paint manufacturer for specific paint material recommendations. NOTE: MATERIALS MAY REQUIRE PRIME COAT SEE "YES", UNDER "CAN BE PAINTED" COLUMN. (J) 1992 Paint Color Codes Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 91181 > Sep > 91 > Exterior Paint - Comprehensive Repair Procedures > Page 6524 Figure 7 The 1992 Paint Color Codes are listed in Figure 7. NOTE: REFER TO THE SERVICE LABOR TIME STANDARDS MANUAL AND THE SPECIFIC PROCEDURE WITHIN THIS BULLETIN FOR REIMBURSEMENT. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under Basic Warranty Coverage OASIS CODES: 106000 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 90153 > Jul > 90 > Lower Body Stone Protection - Repair Procedure Technical Service Bulletin # 90153 Date: 900719 Lower Body Stone Protection - Repair Procedure PAINT - LOWER BODY STONE PROTECTION REPAIR TIPS Article No. 90-15-3 FORD: 1985-90 CROWN VICTORIA, ESCORT, MUSTANG, TEMPO, THUNDERBIRD 1986-90 TAURUS 1988-90 FESTIVA, PROBE LINCOLN-MERCURY: 1985-90 CONTINENTAL, COUGAR, GRAND MARQUIS, MARK VII, TOPAZ, TOWN CAR 1986-90 SABLE 1987-90 TRACER LIGHT TRUCK: 1985-90 BRONCO II, BRONCO, ECONOLINE, F-150, F-250, F-350, RANGER 1988-90 F SUPER DUTY ISSUE: A service repair procedure has been developed to restore damaged factory-applied lower body stone protection vinyl material. ACTION: If service is required, use the following procedure to restore damaged lower body stone protected areas. This abrasion resistant coating material (D9AZ-19515-A) is primarily for repair of factory-applied protective coatings. However, this material may also be installed on previously unprotected vehicles. If the vehicle has body damage in the area of the factory-applied coating, body damage must be repaired before repairing the protective coating. WARNING: WHENEVER USING PAINT, SOLVENT, REFINISHING OR RECONDITIONING MATERIALS, WEAR A NOSE OR FACE MASK, PLUS HAVE ADEQUATE VENTILATION IN THE WORK AREA. Large Repair Areas A large repair area, resulting from peeling or damage, will require removal of the factory-applied vinyl coating. NOTE: WHERE SHEET METAL IS DAMAGED TO THE EXTENT THAT A FENDER, DOOR OR QUARTER PANEL REPLACEMENT IS REQUIRED, (OR IN AN INITIAL INSTALLATION), SKIP STEPS # 1 - 3. 1. Use a heat gun or lamp to soften the vinyl coating until it is pliable. 2. Scrape off the softened vinyl with a putty knife or similar tool. If necessary, sand off any hard-to-remove vinyl coating using an orbital disc sander (# 80 Disc). NOTE: THE REPAIR MATERIAL, ABRASION RESISTANT COATING (D9AZ-19515-A), IS NOT SUITABLE FOR "SPOT" REPAIRS. THE OLD COATING MUST BE REMOVED COMPLETELY FROM EACH DAMAGED PANEL. 3. Make the necessary repairs to the sheet metal. Coating Preparation and Applications: The abrasion resistant coating is available in quart cans. About two quarts will be required for an initial installation on a passenger car similar to a factory-applied system. Slightly more will be required for a larger vehicle such as an Econoline. The specified dry film thickness of 15 to 20 mils (.015 to .020") will require at least three or possibly four applications of coating material, with flash off time allowed between coats. As with painting, spray coat the complete lower panel. The adherence of this coating to properly prepared sheet metal is excellent and it is not necessary to prime the repaired sheet metal. However, adhesion will be adversely affected unless the sheet metal (either repaired or new) is prepared in accordance with the following procedure. Coating Preparation - Masking Car 1. Install covers over the wheels. 2. Determine the area to be coated. ^ If the vehicle has lower body side mouldings (12-14" above the "turn under" of the rocker Panel), the moulding can serve as the upper margin of the area to be coated. ^ If the vehicle does not have suitable mouldings, a sculpture or break line in the sheet metal can be used. ^ The method used in masking off the upper coating margin line will depend on the presence or absence of mouldings in this area. VEHICLES WITH SIDE MOULDINGS 3. Position the masking tape so that the moulding lower side is covered down to, but not on the sheet metal. VEHICLES WITHOUT SIDE MOULDINGS Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 90153 > Jul > 90 > Lower Body Stone Protection - Repair Procedure > Page 6529 4. If the contour of the body side has a break line, or if an arbitrary line is chosen, mask off the upper coating margin using Scotch "Fine Line" tape. This is available nationally from 3M Company Distributors. a. Apply the normal masking tape and paper protection for the vehicle body side first. Position them about a 1/4" above the margin line. b. Apply the "Fine Line" tape over the regular masking tape with the lower edge at the upper coating margin line. c. Extend this "Fine Line" tape into the wheel opening, in absence of wheel opening mouldings, to allow the flange to be coated. d. Since the protective coating does not adhere well to flexible plastic stone shields, mask off the front of the plastic rear stone shield, if exposed. NOTE: IT IS NOT NECESSARY TO MASK OFF THE BODY DOOR OPENINGS IN THE COATING AREA BECAUSE THEY WILL BE UNIFORMLY COATED WHERE THE DOOR MARGINS ALLOW THE COATING TO ENTER. HOWEVER, THESE DOOR OPENING AREAS SHOULD BE CLEANED TO ASSURE COATING ADHERENCE. Coating Preparation - Sheet Metal REPAIRED SHEET METAL 1. Using a clean lint-free cloth, solvent wipe the area to be coated with a silicone and wax remover and allow to flash off. 2. Scuff sand (# 180 Grit Paper) the glossy surface of the painted areas to be coated. 3. Remove sanding dust using a lint-free tack cloth and compressed air. NEW SHEET METAL 1. Using a clean lint-free cloth, solvent wipe the area to be coated with a silicone and wax remover and allow to flash off. 2. Scuff sand (# 180 Grit Paper) the prime paint in the area to be coated. 3. Remove sanding dust using a lint-free tack cloth and compressed air. INITIAL INSTALLATION 1. Using a clean lint-free cloth, solvent wipe the area to be coated with a silicone and wax remover. 2. Sand the glossy surface of the paint in the coating area. (A D/A sander, 220/240 Grit Disc does a good fast job.) CAUTION: DO NOT SAND THROUGH THE COLOR COAT INTO THE PRIMER. 3. Remove sanding dust using a lint-free tack cloth and compressed air. Coating Application Coating applications must be applied with care. ^ The coating must be applied with commercial equipment by an experienced automotive painter. ^ The coating must be thoroughly agitated and used without thinning. ^ Since the material is reasonably heavy-bodied, a pressure cup equipped spray gun is recommended. ^ Satisfactory coating appearance (orange peel) will result with gun pressure of approximately 30 P.S.I. and cup pressures of approximately 15 P.S.I. Spray Procedure Since the lower exposed painted fender, rocker and quarter panel down flanges are to be coated, the vehicle should be elevated high enough so that the painter can spray this area effectively. When an initial installation is to be made, a remote, two-quart capacity pressure cup makes a much more efficient tool because the spray gun can be used closer to the floor. The spray gun, fluid hose and cup must be cleaned immediately after use. While lacquer thinner may be used when the suggested clean up material is unavailable, the Ford Vinyl Paint Precleaner (VC-542-A) is quicker and much more efficient. With the spray gun at 30 P.S.I. and pressure feed cup at 15 P.S.I. proceed as follows: Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 90153 > Jul > 90 > Lower Body Stone Protection - Repair Procedure > Page 6530 1. Apply a wet, sag-free coat. Allow 3 to 5 minutes flash off. 2. Apply a second wet, sag-free coat. Allow 3 to 5 minutes flash off. 3. Apply a third wet, sag-free coat. Allow 3 to 5 minutes flash off. 4. Apply a final wet, sag-free coat. Allow 3 to 5 minutes flash off. Pull off the "Fine Line" tape, exposing the raw upper edge of the coating. 5. Immediately clean the spray equipment using Ford Vinyl Paint Precleaner (VC-542-A) or equivalent. 6. Air drying time depends on the refinishing materials that are used. ^ If you refinish with acrylic lacquer, allow one hour for drying (at 70~F). ^ If you refinish with acrylic enamel, allow two hours for drying (at 70~F). Color Coat In order to paint the entire coated area as well as the upper raw edge, mask off the upper margin line using the "Fine Line" tape. Position the tape 1/16" above the coating edge. The protective coating area can now be finish painted. NOTE: IF DAMAGED SHEET METAL EXTENDS ABOVE THE PROTECTIVE COATING AREA, NORMAL PRIME/COLOR PAINT PROCEDURES SHOULD BE FOLLOWED. Suggested Equipment ^ DeVilbiss - Spray Gun - Model JGA-502-704-FX or equivalent ^ DeVilbiss - Remote Pressure Cup - Model KB-520 (2 Quarts), Model KB-521 (1 Quart) or equivalent ^ Binks - Spray Gun - Model 62 (# 63 Air Cap, # SS Fluid Tip, # 363 AN Needle) ^ Binks - Attached Pressure Cup - Model 80 (1 Quart, with Air Adjusting Gage) or equivalent. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 1100, 1800 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 89133 > Jun > 89 > Paint - Cosmetic Damage From Airborn Materials Paint: All Technical Service Bulletins Paint - Cosmetic Damage From Airborn Materials PAINT COSMETIC DAMAGE FROM AIRBORN MATERIALS Article No. 89-13-3 FORD: 1989 and prior ALL FORD LINES LINCOLN-MERCURY: 1989 and prior ALL LINCOLN-MERCURY LINES LIGHT TRUCK: 1989 and prior ALL LIGHT TRUCK LINES ISSUE: Paint may be damaged from various sources of airborn materials. The two different types are: ^ Inorganic ^ Organic Sometimes it is hard to identify the type of paint damage and know how to remove it. This TSB article gives detailed information and descriptions of both types of airborn materials. It also outlines the service procedures for treating them. ACTION: If service is required, identify the source of damage involved by referring to the following information. Use the following recommended service procedure to correct concerns. INORGANIC AIRBORN MATERIAL The effects of inorganic airborn materials can be seen as: ^ Dark blotches in the paint where the pigment in the paint surface has been attacked ^ Irregular spots that are cracked or etched around the edges and dull in the centers. ^ Small orange colored spots caused by iron particles may appear on the paint surface. Generally, materials that attack a paint film are either acidic or alkaline in nature. Sulfuric and nitric acids, in general, cause extreme damage to automative paint finishes. Even very small concentrations of the same materials can cause chemical spotting damage. Due to evaporation and condensation, these acids can create severe etching "spots" that may eventually crack or lift the paint film after some time in service. Although some automotive finishes are more resistant than others, none are completely immune to these chemicals. The most resistant paints used today are the urethanes because their resin system is least likely to react with chemicals. Air dry coatings are more susceptible to attack only when they are fresh. The longer the paint dries the more resistant it becomes. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 89133 > Jun > 89 > Paint - Cosmetic Damage From Airborn Materials > Page 6535 Metallic colors are more intolerant to chemicals because aluminum flake is fairly reactive with either an acid or alkali. The following chart contains the most common acid materials found on automotive finishes. The chart shows a color, the corresponding damage appearance and also the chemical causal agent. It is not applicable for Basecoat/Clearcoat finishes. * "Caustic" refers to any alkaline substance that may be "harsh" or "corrosive" depending on strength or concentration. The following "pH" chart show the relationship between acidic and alkaline chemicals and their corresponding pH values. This chart is provided for informational reference only. ORGANIC AIRBORN MATERIALS Organic damage is generally easier to identify. Organic damage is mostly due to tree sap, bird and insect droppings, dead insects (Figure 8) and pollen. Tree sap is easily identified by clear raised drops that may be hard or sticky. Bee or bug dropping spots may appear brownish or yellow in color, about an eighth to a quarter inch in diameter. Dead and decomposing insect bodies are readily visible to the eye. Pollen deposits are small yellow clusters. Each of these items is potentially damaging to any currently available paint system. Other noticeable traits of organic damage are spots that are raised (swelling) micro-crazing (cracked) and pitting, due to pollen eating into the paint film. The active ingredients in most organic contaminants are tannic and formic acids . These acids are found in berries and bodily fluids of insects and birds. Investigations completed at dealerships show that the bright lot lights tend to attract insects. The use of "soft lights" for display and storage lot illumination will help reduce damage resulting from decomposing bugs and droppings by decreasing the number of bugs attracted to these lights. Organic damage is accelerated by heat. During very hot weather conditions, it is important to wash vehicles more often. ORGANIC AND INORGANIC REPAIR PROCEDURES FOR MILD DAMAGE Iron dust particles may imbed themselves into the paint film. On some light colored vehicles after some weathering, tiny dots of rust start to appear. They Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 89133 > Jun > 89 > Paint - Cosmetic Damage From Airborn Materials > Page 6536 feel rough to the touch and are difficult to remove. The best way to remove these particles is by treating the finish with an oxalic acid-detergent-water wash. Use the following procedure to perform this service repair. NOTE: OXALIC ACID WASH IS ALSO PRE-PACKAGED IN VARIOUS STRENGTHS UNDER VARIOUS BRAND NAMES, IF YOU CHOOSE NOT TO MIX YOUR OWN BATCHES. 1. Wash and degrease the vehicle first, using Ford Multi Purpose Cleaner (B8A-19523-B) or equivalent, and a suitable wax and grease remover. If this does not remove all of the iron particles, proceed with the oxalic acid wash. 2. Prepare a quantity of oxalic acid-detergent-water solution as follows: a. Dissolve 6-8 ounces of Oxalic Acid (powder) in one gallon of warm water. b. Add 1-2 tablespoons full of non-alkaline detergent such as Ford Multi Purpose Cleaner. 3. Apply this solution liberally to all affected surfaces of the vehicle with a large sponge. Keep the surface wet until the technician can no longer feel any surface roughness with bare or gloved fingertips. NOTE: IF THIS IS NOT DONE THOROUGHLY, STAINING MAY REDEVELOP IF IRON PARTICLES ARE LEFT BEHIND. 4. Rinse the area with clean water. CAUTION: FAILURE TO THOROUGHLY RINSE THIS SURFACE COULD RESULT IN CORROSION OF ANODIZED ALUMINUM OR STAINLESS STEEL PARTS WITH PROLONGED CONTACT. 5. If the iron particles are not totally removed after 2 washings, use one or both of the procedures listed for minor chemical contamination. NOTE: THE USE OF POLISHING (WITH WAX), SANDING WITH MICRO FINE SANDPAPER (1500 GRIT OR GREATER) OR BUFFING WITH VERY LIGHT COMPOUND SHOULD ONLY BE DONE AS A LAST RESORT. CHEMICAL CONTAMINATION Chemical contamination, either acid or alkali, can cause off-color spots and crack the paint film. In the presence of moisture (dew), sulfur contamination will change the color (light/dark) of the paint pigments. (This does not apply to Basecoat/Clearcoat) Since this contamination affects the pigments, lacquers and enamels show no difference in resistance. Production thermal drying and air drying finishes are likely to be spotted. Minor chemical contamination can be removed by using the following step by step procedure. 1. Wash the vehicle first by using Ford Multi Purpose Cleaner (B8A-19523-B) or equivalent to remove the exterior foreign materials. 2. If the spotting is extensive and on the horizontal surfaces, then machine polish. 3. Apply a light grit polishing compound to the affected surface by using a soft brush. The compound should be applied to a small area at a time so that it can be buffed out while still wet to get maximum cutting efficiency. 4. Polish off the spots using a buffer operating at 1700-1800 rpm. Confine polishing to the spotted areas. Repeat as necessary until all spots have been removed. 5. Remove spots on curved surfaces, near edges, and next to mouldings or ornaments by hand polishing as follows: a. Apply some polishing compound to a cotton cloth. (Do not use a synthetic cloth.) b. Rub vigorously until the spots are no longer visible. c. Clean off excess polishing compound by using a clean cloth and compressed air. 6. Buff out the polishing marks and bring up the gloss by using a buffer equipped with a clean, dry lambs wool pad. NOTE: IF POLISHING DOES NOT SUFFICIENTLY REMOVE DAMAGE, THE VEHICLE CAN BE WET SANDED USING 1500 GRIT SANDPAPER AND THE FOLLOWING PROCEDURE Wet Sanding Procedure 1. Clean the exterior surface of the vehicle with Ford Multi Purpose cleaner or an equivalent to remove all contamination. 2. Apply 1500 grit sandpaper to a rubber padded sanding block to sand the paint surface. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 89133 > Jun > 89 > Paint - Cosmetic Damage From Airborn Materials > Page 6537 3. Use a squirt bottle filled with water to lubricate the 1500 grit sandpaper as you begin to sand only the damaged areas. Water is an abrasive as well as a lubricant in this step. NOTE: IF THE DAMAGE HAS GONE DEEPLY INTO THE PAINT FILM AND IT WILL NOT POLISH OR SAND OUT, THEN REFINISHING IS REQUIRED. ORGANIC MATERIAL REPAIR PROCEDURE FOR MILD DAMAGE Minor organic damage can be removed by using the following step by step procedure. 1. Wash and degrease the vehicle thoroughly by using Ford Multi Purpose Cleaner (B8A-19523-B) or equivalent and a wax and grease remover to remove all organics. 2. Inspect the vehicle horizontal surfaces. If spotting or paint film swelling is extensive, use a buffer to repair. 3. Apply a light grit polishing compound to the affected areas by using a soft brush. The compound should be applied to a small area at a time so that it can be buffed out while still wet to get maximum efficiency. 4. Polish off the spots or swelling marks using a buffer that operates between 1700-1800 rpm. Polishing should be confined to the affected areas only. Repeat as necessary until all spots or marks are removed. 5. Remove spots on curved surfaces, near edges, and next to mouldings or ornaments by hand polishing as follows: a. Apply some polishing compound to a cotton cloth. (Do not use a synthetic cloth.) b. Rub vigorously until the spots are no longer visible. c. Clean off excess polishing compound by using a clean cloth and compressed air. 6. Buff out the polishing marks and bring up the gloss by using a buffer equipped with a clean, dry lambs wool pad. NOTE: IF POLISHING DOES NOT SUFFICIENTLY REMOVE DAMAGE, THE VEHICLE CAN BE WET SANDED USING 1500 GRIT SANDPAPER AND THE FOLLOWING PROCEDURE. Wet Sanding Procedure 1. Clean the exterior surface of the vehicle with Ford Multi Purpose cleaner or an equivalent to remove all organics. 2. Apply 1500 grit sandpaper to a rubber padded sanding block to sand the paint surface. 3. Use a squirt bottle filled with water to lubricate the 1500 grit sandpaper as you begin to sand only the damaged areas. Water is an abrasive as well as a lubricant in this step. NOTE: IF THE DAMAGE HAS GONE DEEPLY INTO THE PAINT FILM AND IT WILL NOT POLISH OUT, THEN REFINISHING IS REQUIRED. PAINT RECONDITIONING PROCEDURES FOR SEVERE DAMAGE Acrylic enamel single stage or base/clear paint systems should be painted by using the following procedure. 1. .Wash the vehicle with Ford Multi Purpose Cleaner or equivalent to remove all organic materials. 2. Wash the areas to be painted with wax and grease remover. 3. Prepare the area as follows: a. Neutralize the affected areas with baking soda (sodium bicarbonate) and water. b. Rinse the surface off with plain water. c. Wash the panel with a mild soapy detergent. d. Dry the panel completely. NOTE: IF THE DAMAGE IS THROUGH THE TOP COAT FINISH AND INTO THE PRIMERS, THE PANEL MUST BE SANDED DOWN TO BARE METAL OR PLASTIC AND THEN REFINISHED. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 89133 > Jun > 89 > Paint - Cosmetic Damage From Airborn Materials > Page 6538 4. Apply a self-etching primer for metal surfaces only. NOTE: A FLEX ADDITIVE MAY BE NECESSARY WHEN WORKING WITH FLEXIBLE PLASTICS Then proceed as follows: a. Let dry per instructions. b. Apply a two component urethane primer surfacer. c. Sand the surface with 400 grit sandpaper to get to proper finish. d. Finish sanding with 600 grit sandpaper. 5. Solvent wash panel with wax and grease remover. Then, tack wipe it. 6. Apply base coat or top coat material per applicable paint system. NOTE: THE USE OF ACRYLIC URETHANE ENAMEL IS HIGHLY RECOMMENDED FOR THIS TYPE OF REPAIR. 7. Apply clear acrylic urethane if you are using a base/clear paint system. WAYS TO MINIMIZE EFFECTS OF AIRBORN MATERIAL DAMAGE During the past year, Ford Motor Company and major paint suppliers have participated in a survey to analyze the effects of airborn materials. This survey was conducted on foreign and domestic vehicles. It resulted in the following interesting conclusions. 1. Keeping the vehicles clean, washing frequently with de-ionized water and drying by hand or mechanical means will help minimize the effects of inorganic and organic materials. 2. Spray washing without rubbing will not totally remove all residue on the surface of the vehicle. Damage could possibly occur over a longer period of time. 3. Care should be taken to not allow any painted vehicle surface to become wet in direct sunlight. (A sprinkler system can cause damage if the vehicles are not dried.) Possible alkaline water or mineral deposit may be the cause. 4. The use of "Soft Lights" for lighting around storage lots and showing areas will minimize the attraction of insects and the possibility of organic damage. 5. Ford Motor Company is piloting a program for a transit/storage coating to be applied on the horizontal surfaces of all vehicles. These coatings have shown good protection to the paint surface. They are clear in color and should be left on the vehicles until they are sold. 6. We are testing many "permanent paint sealants" used by dealers. Until all testing is completed, we cannot give any recommendations for what products to use. Testing has shown that a sealant that allows water to bead up on the vehicle does not help to dissipate the materials on the paint surface. Sheeting of water on the vehicle is highly desirable. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 1100 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 87151 > Jul > 87 > Paint - Difficulty Matching Production Colors Paint: All Technical Service Bulletins Paint - Difficulty Matching Production Colors PAINT - DIFFICULTY MATCHING AFTERMARKET Article No. COLORS WITH FORD PRODUCTION COLORS 87-15-1 FORD: 1986-88 ALL CAR LINES LINCOLN-MERCURY: 1986-88 ALL CAR LINES MERKUR: 1986-88 XR4Ti 1988 SCORPIO LIGHT TRUCK: 1986-88 ALL LIGHT TRUCK LINES ISSUE: Paint audits and field reports have indicated concerns in matching aftermarket paint colors to the Ford production paint colors. This matching concern seems to be greater when comparing the metallic paints. ACTION: To correct this, DuPont and PPG Aftermarket Divisions will supply color variance decks by August 1, 1987 to DuPont and PPG Distributors and District Offices for distribution to dealerships. Updated color variance decks will be sent during October, 1987 and will then continue to be sent on a regular basis. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > 9561 > Mar > 95 > Paint - Iron Particle Removal Paint: All Technical Service Bulletins Paint - Iron Particle Removal Article No. 95-6-1 03/27/95 ^ PAINT - IRON PARTICLE REMOVAL - INDUSTRIAL FALLOUT - ACID RAIN NEUTRALIZATION ^ PAINT - ROUGH TEXTURE/FERROUS METAL CONTAMINATION - ACID RAIN DISCOLORATION OR ETCHING FORD: 1980 and after CROWN VICTORIA, ESCORT, MUSTANG, THUNDERBIRD 1982-88 EXP 1984-94 TEMPO 1986 and after TAURUS 1988-93 FESTIVA 1989 and after PROBE 1994-95 ASPIRE 1995 CONTOUR LINCOLN-MERCURY: 1980 and after CONTINENTAL, COUGAR, GRAND MARQUIS, TOWN CAR 1981-87 LYNX 1984-92 MARK VII 1984-94 TOPAZ 1986 and after SABLE 1987-89 TRACER 1991-94 CAPRI 1991 and after TRACER 1993 and after MARK VIII 1995 MYSTIQUE MERKUR: 1985-89 XR4TI 1988-89 SCORPIO LIGHT TRUCK: 1980 and after F-150-350 SERIES 1981 and after ECONOLINE 1982 and after BRONCO 1983 and after RANGER 1984-90 BRONCO II 1986 and after AEROSTAR 1988 and after F SUPER DUTY 1991 and after EXPLORER 1993 and after VILLAGER 1995 and after WINDSTAR MEDIUM/HEAVY TRUCK: 1980-91 C SERIES, CL-CLT-9000 SERIES 1980 and after F & B SERIES, L SERIES 1986 and after CARGO SERIES ISSUE: Ferrous metal particles (hot iron dust) are generated by manufacturing facilities, rail shipments, combustion engines, jet engines, body shops, etc. These particles mechanically/magnetically bond to vehicles' painted surfaces. Moisture and temperature combine with the particles to create a chemical reaction. The reaction causes the particles to corrode and enter into the physical paint film. ACTION: To remove these particles/contaminants, USE ONLY the following procedure. The procedure must be performed before any buffing, polishing, color sanding or refinishing is attempted. The materials in this procedure are alkaline, acidic and neutral. They must be used in the specified order. CAUTION: ANY CHANGES TO THIS PROCEDURE WILL CAUSE AN INCOMPLETE OR UNSATISFACTORY REPAIR AND MAY RESULT IN Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > 9561 > Mar > 95 > Paint - Iron Particle Removal > Page 6548 POSSIBLE DAMAGE TO THE PAINTED SURFACES AND TRIM. WARNING: THE TECHNICIAN MUST WEAR PROTECTIVE CLOTHING AND EYE PROTECTION TO PREVENT SKIN IRRITATION. CAUTION: THE USE OF ANY OTHER PRODUCT OR PROCEDURE MAY CAUSE DAMAGE TO ALUMINUM, FLEXIBLE PAINTED SURFACES OR OTHER PAINTED SURFACES. FOLLOW DIRECTIONS EXACTLY AND RINSE THOROUGHLY AFTER EACH STEP. NOTE: THIS DECONTAMINATION PROCEDURE IS DESIGNED TO REMOVE SURFACE CONTAMINANTS FROM THE PAINT ON VEHICLES THAT HAVE BEEN CONTAMINATED UP TO 120 DAYS. VEHICLES WHICH HAVE EXPERIENCED THE CONDITION LONGER THAN THIS PERIOD MAY REQUIRE AN ADDITIONAL TREATMENT TO REMOVE FERROUS METAL CONTAMINANTS. IDENTIFICATION Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > 9561 > Mar > 95 > Paint - Iron Particle Removal > Page 6549 For ease of identifying, the Radio Shack Model 63-851, 30X, lighted, magnifier is recommended. 1. Ferrous Metal ^ Light colored vehicles: Small rust orange dots with black in center of stain. ^ Dark colored vehicles: Small white or silver dots with a "rainbow hue" around the particle. The surface will also feel rough to the touch. 2. Industrial Fallout ^ The surface feels rough to the touch and may exhibit crystalline deposits. ^ Usually ferrous metal is present, as well as water spots. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > 9561 > Mar > 95 > Paint - Iron Particle Removal > Page 6550 3. Acid Rain ^ Surface will exhibit irregular discolored spotting. ^ Dark colored vehicles will show cloudy or greying spots where the acids have started to etch away the paint. NOTE: IN EXTREME CASES ETCHING OF THE SURFACE WILL BE VISIBLE OR FELT. DECONTAMINATION Use Finish Kare Inc. products 1119/883/11850 to decontaminate the paint surface. Follow the manufacturer's recommended procedures. NOTE: FORD DOES NOT RECOMMEND THE USE OF OXALIC ACIDS OR OTHER "FALLOUT REMOVERS". 1. Rinse off dust and debris with cold water. Be sure to start at the bottom and work up. 2. Prepare product "1119" by mixing one (1) part "1119" with four (4) parts cold water. 3. Use clean wash mitt and apply mixture to entire car, starting at the bottom and working up to the top surface. Keep car wet with the solution for 5 to 10 minutes. Do not allow product to dry on the car, and do not allow it to streak down the sides. Rewipe with mitt if necessary to avoid streaks. 4. Rinse car with cold water. 5. Dry the flat surfaces of the vehicle hood, roof and deck lid. 6. Apply product "883" directly to the contaminated surfaces using a clean dry sponge, wash mitt, or soft truck brush ("883" is ready to use from the bottle, with no mixing involved). Keep the areas wet with the "883" for 5 to 7 minutes. Do not allow to dry on the car. Wipe down to the body line on the sides. 7. Prepare product "118SC" by mixing 1 oz (0.03 L) with 1 gal (3.785 L) of water. 8. Shampoo the vehicle with "118SC" shampoo mixture using a clean wash mitt and then rinse with cold water. NOTE: DO NOT USE "1185C" MITT WITH "1119" OR "883" SOLUTIONS. USE SEPARATE MITTS AND ALWAYS KEEP THEM SEPARATE. 9. Inspect paint surface to see if rust particles have been removed. If rust particles have been on the vehicle for a long time, it may be necessary to repeat each of the above steps. NOTE: THE NEUTRALIZER CONCENTRATE IS A HEAVY DUTY SHAMPOO AND CAN BE USED IN AN AUTOMATIC CAR WASH SYSTEM. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > 9561 > Mar > 95 > Paint - Iron Particle Removal > Page 6551 CORRECTION OF SURFACE FOLLOWING DECONTAMINATION: 1. Visually inspect surface for evidence of removal of ferrous metal particles, crystalline deposits and water spots. Acid rain discoloring or etching will require either buffing, color sanding or refinishing if etching is visible. 2. Use the buffing products from only one (1) manufacturer. Do not intermix products. 3. Always follow the manufacturer's product sequence. Use appropriate pads with each product as recommended by the manufacturer. NOTE: DO NOT REMOVE MORE THAN 0.3 OF A MIL OF PAINT MATERIAL, OR REPAINTING WILL BE REQUIRED. 4. Use a dual action sander (D/A Sander) with a velcro-mount backing plate and appropriate foam pad for final polishing swirl removal. 5. Use an alcohol and water mixture (1:4 ratio) to clean buffed areas to verify removal of scratches and swirls before application of final protective glaze. NOTE: FREQUENT WASHING OF VEHICLES IS IMPORTANT. CONTAMINANTS SETTLE ONTO THE VEHICLE EVERY DAY. USE CLEAN WATER (DEIONIZED, REVERSE OSMOSIS, ETC.) TWICE WEEKLY TO REMOVE HEAVY DUST, AND PARTICULATES. THE USE OF A NEUTRAL pH CAR WASH SOAP EVERY TWO (2) WEEKS IS RECOMMENDED TO NEUTRALIZE VEHICLE CONTAMINATION. Parts Block NOTE: DEALERS SHOULD USE PROGRAM CODE R-23 AND CONDITION CODES C5 AND C6. REFER TO W & P MANUAL, SECTION 5-1, PAGE 3. OTHER APPLICABLE ARTICLES: 91-18-1, 92-6-4 WARRANTY STATUS: Eligible Under The Provisions Of 12 Month/12,000 Mile Basic Warranty Coverage OPERATION DESCRIPTION TIME 950601A Decontaminate And Surface 0.6 Hr. Correction - Aspire 950601B Decontaminate And Surface 0.6 Hr. Correction - Escort/Tracer 950601C Decontaminate And Surface 0.6 Hr. Correction - Probe Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > 9561 > Mar > 95 > Paint - Iron Particle Removal > Page 6552 950601D Decontaminate And Surface 0.6 Hr. Correction - Contour/Mystique 950601E Decontaminate And Surface 0.6 Hr. Correction - Mustang 950601F Decontaminate And Surface 0.7 Hr. Correction - Taurus/Sable 950601G Decontaminate And Surface 0.7 Hr. Correction - Thunderbird/Cougar 950601H Decontaminate And Surface 0.7 Hr. Correction - Crown Victoria/Grand Marquis 950601I Decontaminate And Surface 0.7 Hr. Correction - Mark VIII 950601J Decontaminate And Surface 0.7 Hr. Correction - Continental 950601K Decontaminate And Surface 0.6 Hr. Correction - Capri 950601L Decontaminate And Surface 0.8 Hr. Correction - Town Car 950601M Decontaminate And Surface 0.7 Hr. Correction - Villager 950601N Decontaminate And Surface 0.6 Hr. Correction - Windstar 9506010 Decontaminate And Surface 0.7 Hr. Correction - Aerostar 950601P Decontaminate And Surface 0.6 Hr. Correction - Bronco 9506010 Decontaminate And Surface 1.1 Hrs. Correction - Econoline 950601R Decontaminate And Surface 0.9 Hr. Correction - F-Series 950601S Decontaminate And Surface 0.6 Hr. Correction - Explorer 950601T Decontaminate And Surface 0.7 Hr. Correction - Ranger 950601U Decontaminate And Surface 0.5 Hr. Correction - F-Super Duty 950601V Decontaminate And Surface 0.7 Hr. Correction - F/B-Series 950601W Decontaminate And Surface 0.7 Hr. Correction - L-Series 950601X Decontaminate And Surface 0.5 Hr. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > 9561 > Mar > 95 > Paint - Iron Particle Removal > Page 6553 Correction - Cargo 950601Y Decontaminate And Surface 0.6 Hr. Correction - Tempo/Topaz DEALER CODING BASIC PART NO. CONDITION CODE ENTRE C5 OR C6 OASIS CODES: 106000 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > 94234 > Nov > 94 > Paint - Preparation Procedure And MSDS Information Paint: All Technical Service Bulletins Paint - Preparation Procedure And MSDS Information Article No. 94-23-4 11/14/94 PAINT - PRIMED SHEET METAL - PREP PROCEDURE AND MSDS INFORMATION FORD: 1980 and after CROWN VICTORIA, ESCORT, MUSTANG, THUNDERBIRD 1982-88 EXP 1984 and after TEMPO 1986 and after TAURUS 1988-93 FESTIVA 1989 and after PROBE LINCOLN-MERCURY: 1980 and after CONTINENTAL, COUGAR, GRAND MARQUIS, TOWN CAR 1981-87 LYNX 1984-92 MARK VII 1984 and after TOPAZ 1986 and after SABLE 1987-89 TRACER 1991-94 CAPRI 1993 and after MARK VIII MERKUR: 1985-89 XR4TI 1988-90 SCORPIO LIGHT TRUCK: 1980 and after F-150-350 SERIES 1981 and after ECONOLINE 1982 and after BRONCO 1983 and after RANGER 1984-90 BRONCO II 1986 and after AEROSTAR 1988 and after F SUPER DUTY 1991 and after EXPLORER 1993 and after VILLAGER 1995 WINDSTAR MEDIUM/HEAVY TRUCK: 1980-91 C SERIES, CL-CLT-9000 SERIES 1980 and after F & B SERIES, L SERIES 1986 and after CARGO SERIES ISSUE: This procedure is being published to advise all body and paint technicians about proper procedures for preparation of sheet metal parts coated with electrodeposition primer (E-Coat). ACTION: When prepping a replacement body panel for installation, it is mandatory to leave the E-Coat intact. DO NOT SAND OFF THE E-COAT. Improper preparation with excessive sanding of the E-Coat to bare metal will jeopardize the sheet metal warranty and overall customer satisfaction. In particular, the E-Coat is necessary to protect the parts from rust. Light scuff sanding using a Scotch Brite pad or wet 320 grit sand paper is recommended for minor flaws. If a minor flaw exists, wet sand or scuff out the flaw and prime the repair area. Again, do not remove all of the E-Coat from the panel. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > 94234 > Nov > 94 > Paint - Preparation Procedure And MSDS Information > Page 6558 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > 94234 > Nov > 94 > Paint - Preparation Procedure And MSDS Information > Page 6559 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > 94234 > Nov > 94 > Paint - Preparation Procedure And MSDS Information > Page 6560 WARNING: LEAD CONTAMINATION POTENTIAL: THE ELECTRODEPOSITION PRIMER USED BY FORD MOTOR COMPANY OVER BASE METAL ON SERVICE REPLACEMENT PARTS OR COMPLETED VEHICLES CONTAINS SMALL AMOUNTS OF LEAD FOR CORROSION PROTECTION OF STEEL. EXCESSIVE DUSTS GENERATED BY UNNECESSARY AND IMPROPER SANDING MAY CONTAIN AIRBORNE LEAD CONTAMINATION IN EXCESS OF OSHA STANDARDS. INFORMATION REGARDING THE HAZARDS OF LEAD CAN BE FOUND IN THE CHEMICAL FACT SHEETS IN THE FIGURES IN THIS ARTICLE. NOTE: READ ALL INFORMATION IN THIS TECHNICAL SERVICE BULLETIN CAREFULLY AND FORWARD TO ALL EMPLOYEES PERFORMING PAINT PREPPING OPERATIONS. DEALERS SHOULD CONTACT LEGAL COUNSEL AND/OR LOCAL OSHA Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > 94234 > Nov > 94 > Paint - Preparation Procedure And MSDS Information > Page 6561 AUTHORITIES FOR DIRECTION REGARDING OSHA LEAD STANDARD REQUIREMENTS. If a replacement body panel contains more than a minor flaw in the E-coat, it should be returned. Contact your Customer Service representative for instructions. If more extensive sanding, other than that described above, is necessary, (e.g., refinishing original vehicle sheet metal) follow the procedures outlined below: ALTERNATIVE SANDING PROCEDURES WHEN EXTENSIVE SANDING IS REQUIRED The following procedures for sheet metal preparation by sanding or media blasting are based on tests conducted by Ford Motor Company in accordance with requirements set forth in the Federal OSHA Inorganic Lead Standard 29 CFR 1910.1025. SANDING PROCEDURE 1. Each technician performing the sanding operation MUST wear an approved respirator with high efficiency particulate filter (HEPA). 2. Technicians should use dual action sander with vacuum collection. 3. The vacuum equipment MUST be equipped with a HEPA filter on the air exhaust. Dealers are cautioned not to exhaust vacuum air into the atmosphere. Operators are cautioned to follow the manufacturer's guidelines for maintenance and the replacement of filters. MEDIA BLASTING PROCEDURE 1. Testing has shown that plastic media blasting meets OSHA lead standard requirements and is efficient when the manufacturer's published procedures are followed. 2. The operator must wear an air supplied hood using compressed air free from carbon monoxide, oil, water, and other contamination when performing this operation. Specifics of the media blasting procedure for whole body paint removal have been previously published. NOTE: PLEASE READ THE CHEMICAL FACT SHEETS IN THE FIGURES. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 106000 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > 9366 > Mar > 93 > Paint to Match Parts - Generic Paint Procedure Paint: All Technical Service Bulletins Paint to Match Parts - Generic Paint Procedure Article No. 93-6-6 03/17/93 PAINT - "DEALER PAINT TO MATCH" PARTS - GENERIC PAINTING PROCEDURE FLARESIDE FENDER AND DUAL REAR WHEEL MODELS WITH PICKUP BOX LIGHT TRUCK: 1980-92 F-150-350 SERIES ISSUE: Ford Motor Company is continuing to supply selected parts in "Dealer Paint To Match" form. These selected parts are not painted and require painting at the dealership. ACTION: Use the following painting procedure as a generic process for preparing SMC (Sheet Moulded Compound) plastic body panels. 1. Wash the panel down with detergent and medium warm water. 2. Scuff the entire panel with a "Scotchbrite" fine pad. 3. Blow off the panel to remove debris. 4. Use a low VOC (Volatile Organic Compound) type wax and grease remover or pre-paint cleaner to clean the part. WARNING: REGULAR WAX AND GREASE REMOVERS CONTAIN LOW FLASH POINT SOLVENTS THAT MAY IGNITE WHEN CLEANING PLASTIC. THIS IS DUE TO STATIC ELECTRICITY BUILD UP. 5. Mix and apply one (1) coat of epoxy primer and let flash per the manufacturer's label instructions. 6. Mix and apply one (1) coat of colored urethane primer/sufacer or primer/sealer per the manufacturer's label instructions. 7. Mix and apply either single stage or basecoat/clearcoat paint system per vehicle requirement. Use manufacturer's label instructions. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 106000, 111000, 190000 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > 91181 > Sep > 91 > Exterior Paint - Comprehensive Repair Procedures Technical Service Bulletin # 91181 Date: 910905 Exterior Paint - Comprehensive Repair Procedures Article No. 91-18-1 09/05/91 PAINT-EXTERIOR-COMPREHENSIVE REPAIR PROCEDURES FORD: 1985-86 LTD 1985-92 CROWN VICTORIA, ESCORT, MUSTANG, TEMPO, THUNDERBIRD 1986-92 TAURUS 1988-92 FESTIVA 1989-92 PROBE LINCOLN-MERCURY: 1985-86 CAPRI, MARQUIS 1985-87 LYNX 1985-92 CONTINENTAL, COUGAR, GRAND MARQUIS, MARK VII, TOPAZ, TOWN CAR 1986-92 SABLE 1988-92 TRACER MERKUR: 1985-89 XR4TI 1988-89 SCORPIO LIGHT TRUCK: 1985-90 BRONCO II 1985-92 BRONCO, ECONOLINE, F-150-350 SERIES, RANGER 1986-92 AEROSTAR 1991 EXPLORER ISSUE: A comprehensive paint repair procedure TSB has been developed for service use. It includes the following paint repair topics: Section (A) has been superseded by TSB # 9264, dated 3/92. (B) Exterior Color Peeling From Ultra Violet Light (C) Lower Body Stone Protection Repair Tips (D) Procedures For PVC Body Side Moldings (E) Lower Body-Side Stone Chip Protection Program (F) Surface Defect Removal Without Repainting (G) 1991 Color Matched/Compatible Spray Primer Chart (H) Repair For Tinted Clearcoat (I) Frequently Used And Paintable Plastics (J) 1992 Paint Codes ACTION: If paint repair is required, refer to the following procedures for paint restoration. Section A Has Been Superseded By TSB # 9264, Dated 3/92. CAUTION: FAILURE TO THOROUGHLY RINSE THIS SURFACE COULD RESULT IN CORROSION OF ANODIZED ALUMINUM OR STAINLESS STEEL PARTS PROCEDURE # 2 FINISH KARE FORMULA # 1119 AND # 883 (Buffered solution not as harsh on aluminum parts) WARNING: FOR YOUR SAFETY, USE RUBBER GLOVES, GOGGLES AND PROTECTIVE CLOTHING WHEN HANDLING THESE PRODUCTS. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > 91181 > Sep > 91 > Exterior Paint - Comprehensive Repair Procedures > Page 6570 1. Apply hot diluted solution with soft mitt. 2. Agitate to create suds. Suds hold the acid solution in suspension and to the surface creating greater and extended activity. 3. Allow 3 to 5 minutes dwell time. 4. Rinse with COLD WATER. 5. Apply # 883 per label instructions. LIQUID NEUTRALIZER CONCENTRATE 1. Using a mitt, thoroughly go over the entire surface with the diluted solution (50-1) of water and # 118 Liquid Neutralizer Concentrate. Then wipe dry. 2. If the iron particles are not totally removed after 2 washings, use one or both of the following service actions. a. Sand with micro fine sandpaper (1500 Grid or greater) in localized areas. b. Buff with very light compound and polish with wax in localized areas. WARNING: OUR ENVIRONMENT IS PRECIOUS - PLEASE USE PROPER DISPOSAL TECHNIQUES FOR ANY VOLATILE ORGANIC COMPOUNDS (V.O.C.'S) OR EXCESS MATERIALS. (B) Paint Exterior Color Peeling From Ultra Violet Light Paint may be damaged because of ultra violet light absorption through the color coat. This damage will cause the top coat to peel to the E-coat primer. If service is required, use the following procedure to correct the concerns. NOTE: READ THE ENTIRE SERVICE PROCEDURE BEFORE STARTING REPAIRS. WARNING: ALWAYS WEAR A NOISHA/MSHA RECOMMENDED VAPOR/PARTICULATE RESPIRATOR AND USE OTHER RECOMMENDED SAFETY EQUIPMENT. 1. Wash the vehicle with soap and water. 2. Verify topcoat adhesion by applying a 2 inch wide masking tape strip on all body panels above and below the beltline on each panel. a. Pull the tape up quickly. b. Inspect the adhesive side of the tape for paint removal. NOTE: IF PAINT WAS REMOVED DURING THE TAPE TEST, THE ENTIRE PANEL SHOULD BE STRIPPED AND REFINISHED AS NECESSARY. 3. Remove all trim (mouldings, name plates, striping, etc.) from the areas which will be repainted. NOTE: ALL REQUIRED REPLACEMENT MOULDINGS AND STRIPES SHOULD BE ORDERED AND RECEIVED PRIOR TO REPAIRING THE CUSTOMER'S VEHICLE. 4. Wipe the entire vehicle with wax and grease remover. ^ BASF Product # 900 Prekleano ^ PPG Product # DX300 ^ S-W Product # R7-K156 ^ DuPont Product # 3919 S ^ Sikkens Product # M 600 5. Mask off all areas on the vehicle which are not going to be painted or will be affected by overspray (engine compartment, wheels, etc.). Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > 91181 > Sep > 91 > Exterior Paint - Comprehensive Repair Procedures > Page 6571 6. Remove the paint to bare metal from all the areas of the vehicle which are going to be repainted. Use one of the following methods. SAND THE AFFECTED AREAS TO BARE METAL USING 40 GRIT 3M GREEN CORPS SANDING DISCS OR EQUIVALENT AND A SOFT PAD ON A 1700 RPM POLISHER. KEEP THE POLISHER MOVING TO AVOID DEVELOPING HOT SPOTS ON THE METAL. NOTE: CHEMICAL STRIPPING IS NOT RECOMMENDED. NOTE: IF AVAILABLE, PAINT MAY BE REMOVED USING A PLASTIC MEDIA BLAST SYSTEM. IF THIS PROCESS IS USED, EXTRA CARE MUST BE TAKEN DURING THE MASKING PROCESS TO PREVENT DAMAGE TO GLASS, MOULDING, ETC. 7. Blow off the entire vehicle to remove loose dust and debris. NOTE: IF RUST IS PRESENT, USE APPROPRIATE METAL CLEANER AND CONDITIONER (PHOSPHATE COATING) OVER BARE METAL AREAS. 8. Wipe all affected areas with a fast dry enamel reducer solvent, followed by a dry wipe using a clean, lint free cloth to remove all residue. CAUTION: KEEP WIPING UNTIL SURFACE IS COMPLETELY DRY. ANY RESIDUE WILL RESULT IN POPPING OF THE COATINGS TO BE APPLIED FOLLOWING THIS STEP. NOTE: THIS STEP WILL REDUCE THE POSSIBILITY OF FLASH RUST. ^ BASF Product # BR 50 ^ PPG Product # DX 300 ^ S-W Product # R7 K156 ^ DuPont Product # 3812 S ^ Sikkens Product # 123 FAST 9. Apply two medium wet coats (1.0 mil total) of self-etching, anti-corrosion primer using the manufacturer's recommendations and flash times. ^ BASF Product # DE-17 ^ PPG Product # DP EPOXY PRIMER ^ S-W Product # E2-6980 ^ DuPont Product # VARIPRIME ^ Sikkens Product # WASH FILLER 580 10. Apply three medium wet coats (2.0 mils total) of acrylic urethane primer surfacer following the manufacturer's recommended procedures. ^ BASF Product # DP-20 PRIMER/SUFACER ^ PPG Product # K-36 ^ S-W Product # P6-M49 OR P6-A48 ^ DuPont Product # URO PRIMERFILLER ^ Sikkens Product # AUTOCRYL 3+1 FILLER 11. Sand the vehicle using one of the following methods: ^ Wet-sand by hand using 400 grit or finer sandpaper. ^ Dry-sand by hand using 320 grit or finer sandpaper. 12. Blow the entire vehicle off to remove loose dust and debris. 13. Demask (remove all paper and tape) as necessary to remove the primer and dirt buildup on the paper and tape. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > 91181 > Sep > 91 > Exterior Paint - Comprehensive Repair Procedures > Page 6572 14. Wipe the entire vehicle with wax and grease remover, followed by a dry wipe using a clean, lint free cloth to remove all residue. CAUTION: KEEP WIPING UNTIL SURFACE IS COMPLETELY DRY. ANY RESIDUE WILL RESULT IN POPPING OF THE COATINGS TO BE APPLIED FOLLOWING THIS STEP. ^ BASF Product # 901 PRE-PAINT CLEANER ^ PPG Product # DX 330 ^ S-W Product # R7-K156 ^ DuPont Product # 3812 S ^ Sikkens Product # M 600 15. Mask all areas on the vehicle which are not to be painted or will be affected by paint overspray (engine compartment, wheels, etc.). NOTE: APPLY BASECOAT/CLEAR COAT ONLY TO SURFACES WHICH ORIGINALLY HAD BASECOAT/CLEAR COAT 16. Apply three medium wet coats (enough material to hide primer) of acrylic enamel base coat or acrylic urethane monocoat following the manufacturer's recommended procedure. ^ BASF Product # DIAMONT BASECOAT/Solo ^ PPG Product # DELTRON BASECOAT DBC/Deltron ^ S-W Product # ULTRA BASE/Ultra One Stage ^ DuPont Product # CHROMABASE/Cronar ^ Sikkens Product # AUTO BASE/Autocryl 17. Apply two medium wet coats of 2K acrylic urethane enamel clear coat, following manufacturer's recommended procedure. ^ BASF Product # DIAMONT CLEAR 88/89 ^ PPG Product # CONCEPT 2001 DCU ^ S-W Product # CC-650 OR CC-640 ^ DuPont Product # 1080 S URO CLEAR ^ Sikkens Product # AUTO CLEAR 18. After the paint is dry, demask the entire vehicle and clean up any areas which have overspray. 19. Polish the vehicle as necessary to remove any defects in the paint which may create a customer concern. CAUTION: USE LOW SPEED (1700 RPM MAXIMUM) POLISHER. 20. Install all trim (mouldings, name plates, striping, etc.) on the vehicle which were removed prior to repainting. 21. Clean the exterior and interior of the vehicle thoroughly, including air ducts and other areas which are prone to accumulating dust. This step is essential to ensure customer satisfaction. WARNING: OUR ENVIRONMENT IS PRECIOUS - PLEASE USE PROPER DISPOSAL TECHNIQUES FOR ANY VOLATILE ORGANIC COMPOUNDS (V.O.C.'s) OR EXCESS MATERIALS. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > 91181 > Sep > 91 > Exterior Paint - Comprehensive Repair Procedures > Page 6573 Figure 1 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > 91181 > Sep > 91 > Exterior Paint - Comprehensive Repair Procedures > Page 6574 Figure 2 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > 91181 > Sep > 91 > Exterior Paint - Comprehensive Repair Procedures > Page 6575 Figure 3 STRIP AND REFINISH CLAIMING METHODOLOGY The claiming instructions shown in Figure 1 are applicable to the repair of the EXTERIOR COLOR PEELING FROM ULTRA VIOLET LIGHT concern covered in this TSB only. See the SAMPLE CLAIMS, Figures 2 and 3, for examples. (C) Lower Body Stone Protection Repair Tips Ford has introduced a vinyl anti-stone abrasion material for the lower exterior body surfaces of selected passenger vehicles and light trucks. The anti-stone abrasion material is applied to the lower fenders, rocker panels, lower doors, quarter panel dogleg, and lower rear of quarter panel behind the wheel. The anti-stone abrasion material will usually end at a body character line. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > 91181 > Sep > 91 > Exterior Paint - Comprehensive Repair Procedures > Page 6576 While primarily for servicing of factory-applied protective coating, the following provides installation information. If the vehicle has experienced body damage in the factory-applied material protective area, the sheet metal damage must be serviced prior to the application of the new protective coating. SMALL AREAS - MINOR DEFECTS (VEHICLES WITH FACTORY SPRAYED-ON VINYL) A small dent in the sheet metal that did not mar the vinyl surface, can possibly be corrected with proper bumping tools without damage to the vinyl coating. However, noticeable scratches or gouges (not over 1/2 inch in diameter) or dings and dents that when "ironed out" show vinyl damage, can be satisfactorily serviced with the following procedure: 1. Solvent-wipe the damaged area with "Silicone and Wax Remover." 2. Using a heat gun or lamp, soften the vinyl coating of the damaged area until it can be scraped off with a putty knife or a similar tool. If necessary, sand off any hard to remove coating using an orbital disc sander (No. 80 Disc). (The spray-on vinyl protective coatings may not be suitable for "spot" application. See Manufacturer's label for instructions.) 3. Perform necessary servicing to correct the sheet metal damage. 4. Using white bodyfiller, fill the damaged area. Follow the instructions on the label and blend the bodyfiller with the surrounding sheet metal. 5. Allow the bodyfiller to completely cure and then carefully sand the area smooth, removing any high spots. 6. Refer to "Spray Procedure" for restoration of vinyl anti-stone abrasion material. LARGE DAMAGED AREAS - VEHICLE WITH FACTORY SPRAYED ON VINYL Peeling or damage over a large area will necessitate removal of the factory sprayed-on vinyl coating. The following procedure is suggested. NOTE: WHERE SHEET METAL IS DAMAGED TO THE EXTENT THAT A FENDER, DOOR, OR QUARTER PANEL REPLACEMENT IS REQUIRED (OR IN AN INITIAL INSTALLATION), DISREGARD STEPS NO. 1 AND NO. 2. 1. Using a heat gun or lamp, soften the vinyl coating until it is pliable. Scrape coating off with a putty knife or a similar tool. If necessary, sand off any hard to remove coating using an orbital disc sander (No. 80 Disc). (The vinyl material, abrasion resistant coating may not be suitable for "spot" applications. See manufacturer's label for instructions.) 2. Perform necessary servicing to correct the sheet metal damage. 3. Refer to "Spray Procedure" for restoration of vinyl anti-stone abrasion material. COATING APPLICATIONS Approximately two quarts will be required for an initial installation on a passenger car or F-Series. Slightly more will be required for an Econoline. The specified dry film thickness of 15 to 20 mils (.015 to .020 inch) will require at least three, possibly four, applications of coating material, with "flash off" time between coats. Spray coat complete panels only. The coating must be applied with commercial equipment by an experienced automotive painter. The coating must be thoroughly agitated before application. The material is heavy bodied. A pressure cup spray gun or "Rocker Schutz Gun" is recommended. COATING PREPARATION - MASKING VEHICLE Install suitable covers over the wheels. NOTE: IF THE VEHICLE HAS LOWER BODY SIDE MOULDINGS (12-14 INCHES ABOVE THE "TURN UNDER" OF THE ROCKER PANEL), THE MOULDING CAN SERVE AS THE UPPER MARGIN OF THE AREA TO BE COATED. IF THE VEHICLE DOES NOT HAVE SUITABLE MOULDINGS, A SCULPTURE OR BREAK LINE IN THE SHEET METAL CAN BE UTILIZED. THIS LINE SHOULD BE SELECTED TO ENSURE ADEQUATE PROTECTION OF THE PAINTED SURFACES. VEHICLES WITH BODY SIDE MOULDINGS 1. Masking tape should be positioned so that the moulding lower edge is also covered. The adjoining sheet metal should be left uncovered too so anti-stone, abrasion vinyl can be applied. VEHICLES WITHOUT BODY SIDE MOULDINGS 2. If the contour of the body side has a break line, the upper coating margin must be masked off using 3M "Fine Line" Tape. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > 91181 > Sep > 91 > Exterior Paint - Comprehensive Repair Procedures > Page 6577 a. The normal masking tape and paper protection for the body side should be applied first and positioned about a quarter inch above the margin line. b. The "Fine Line" tape should then be applied over the regular masking tape with the lower edge at the upper coating margin line. Extend this "Fine Line" tape into the wheel opening, in the absence of wheel opening mouldings, allowing the flange to be coated. c. The anti-stone abrasion coating does not adhere well to flexible plastic parts. If left exposed, they must be masked off. d. It is not necessary to mask off the body door openings in the coating area, as they will be uniformly coated where the door margins allow the coating to enter. NOTE: DOOR OPENING AREAS SHOULD BE CLEANED TO ASSURE COATING ADHERENCE. COATING PREPARATION - SHEET METAL REPAIRED SHEETMETAL 1. Scuff sand (No. 180 Grit Paper) the glossy surface of the painted areas to be coated. 2. Using a clean, lint-free cloth, solvent wipe the area to be coated with wax and grease remover. 3. Remove sanding dust using compressed air and lint-free tack cloth. NEW SHEET METAL 1. Sand off (No. 180 Grit Paper) the prime paint in the area to be coated. 2. Using a lint-free cloth, solvent wipe the area to be coated with wax and grease remover. 3. Remove sanding dust using compressed air and a lint-free tack cloth. NEW INSTALLATION 1. The glossy surface of the paint in the coating area must be sanded with a D/A sander. A 220/240 Grit Disc does a good, fast job. DO NOT sand through the primer. 2. Using a clean, lint-free cloth, solvent wipe the area to be coated with wax and grease remover. 3. Remove sanding dust using compressed air and a lint-free tack cloth. SPRAY PROCEDURE The lower exposed painted fender, rocker, and quarter panel down flanges should be protected. The vehicle must be elevated high enough so that the painter can spray this area effectively. When an initial installation is to be made, a remote two-quart capacity pressure cup makes a much more efficient tool, as the spray gun can be used closer to the floor. The spray gun, fluid hose and/or cup must be cleaned immediately after use. Refer to manufacturer's recommended cleaning procedure. Lacquer thinner can be used when the suggested clean up material is unavailable. WARNING: WEAR A NOISHA/MSHA RECOMMENDED VAPOR/PARTICULATE RESPIRATOR AND USE ALL OTHER RECOMMENDED SAFETY EOUIPMENT. 1. After preparing the new or damaged area(s), mix either Epoxy primer or Self-etch prime, per manufacturer's label instructions, and spray bare metal areas. ^ BASF DE15 or DE17 ^ Sikkens Metalflex CR Primer (1 coat only) ^ DuPont Variprime ^ S-W E2G 980 GBP Etching Filler ^ PPG DP 40 (only) 2. Apply 1-2 light prime coats over the bare metal areas. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > 91181 > Sep > 91 > Exterior Paint - Comprehensive Repair Procedures > Page 6578 3. Allow the material to dry for 15-20 minutes before applying the anti-stone abrasion material. 4. Mix and apply anti-stone abrasion material per manufacturer's label instructions over the primed area. NOTE: AN ORANGE PEELED FINISH IS NORMAL WITH THESE PRODUCTS. ^ BASF Glassohyd 1109-1240/6 ^ Sikkens 0TO Bodycoat ^ DuPont 123-5 Vinyl ^ S-W G/W 295 Vinyl Gravel Guard ^ PPG DX 54 Roadguard ^ 3M Rocker Schutz NOTE: SOME ANTI-STONE ABRASION MATERIAL MAY REQUIRE A SLIGHTLY DIFFERENT MIXING PREPARATION, PROCEDURE AND APPLICATION. SOME ANTI-STONE ABRASION MATERIALS CAN NOT BE USED FOR SPOT REPAIR. CHECK WITH THE PAINT MANUFACTURER FOR RECOMMENDATIONS ABOUT THEIR PRODUCT. 5. Allow the stone abrasion material to dry. Heat can be used to accelerate the drying time. Check the manufacturer's instructions. COLOR COAT The complete coated area, as well as the upper raw edge, must be covered with color coat. Mask off the upper margin line using "Fine Line" tape positioned 1/16 inch above the coating edge. Using appropriate service paint and application procedures, the protective coating area can now be finish painted with monocoat or a basecoat/clearcoat urethane system. NOTE: IF DAMAGED SHEET METAL EXTENDS ABOVE THE PROTECTIVE COATING AREA, NORMAL PRIME/COLOR PAINT PROCEDURES SHOULD BE FOLLOWED. CAUTION: OUR ENVIRONMENT IS PRECIOUS - PLEASE USE PROPER DISPOSAL TECHNIQUES FOR ANY VOLATILE ORGANIC COMPOUNDS (V.O.C.'s) OR EXCESS MATERIALS. Figure 4 Refer to the Lower Body Stone Protection Chart, Figure 4, for the material and labor hours involved. (D) Procedure For PVC Body Side Moldings If replacement of the body side molding is necessary, some dealer service kits will be supplied "paint to match." Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > 91181 > Sep > 91 > Exterior Paint - Comprehensive Repair Procedures > Page 6579 The painting procedures in the following instructions (also included with the part) address materials from five (5) major aftermarket paint suppliers. Use the paint system materials you are the most familiar with. NOTE: CAREFULLY READ ALL LABEL WARNINGS BEFORE APPLYING THESE PRODUCTS. WARNING: ALWAYS WEAR A NOISHA/MSHA RECOMMENDED VAPOR/PARTICULATE RESPIRATOR AND USE ALL OTHER RECOMMENDED SAFETY EQUIPMENT. SIKKENS PRODUCTS PREPARATION 1. Degrease with M600 wax and grease remover. 2. Scuff with # 320 dry paper or Scotchbrite 7447 (red). 3. Repeat degreasing step. 4. Spray two medium coats of Plastoflex primer. Allow 5 to 10 minutes flash between coats. 5. Allow 20 minutes flash-off at 70~ F before topcoating. TOPCOATING 1. Mix Autocryl color with Elast-O-Actif 50:50 by volume. 2. Mix this material with 1.2.3 hardner and 1.2.3 reducer (use correct reducer for temperature) 100:50:30 by volume. 3. Apply three medium coats, allowing enough flash off to dry to a light touch. 4. Dry one hour at 140~F after 10 minutes flash off or dry 24 hours at 75~F. PPG PRODUCTS PPG MONO-COAT SYSTEMS 1. Solvent wipe with DX330 Acryli-clean. 2. Scuff with red Scotchbrite pad. 3. Repeat solvent wipe. TOPCOATING 1. Mix and apply Deltron topcoat color with DX-369 Flexative per label instructions. 2. Use 40-50 PSI at the gun. PPG BASECOAT/CLEARCOAT SYSTEMS PREPARATION 1. Solvent wipe with SX330 Acryli-clean. 2. Scuff with red Scotchbrite pad. 3. Repeat solvent wipe. TOPCOATING 1. Mix and apply Deltron basecoat color (DBU), with the recommended reducer for the temperature, per label instructions. 2. Mix and apply clearcoat material DBU-88 or DCU-2001, with DX-369 Flexative, per label instructions. SHERWIN-WILLIAMS PRODUCTS Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > 91181 > Sep > 91 > Exterior Paint - Comprehensive Repair Procedures > Page 6580 Ultrabase 7 Basecoat/Clearcoat or Ultra One Stage Acrylic Urethane Enamel PREPARATION 1. Wash the material with a mild detergent and wipe dry. 2. Solvent wash with R7 K 156 and wipe dry. 3. Clean with a tack cloth. 4. Apply desired system with correct amount of Multi-flex, V6 V 299. TOPCOATING Prepare topcoating as follows: ^ S-W Ultra One Stage: (Mono-coat) 4 Parts Color 3 Parts SSR 650 Reducer 1 Part V6 V 440 or SSH 520 2 Parts V6 V 299 ^ S-W UB7 Basecoat: 8 Parts Basecoat Color 8 Parts Stabilizer 1 Part V6 V 299 ^ S-W UB7 Clearcoat: 4 Parts T1 C 650 Clearcoat 2 Parts T1 C 650 Reducer 1 Part CCH 690 1 Part V6 V 299 ^ S-W Ultra One Stage: (Mono-coat) Apply 2-3 medium wet coats at 50 PSI ^ UB7 Basecoat: Apply 2-3 medium coats at 45 PSI ^ UB7 Clearcoat: Apply 2-3 medium coats at 50 PSI DUPONT PRODUCTS DUPONT CRONAR POLYOXITHANE MONOCOAT SYSTEM PREPARATION 1. Wash the surface thoroughly with a mild detergent. 2. Clean with Prep Sol. TOPCOATING 1. Add 8 parts of Cronar single stage enamel. 2. Add 1 part Cronar initiator 9404S. 3. Add two parts of (9475S, 9485S, or 9495S,) depending on shop temperature. 4. Add 2 parts flex-additive 9250S. 5. Mix thoroughly. 6. Spray at 45-55 PSI at the gun, 2-3 medium wet coats or until hiding. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > 91181 > Sep > 91 > Exterior Paint - Comprehensive Repair Procedures > Page 6581 7. If a clear coat is applied, use 9500S. DUPONT CENTARI MONO-COAT ENAMEL SYSTEMS PREPARATION 1. Wash the surface thoroughly with a mild detergent. 2. Clean with Prep Sol. TOPCOATING (Follow Manufacturer's Recommendation) 1. Add 8 parts of Centari enamel color and 1 part 793S hardener. 2. Add 4 parts of (8022S, 8093S, or 8096S) reducer, depending on shop temperature. 3. Add 355S flex additive per label instructions. 4. Mix thoroughly. 5. Spray 2-3 wet coats, with 5 minutes flash time, at 50-65 PSI. BASF PRODUCTS The following procedure is applicable to 4 paint systems in the BASF paint line. Read individual "system" instructions carefully. PREPARATION 1. Solvent wipe the molding with RM Pre-klean-o 900. 2. Sand with 400 grit sand paper and rinse with 901 pre-paint cleaner. TOPCOATING BASECOAT ^ "Glasurit" 54-line color 2 vol. parts ^ 54-line reducer 1 vol. part ^ "Diamont" basecoat color 2 vol. parts ^ B R Diamont reducer 2 vol. parts ^ "Miracryl" basecoat color 2 vol. parts ^ BCR reducer 2 vol. parts ^ "Supreme Gold" basecoat color 2 vol. parts ^ LBR reducer 2 vol. parts Apply basecoat color until hiding is achieved. Allow 3-5 minutes flash time between coats. NOTE: USE APPROPRIATE REDUCER FOR SHOP CONDITIONS. ALLOW 15 MINUTES FLASH-OFF BEFORE SPRAYING CLEARCOAT. TOPCOATING Apply clearcoat per manufacturer's label instructions: CLEARCOAT REDUCTIONS ^ DC-88 Diamont Clear 4 Vol. Parts ^ DH-44 Diamont Hardener 1 Vol. Part ^ MC-1000 Clear 4 Vol. Parts ^ 894 Hardener 1 Vol. Part ^ LC-1300 Supreme Gold Clear 4 Vol. Parts ^ LH-1301 Hardener 1 Vol. Part Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > 91181 > Sep > 91 > Exterior Paint - Comprehensive Repair Procedures > Page 6582 ^ 92354 Glasurit Clear 100 Parts ^ 521-111 Elastifier 20 Parts ^ 929-29 Hardener 60 Parts Apply 2 wet coats with 5 to 10 minutes flash time between coats. Overnight dry or force dry at 140~F for 30 minutes. CAUTION: OUR ENVIRONMENT IS PRECIOUS - PLEASE USE PROPER DISPOSAL TECHNIQUES FOR ANY VOLATILE ORGANIC COMPOUNDS (V.O.C.'s) OR EXCESS MATERIALS. (E) Lower Body-Side Stone Chip Protection Program Ford Motor Company has recently initiated a program to provide improved stone-chip protection on some vehicles and to increase the corrosion protection on cars and trucks. Some customers are unaware of body side anti-stone chip protection which appears as wavy orange peel texture on the lower body areas. Ford is increasing the use of PVC (poly vinyl chloride) material which is applied in a thicker coating on the lower body-side. This material has been in use on vehicles destined for the Canadian market for many years. This PVC material is now applied at the following plants on ALL vehicles. ^ Edison - Ranger ^ Hermosillo - Escort/Tracer ^ Louisville - Ranger and Explorer ^ Ohio Truck - Econoline ^ Wayne - Escort/Tracer This process is also planned for Kansas City, Oakville, Twin Cities and Wixom. This material can be identified by the "orange peel" appearance and a visible "break-line" between protected and unprotected areas in the lower body areas. CAUTION: THIS PROTECTION MUST NOT BE REMOVED IF VEHICLE IS EXPECTED TO MAINTAIN THE CORROSION PROTECTION. Some customers have expressed concerns due to the appearance of the treated areas. These customers did not know about the extra protection this material provides their vehicle. Once explained, customers were pleased with the added protection and accepted the orange peel finish. NOTE: DEALERS SHOULD ADVISE THEIR SALES PEOPLE, SERVICE PEOPLE, AND CUSTOMERS, OF THE REASONS AND BENEFITS OF THIS PROTECTION. CANADIAN DEALERS STRESS THIS AS A SELLING POINT WITH THEIR SALES PEOPLE. IT IS CONSIDERED A COMPETITIVE ADVANTAGE. (F) Surface Defect Removal Without Repainting Exterior paint surface damage or imperfections, where the primer coat does not show through, should be restored without repainting. The restoration of gloss and luster, after the condition has been repaired, is possible with new techniques and improved materials. The following procedure is applicable to surface conditions such as dirt particles, orange peel, runs, sags, industrial fallout stains, swirl marks, light scratches and other minor surface imperfections. For dirt particles or scratches in several localized areas, the entire panel should be refinished to maintain a uniform appearance. PREPARATION To repair the affected surface it must be clean and dry. Mask off adjacent panels, mouldings, stripe and character lines as required. CAUTION: EYE PROTECTION, AND FACE MASK SHOULD BE WORN. RINGS, BRACELETS, WATCHES AND BELT BUCKLES MUST BE REMOVED TO PREVENT ACCIDENTAL DAMAGE TO PAINT FINISH. SERVICE PROCEDURE 1. Remove sanding marks with rubbing compound. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > 91181 > Sep > 91 > Exterior Paint - Comprehensive Repair Procedures > Page 6583 2. Swirl marks, evident after buffing, are removed by polishing. 3. Remove light scratches and small dirt particles with a power buffer and medium buffing compound followed with polishing. 4. Remove deeper scratches and heavy dirt particles or orange peel, by wet sanding. 5. Buff with compound to remove the sanding marks and then polish to remove the swirl marks from the buffing operation. NOTE: PERFORM A TRIAL REPAIR WITH A SMALL AREA. FIRST, TRY POLISHING; IF THIS IS NOT SUCCESSFUL, TRY BUFFING AND, FINALLY, USE WET SANDING TO REMOVE THE CONDITION. USE MOST EFFECTIVE TECHNIQUE ON REMAINDER OF AREAS. AN OUTLINE OF THE COMPLETE PROCEDURE AND REQUIRED MATERIALS FOLLOWS. POLISHING - VERY MINOR SCRATCHES OR SWIRL MARKS AND/OR RESTORING A DULL FINISH 1. Apply a small amount of Meguiar's Mirror Glaze, or equivalent, to the affected panel (or pad). 2. Use a suitable electric or air powered polish/buffing wheel (1750 max. RPM) and a Meguiar's Finesse Polishing Pad, or equivalent, to polish the affected area until all swirl marks are gone and desired luster is obtained. 3. When polishing, keep the pad flat against the surface. Do not bear down. The weight of the buffer is sufficient. CAUTION: DO NOT MIX PRODUCTS! USE A SEPARATE, DEDICATED BUFFING PAD FOR EACH PRODUCT TO ACHIEVE DESIRED RESULTS. Variable speed buffers are available in a variety of buffing speeds. The recommended speed range is 1200-1750 RPM. COMPOUNDING - LIGHT SCRATCHES, SMALL DIRT PARTICLES, MINOR GRIND MARKS, AND SANDING MARKS 1. Apply Meguiar's Rubbing Compound (medium) or equivalent to the panel with a clean compound pad on the wheel. 2. Spread the compound evenly and continue buffing until the condition is removed. 3. Keep the wheel flat to the surface and use light to moderate pressure and long strokes. 4. Periodically check the finish and add compound as required. 5. When buffing is complete, polish the panel as described previously. Twisted wool cutting pads are the most effective compounding pads to use with Glaze Machine Cleaner for removing paint defects and heavy oxidation. Following the use of a wool compounding pad, it may be necessary to polish the finish with No. 2 Mirror Glaze Hi-Tech Cleaner using a Mirror Glaze Finesse Polishing Pad to remove the deep swirl marks. GENERAL TECHNIQUES AND HINTS ^ "Foam" buffing pads create added gloss and depth of color on all types of paint finishes without creating buffer swirl marks. ^ When "buffing out" oxidation or other paint defects with a cleaning material, use a liberal amount of material, slower buffing motion and added downward pressure to increase cutting action. ^ Always apply cleaner to buffing pad, not directly on the oxidized paint surface. Dry paint absorbs material into pores upon contact. ^ Always keep the face of the buffing pad completely flat to the surface, reducing the risk of buffer swirl marks. Watch your pad, especially on angled surfaces, to be certain that it stays flat. ^ Avoid short rapid strokes. Move the buffer slowly across the surface using long straight motions and overlap by 50% the buffing pattern left by the previous pass. This insures uniform coverage and allows both material and buffer to perform at maximum efficiency. ^ Avoid buffing directly on raised character lines. The reduced paint film on these surfaces increases the risk of paint burn through. It is best to buff up to them from each side. ^ Always use a "wet buff" technique on a basecoat/clearcoat finish. This is a precaution against buffer swirls. Stop buffing just after the product begins to break down and before an overall dry, glossy finish appears. After "wet buffing", use a towel to wipe off the excess material. ^ Always use a "dry buff" technique on light colored, conventional paint finishes. Continue buffing until the material breaks down and only a slight film remains for final wipe off. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > 91181 > Sep > 91 > Exterior Paint - Comprehensive Repair Procedures > Page 6584 ^ If a paint blemish remains after buffing, reapply a small amount of material over the blemish. Confine your buffing strokes to the immediate area of the blemish while applying additional downward pressure and keeping the pad flat. NOTE: ALWAYS KEEP THE PAD MOVING AND LIMIT YOUR STROKES OVER THE BLEMISH TO PREVENT EXCESSIVE HEAT BUILD-UP AND POSSIBLE BURN THROUGH. STOP IMMEDIATELY IF THE SURFACE BECOMES TOO HOT TO LAY THE PALM OF YOUR HAND ON IT. NOTE: HEAT BUILD-UP: WHEN BUFFING CREATES EXCESSIVE HEAT, HAZING MAY APPEAR ACROSS THE SURFACE BEING BUFFED AND THE PRODUCT MAY DRY LIKE A FILM AND REFUSE TO BUFF OUT. TO REMEDY, WIPE THE AREA DOWN WITH COOL WATER, DRY THE SURFACE AND RESUME BUFFING ... AT A LOWER RPM IF POSSIBLE. NOTE: STATIC: STATIC ELECTRICITY MAY BE PRESENT ON PAINTED FIBERGLASS/PLASTIC SURFACE BEING BUFFED, THE MATERIAL MAY DRY LIKE A FILM OR TURN "GUMMY" AND BEGIN TO BALL UP. TO REMEDY, GROUND THE SURFACE BEING BUFFED TO METAL. WET SANDING Paint defects and sanding marks must be completely removed without using compounds and abrasive cleaners that scar the finish. Mirror Glaze Hi-Tech Finesse Sanding Papers provide uniformity in grit particle size and distribution. Using these precision made sanding papers, water sanding marks can be removed with Meguiar's cleaner and finesse polishing pads. ^ Typical paint defects that are repaired with this system include: dirt-in paint, solvent pop, cratering, orange peel, drips, scratches, water spots, and acid rain. ^ Always use the least abrasive (highest grit) sanding products possible to do this job. The following wet sanding procedure utilizes light grit sand paper or sanding blocks for removal of surface damage. These materials cut quickly leaving a uniform finish requiring a minimum of buffing to restore gloss. PROCEDURE 1. Squeeze water to flush the area to be sanded. Continue to flush water to the surface during sanding for maximum lubrication. 2. Use small circular motions to contain the abrasion to the immediate area of the defect. Keep the blocks in water when not in use. 3. If the sanding block is cutting too slow, switch to a lower grade block and resume sanding. When 90% of the defect is removed, switch to a 2000 grade Finesse Sanding Paper or Sanding Block to finish smoothing and prepare the surface for buffing. 4. Finesse Sanding Blocks can be shaped to work on any angle. When the block is wet, rub it against a dry sanding block for shaping. 5. When using Finesse Sanding Papers, wrap the paper tightly around a E-7200 Backing Pad. This pad evenly distributes pressure over the entire surface of the sanding paper. This creates a uniform sanding pattern. 6. Plan your strokes to limit the abrasion to the smallest area possible. NOTE: ALWAYS SAND IN ONE DIRECTION AND KEEP YOUR STROKES STRAIGHT. 7. Always finish sanding with 2000 Grit Finesse Sanding Paper. This eliminates the need for compounding. 8. Buff out sanding marks by applying Meguiar's Cleaner with a Finesse "Foam" Polishing Pad. Follow with a Mirror Glaze Polish for swirl-free gloss. WARNING: OUR ENVIRONMENT IS PRECIOUS - PLEASE USE PROPER DISPOSAL TECHNIQUES FOR ANY VOLATILE ORGANIC COMPOUNDS (V.O.C.'s) OR EXCESS MATERIALS RUNS AND SAGS REMOVAL This procedure consists of shaving the run or sag flush with a commercial single edge razor blade, shaving file or sanding with a hard block and then compounding. NOTE: IF IT IS NECESSARY TO SHAVE RUNS AND SAGS WITH A RAZOR BLADE, FIRST DULL THE CORNERS WITH SANDPAPER TO AVOID SCRATCHING THE ADJACENT PANEL FINISH. MEGUIAR'S PRODUCTS Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > 91181 > Sep > 91 > Exterior Paint - Comprehensive Repair Procedures > Page 6585 PART NUMBER GRADE PART NAME S-1005 1000 Mirror Glaze Hi-Tech Finesse Sanding Papers - Half Sheets S-1205 1200 S-1505 1600 S-2005 2000 S-1000 1000 Mirror Glaze Hi-Tech Finesse Sanding Papers - Full Sheets 8-1200 1200 8-1500 1500 S-2000 2000 E-7200 - Mirror Glaze Hi-Tech Finesse Backing Pad E-2000 - Mirror Glaze Hi-Tech Tach Sponge K-400 400 Mirror Glaze Hi-Tech Finesse Sanding Blocks K-1000 1000 K-1500 1500 K-2000 2000 K-3000 3000 Other Applicable Articles: 82-3-3 (G) Color Compatible Spray Primer Chart Ford has released color compatible spray primers for exterior and some interior surfaces. Colored sprayed primers are being used by our "Best-in-Class" competition and are now being implemented at Ford in order to improve process capability and to help in minimizing unsightly paint chipping from stone abrasion. Color keyed (matched) spray primer for exterior body colors is being used in an effort to help in the elimination of unsightly paint chipping from stone abrasion. As with "Best-In-Class" competition, the engine compartment will be left with color compatible primer only and not be topcoated as per past practice. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > 91181 > Sep > 91 > Exterior Paint - Comprehensive Repair Procedures > Page 6586 Figure 5 When any paint repair is required, remember that the vehicle may have a colored primer. Refer to the Spray Primer Chart, Figure 5. This information may be of help in correction of exterior paint color match concerns. (H) Paint Repair For Tinted Clear Coat Ford introduced (Early Spring, 1991) a new paint color using a tinted clearcoat. The first color to use this new system is Rio Red. If a paint repair is necessary, refer to the following procedure for repair instructions. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > 91181 > Sep > 91 > Exterior Paint - Comprehensive Repair Procedures > Page 6587 BACKGROUND The Probe production paint system for Rio Red includes a Medium Green E-Coat primer, a Light Gray spray primer, bright Rio Red (E4) basecoat and a slightly Red tinted clearcoat topcoat. NOTE: BEFORE ANY REPAIRS ARE BEGUN, IT IS CRITICAL THAT PRIMER, RED BASECOAT AND TINTED CLEARCOAT BE SPRAYED ON A TEST PANEL. THE COLOR MATCH IN EACH STEP IS VERY IMPORTANT FOR A SUCCESSFUL REPAIR. WARNING: ALWAYS WEAR A NOISHA/MSHA RECOMMENDED VAPOR/PARTICULATE RESPIRATOR AND USE ALL OTHER RECOMMENDED SAFETY EQUIPMENT. SMALL SPOT REPAIR PROCEDURE 1 Wash the vehicle with detergent soap and water. 2 Wipe the vehicle down with wax and grease remover. 3. Sand the spot using 400 grit paper. Do not sand through the E-coat. 4. Wipe the sanded surface again with wax and grease remover/pre-cleaner. ^ BASF Product # 90 Pre-Kleano ^ PPG Product # DX 330 ^ S-W Product # R7-K156 ^ DuPont Product # 3919 S ^ Sikkens Product # M 600 5. Mix and apply tintable (Light Gray) self-etching or epoxy primer per manufacturer's label instructions. NOTE: COLOR MATCH OF PRIME COAT IS KEY IN COLOR MATCH OF REPAIRED AREA. ^ BASF Product # DE 17 ^ PPG Product # DP 40 ^ S-W Product # E2-G973 ^ DuPont Product # 615S ^ Sikkens Product # 1016 6. Mix and apply bright Rio Red base coat material per manufacturer's label instructions. NOTE: COLOR MATCH OF BASE CLEAR COAT IS KEY IN COLOR MATCH OF REPAIRED AREA. 7. Mix and apply red tinted clearcoat material per manufacturer's label instructions. NOTE: COLOR MATCH OF TINTED CLEAR COAT IS KEY IN COLOR MATCH OF REPAIRED AREA. FULL PANEL REPAIR PROCEDURE 1. Wash the vehicle with detergent soap and water. 2. Wipe the vehicle down with wax and grease remover. 3. Sand the complete panel and feather edge into the next panel using 400 grit paper. Do not sand through the E-Coat primer. 4. Wipe the sanded surface with wax and grease remover. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > 91181 > Sep > 91 > Exterior Paint - Comprehensive Repair Procedures > Page 6588 5. Mix and apply tintable (light gray) primer per manufacturer's label instructions. 6. Mix and apply Rio Red basecoat per manufacturer's label instructions. 7. Mix and apply Red tinted clearcoat per manufacturer's label instructions. 8. Mix and apply one coat of non-tinted clearcoat per manufacturer's label instructions. NOTE: COLOR MATCH OF EACH COAT ARE KEY TO COLOR MATCH OF FINISH REPAIR. WARNING: OUR ENVIRONMENT IS PRECIOUS - PLEASE USE PROPER DISPOSAL TECHNIQUES FOR ANY VOLATILE ORGANIC COMPOUNDS (V.O.C's) OR EXCESS MATERIALS. (I) Paintable Plastics Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > 91181 > Sep > 91 > Exterior Paint - Comprehensive Repair Procedures > Page 6589 Figure 6 The Paintable Plastics Chart, Figure 6, is a summary of widely used plastics in our industry. The standard symbol should be located on the part for ease of material identification. If painting or repair of these plastics is necessary, the following chart identifies those materials which can be painted. Refer to paint manufacturer for specific paint material recommendations. NOTE: MATERIALS MAY REQUIRE PRIME COAT SEE "YES", UNDER "CAN BE PAINTED" COLUMN. (J) 1992 Paint Color Codes Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > 91181 > Sep > 91 > Exterior Paint - Comprehensive Repair Procedures > Page 6590 Figure 7 The 1992 Paint Color Codes are listed in Figure 7. NOTE: REFER TO THE SERVICE LABOR TIME STANDARDS MANUAL AND THE SPECIFIC PROCEDURE WITHIN THIS BULLETIN FOR REIMBURSEMENT. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under Basic Warranty Coverage OASIS CODES: 106000 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > 90153 > Jul > 90 > Lower Body Stone Protection - Repair Procedure Technical Service Bulletin # 90153 Date: 900719 Lower Body Stone Protection - Repair Procedure PAINT - LOWER BODY STONE PROTECTION REPAIR TIPS Article No. 90-15-3 FORD: 1985-90 CROWN VICTORIA, ESCORT, MUSTANG, TEMPO, THUNDERBIRD 1986-90 TAURUS 1988-90 FESTIVA, PROBE LINCOLN-MERCURY: 1985-90 CONTINENTAL, COUGAR, GRAND MARQUIS, MARK VII, TOPAZ, TOWN CAR 1986-90 SABLE 1987-90 TRACER LIGHT TRUCK: 1985-90 BRONCO II, BRONCO, ECONOLINE, F-150, F-250, F-350, RANGER 1988-90 F SUPER DUTY ISSUE: A service repair procedure has been developed to restore damaged factory-applied lower body stone protection vinyl material. ACTION: If service is required, use the following procedure to restore damaged lower body stone protected areas. This abrasion resistant coating material (D9AZ-19515-A) is primarily for repair of factory-applied protective coatings. However, this material may also be installed on previously unprotected vehicles. If the vehicle has body damage in the area of the factory-applied coating, body damage must be repaired before repairing the protective coating. WARNING: WHENEVER USING PAINT, SOLVENT, REFINISHING OR RECONDITIONING MATERIALS, WEAR A NOSE OR FACE MASK, PLUS HAVE ADEQUATE VENTILATION IN THE WORK AREA. Large Repair Areas A large repair area, resulting from peeling or damage, will require removal of the factory-applied vinyl coating. NOTE: WHERE SHEET METAL IS DAMAGED TO THE EXTENT THAT A FENDER, DOOR OR QUARTER PANEL REPLACEMENT IS REQUIRED, (OR IN AN INITIAL INSTALLATION), SKIP STEPS # 1 - 3. 1. Use a heat gun or lamp to soften the vinyl coating until it is pliable. 2. Scrape off the softened vinyl with a putty knife or similar tool. If necessary, sand off any hard-to-remove vinyl coating using an orbital disc sander (# 80 Disc). NOTE: THE REPAIR MATERIAL, ABRASION RESISTANT COATING (D9AZ-19515-A), IS NOT SUITABLE FOR "SPOT" REPAIRS. THE OLD COATING MUST BE REMOVED COMPLETELY FROM EACH DAMAGED PANEL. 3. Make the necessary repairs to the sheet metal. Coating Preparation and Applications: The abrasion resistant coating is available in quart cans. About two quarts will be required for an initial installation on a passenger car similar to a factory-applied system. Slightly more will be required for a larger vehicle such as an Econoline. The specified dry film thickness of 15 to 20 mils (.015 to .020") will require at least three or possibly four applications of coating material, with flash off time allowed between coats. As with painting, spray coat the complete lower panel. The adherence of this coating to properly prepared sheet metal is excellent and it is not necessary to prime the repaired sheet metal. However, adhesion will be adversely affected unless the sheet metal (either repaired or new) is prepared in accordance with the following procedure. Coating Preparation - Masking Car 1. Install covers over the wheels. 2. Determine the area to be coated. ^ If the vehicle has lower body side mouldings (12-14" above the "turn under" of the rocker Panel), the moulding can serve as the upper margin of the area to be coated. ^ If the vehicle does not have suitable mouldings, a sculpture or break line in the sheet metal can be used. ^ The method used in masking off the upper coating margin line will depend on the presence or absence of mouldings in this area. VEHICLES WITH SIDE MOULDINGS 3. Position the masking tape so that the moulding lower side is covered down to, but not on the sheet metal. VEHICLES WITHOUT SIDE MOULDINGS Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > 90153 > Jul > 90 > Lower Body Stone Protection - Repair Procedure > Page 6595 4. If the contour of the body side has a break line, or if an arbitrary line is chosen, mask off the upper coating margin using Scotch "Fine Line" tape. This is available nationally from 3M Company Distributors. a. Apply the normal masking tape and paper protection for the vehicle body side first. Position them about a 1/4" above the margin line. b. Apply the "Fine Line" tape over the regular masking tape with the lower edge at the upper coating margin line. c. Extend this "Fine Line" tape into the wheel opening, in absence of wheel opening mouldings, to allow the flange to be coated. d. Since the protective coating does not adhere well to flexible plastic stone shields, mask off the front of the plastic rear stone shield, if exposed. NOTE: IT IS NOT NECESSARY TO MASK OFF THE BODY DOOR OPENINGS IN THE COATING AREA BECAUSE THEY WILL BE UNIFORMLY COATED WHERE THE DOOR MARGINS ALLOW THE COATING TO ENTER. HOWEVER, THESE DOOR OPENING AREAS SHOULD BE CLEANED TO ASSURE COATING ADHERENCE. Coating Preparation - Sheet Metal REPAIRED SHEET METAL 1. Using a clean lint-free cloth, solvent wipe the area to be coated with a silicone and wax remover and allow to flash off. 2. Scuff sand (# 180 Grit Paper) the glossy surface of the painted areas to be coated. 3. Remove sanding dust using a lint-free tack cloth and compressed air. NEW SHEET METAL 1. Using a clean lint-free cloth, solvent wipe the area to be coated with a silicone and wax remover and allow to flash off. 2. Scuff sand (# 180 Grit Paper) the prime paint in the area to be coated. 3. Remove sanding dust using a lint-free tack cloth and compressed air. INITIAL INSTALLATION 1. Using a clean lint-free cloth, solvent wipe the area to be coated with a silicone and wax remover. 2. Sand the glossy surface of the paint in the coating area. (A D/A sander, 220/240 Grit Disc does a good fast job.) CAUTION: DO NOT SAND THROUGH THE COLOR COAT INTO THE PRIMER. 3. Remove sanding dust using a lint-free tack cloth and compressed air. Coating Application Coating applications must be applied with care. ^ The coating must be applied with commercial equipment by an experienced automotive painter. ^ The coating must be thoroughly agitated and used without thinning. ^ Since the material is reasonably heavy-bodied, a pressure cup equipped spray gun is recommended. ^ Satisfactory coating appearance (orange peel) will result with gun pressure of approximately 30 P.S.I. and cup pressures of approximately 15 P.S.I. Spray Procedure Since the lower exposed painted fender, rocker and quarter panel down flanges are to be coated, the vehicle should be elevated high enough so that the painter can spray this area effectively. When an initial installation is to be made, a remote, two-quart capacity pressure cup makes a much more efficient tool because the spray gun can be used closer to the floor. The spray gun, fluid hose and cup must be cleaned immediately after use. While lacquer thinner may be used when the suggested clean up material is unavailable, the Ford Vinyl Paint Precleaner (VC-542-A) is quicker and much more efficient. With the spray gun at 30 P.S.I. and pressure feed cup at 15 P.S.I. proceed as follows: Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > 90153 > Jul > 90 > Lower Body Stone Protection - Repair Procedure > Page 6596 1. Apply a wet, sag-free coat. Allow 3 to 5 minutes flash off. 2. Apply a second wet, sag-free coat. Allow 3 to 5 minutes flash off. 3. Apply a third wet, sag-free coat. Allow 3 to 5 minutes flash off. 4. Apply a final wet, sag-free coat. Allow 3 to 5 minutes flash off. Pull off the "Fine Line" tape, exposing the raw upper edge of the coating. 5. Immediately clean the spray equipment using Ford Vinyl Paint Precleaner (VC-542-A) or equivalent. 6. Air drying time depends on the refinishing materials that are used. ^ If you refinish with acrylic lacquer, allow one hour for drying (at 70~F). ^ If you refinish with acrylic enamel, allow two hours for drying (at 70~F). Color Coat In order to paint the entire coated area as well as the upper raw edge, mask off the upper margin line using the "Fine Line" tape. Position the tape 1/16" above the coating edge. The protective coating area can now be finish painted. NOTE: IF DAMAGED SHEET METAL EXTENDS ABOVE THE PROTECTIVE COATING AREA, NORMAL PRIME/COLOR PAINT PROCEDURES SHOULD BE FOLLOWED. Suggested Equipment ^ DeVilbiss - Spray Gun - Model JGA-502-704-FX or equivalent ^ DeVilbiss - Remote Pressure Cup - Model KB-520 (2 Quarts), Model KB-521 (1 Quart) or equivalent ^ Binks - Spray Gun - Model 62 (# 63 Air Cap, # SS Fluid Tip, # 363 AN Needle) ^ Binks - Attached Pressure Cup - Model 80 (1 Quart, with Air Adjusting Gage) or equivalent. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 1100, 1800 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > 89133 > Jun > 89 > Paint - Cosmetic Damage From Airborn Materials Paint: All Technical Service Bulletins Paint - Cosmetic Damage From Airborn Materials PAINT COSMETIC DAMAGE FROM AIRBORN MATERIALS Article No. 89-13-3 FORD: 1989 and prior ALL FORD LINES LINCOLN-MERCURY: 1989 and prior ALL LINCOLN-MERCURY LINES LIGHT TRUCK: 1989 and prior ALL LIGHT TRUCK LINES ISSUE: Paint may be damaged from various sources of airborn materials. The two different types are: ^ Inorganic ^ Organic Sometimes it is hard to identify the type of paint damage and know how to remove it. This TSB article gives detailed information and descriptions of both types of airborn materials. It also outlines the service procedures for treating them. ACTION: If service is required, identify the source of damage involved by referring to the following information. Use the following recommended service procedure to correct concerns. INORGANIC AIRBORN MATERIAL The effects of inorganic airborn materials can be seen as: ^ Dark blotches in the paint where the pigment in the paint surface has been attacked ^ Irregular spots that are cracked or etched around the edges and dull in the centers. ^ Small orange colored spots caused by iron particles may appear on the paint surface. Generally, materials that attack a paint film are either acidic or alkaline in nature. Sulfuric and nitric acids, in general, cause extreme damage to automative paint finishes. Even very small concentrations of the same materials can cause chemical spotting damage. Due to evaporation and condensation, these acids can create severe etching "spots" that may eventually crack or lift the paint film after some time in service. Although some automotive finishes are more resistant than others, none are completely immune to these chemicals. The most resistant paints used today are the urethanes because their resin system is least likely to react with chemicals. Air dry coatings are more susceptible to attack only when they are fresh. The longer the paint dries the more resistant it becomes. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > 89133 > Jun > 89 > Paint - Cosmetic Damage From Airborn Materials > Page 6601 Metallic colors are more intolerant to chemicals because aluminum flake is fairly reactive with either an acid or alkali. The following chart contains the most common acid materials found on automotive finishes. The chart shows a color, the corresponding damage appearance and also the chemical causal agent. It is not applicable for Basecoat/Clearcoat finishes. * "Caustic" refers to any alkaline substance that may be "harsh" or "corrosive" depending on strength or concentration. The following "pH" chart show the relationship between acidic and alkaline chemicals and their corresponding pH values. This chart is provided for informational reference only. ORGANIC AIRBORN MATERIALS Organic damage is generally easier to identify. Organic damage is mostly due to tree sap, bird and insect droppings, dead insects (Figure 8) and pollen. Tree sap is easily identified by clear raised drops that may be hard or sticky. Bee or bug dropping spots may appear brownish or yellow in color, about an eighth to a quarter inch in diameter. Dead and decomposing insect bodies are readily visible to the eye. Pollen deposits are small yellow clusters. Each of these items is potentially damaging to any currently available paint system. Other noticeable traits of organic damage are spots that are raised (swelling) micro-crazing (cracked) and pitting, due to pollen eating into the paint film. The active ingredients in most organic contaminants are tannic and formic acids . These acids are found in berries and bodily fluids of insects and birds. Investigations completed at dealerships show that the bright lot lights tend to attract insects. The use of "soft lights" for display and storage lot illumination will help reduce damage resulting from decomposing bugs and droppings by decreasing the number of bugs attracted to these lights. Organic damage is accelerated by heat. During very hot weather conditions, it is important to wash vehicles more often. ORGANIC AND INORGANIC REPAIR PROCEDURES FOR MILD DAMAGE Iron dust particles may imbed themselves into the paint film. On some light colored vehicles after some weathering, tiny dots of rust start to appear. They Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > 89133 > Jun > 89 > Paint - Cosmetic Damage From Airborn Materials > Page 6602 feel rough to the touch and are difficult to remove. The best way to remove these particles is by treating the finish with an oxalic acid-detergent-water wash. Use the following procedure to perform this service repair. NOTE: OXALIC ACID WASH IS ALSO PRE-PACKAGED IN VARIOUS STRENGTHS UNDER VARIOUS BRAND NAMES, IF YOU CHOOSE NOT TO MIX YOUR OWN BATCHES. 1. Wash and degrease the vehicle first, using Ford Multi Purpose Cleaner (B8A-19523-B) or equivalent, and a suitable wax and grease remover. If this does not remove all of the iron particles, proceed with the oxalic acid wash. 2. Prepare a quantity of oxalic acid-detergent-water solution as follows: a. Dissolve 6-8 ounces of Oxalic Acid (powder) in one gallon of warm water. b. Add 1-2 tablespoons full of non-alkaline detergent such as Ford Multi Purpose Cleaner. 3. Apply this solution liberally to all affected surfaces of the vehicle with a large sponge. Keep the surface wet until the technician can no longer feel any surface roughness with bare or gloved fingertips. NOTE: IF THIS IS NOT DONE THOROUGHLY, STAINING MAY REDEVELOP IF IRON PARTICLES ARE LEFT BEHIND. 4. Rinse the area with clean water. CAUTION: FAILURE TO THOROUGHLY RINSE THIS SURFACE COULD RESULT IN CORROSION OF ANODIZED ALUMINUM OR STAINLESS STEEL PARTS WITH PROLONGED CONTACT. 5. If the iron particles are not totally removed after 2 washings, use one or both of the procedures listed for minor chemical contamination. NOTE: THE USE OF POLISHING (WITH WAX), SANDING WITH MICRO FINE SANDPAPER (1500 GRIT OR GREATER) OR BUFFING WITH VERY LIGHT COMPOUND SHOULD ONLY BE DONE AS A LAST RESORT. CHEMICAL CONTAMINATION Chemical contamination, either acid or alkali, can cause off-color spots and crack the paint film. In the presence of moisture (dew), sulfur contamination will change the color (light/dark) of the paint pigments. (This does not apply to Basecoat/Clearcoat) Since this contamination affects the pigments, lacquers and enamels show no difference in resistance. Production thermal drying and air drying finishes are likely to be spotted. Minor chemical contamination can be removed by using the following step by step procedure. 1. Wash the vehicle first by using Ford Multi Purpose Cleaner (B8A-19523-B) or equivalent to remove the exterior foreign materials. 2. If the spotting is extensive and on the horizontal surfaces, then machine polish. 3. Apply a light grit polishing compound to the affected surface by using a soft brush. The compound should be applied to a small area at a time so that it can be buffed out while still wet to get maximum cutting efficiency. 4. Polish off the spots using a buffer operating at 1700-1800 rpm. Confine polishing to the spotted areas. Repeat as necessary until all spots have been removed. 5. Remove spots on curved surfaces, near edges, and next to mouldings or ornaments by hand polishing as follows: a. Apply some polishing compound to a cotton cloth. (Do not use a synthetic cloth.) b. Rub vigorously until the spots are no longer visible. c. Clean off excess polishing compound by using a clean cloth and compressed air. 6. Buff out the polishing marks and bring up the gloss by using a buffer equipped with a clean, dry lambs wool pad. NOTE: IF POLISHING DOES NOT SUFFICIENTLY REMOVE DAMAGE, THE VEHICLE CAN BE WET SANDED USING 1500 GRIT SANDPAPER AND THE FOLLOWING PROCEDURE Wet Sanding Procedure 1. Clean the exterior surface of the vehicle with Ford Multi Purpose cleaner or an equivalent to remove all contamination. 2. Apply 1500 grit sandpaper to a rubber padded sanding block to sand the paint surface. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > 89133 > Jun > 89 > Paint - Cosmetic Damage From Airborn Materials > Page 6603 3. Use a squirt bottle filled with water to lubricate the 1500 grit sandpaper as you begin to sand only the damaged areas. Water is an abrasive as well as a lubricant in this step. NOTE: IF THE DAMAGE HAS GONE DEEPLY INTO THE PAINT FILM AND IT WILL NOT POLISH OR SAND OUT, THEN REFINISHING IS REQUIRED. ORGANIC MATERIAL REPAIR PROCEDURE FOR MILD DAMAGE Minor organic damage can be removed by using the following step by step procedure. 1. Wash and degrease the vehicle thoroughly by using Ford Multi Purpose Cleaner (B8A-19523-B) or equivalent and a wax and grease remover to remove all organics. 2. Inspect the vehicle horizontal surfaces. If spotting or paint film swelling is extensive, use a buffer to repair. 3. Apply a light grit polishing compound to the affected areas by using a soft brush. The compound should be applied to a small area at a time so that it can be buffed out while still wet to get maximum efficiency. 4. Polish off the spots or swelling marks using a buffer that operates between 1700-1800 rpm. Polishing should be confined to the affected areas only. Repeat as necessary until all spots or marks are removed. 5. Remove spots on curved surfaces, near edges, and next to mouldings or ornaments by hand polishing as follows: a. Apply some polishing compound to a cotton cloth. (Do not use a synthetic cloth.) b. Rub vigorously until the spots are no longer visible. c. Clean off excess polishing compound by using a clean cloth and compressed air. 6. Buff out the polishing marks and bring up the gloss by using a buffer equipped with a clean, dry lambs wool pad. NOTE: IF POLISHING DOES NOT SUFFICIENTLY REMOVE DAMAGE, THE VEHICLE CAN BE WET SANDED USING 1500 GRIT SANDPAPER AND THE FOLLOWING PROCEDURE. Wet Sanding Procedure 1. Clean the exterior surface of the vehicle with Ford Multi Purpose cleaner or an equivalent to remove all organics. 2. Apply 1500 grit sandpaper to a rubber padded sanding block to sand the paint surface. 3. Use a squirt bottle filled with water to lubricate the 1500 grit sandpaper as you begin to sand only the damaged areas. Water is an abrasive as well as a lubricant in this step. NOTE: IF THE DAMAGE HAS GONE DEEPLY INTO THE PAINT FILM AND IT WILL NOT POLISH OUT, THEN REFINISHING IS REQUIRED. PAINT RECONDITIONING PROCEDURES FOR SEVERE DAMAGE Acrylic enamel single stage or base/clear paint systems should be painted by using the following procedure. 1. .Wash the vehicle with Ford Multi Purpose Cleaner or equivalent to remove all organic materials. 2. Wash the areas to be painted with wax and grease remover. 3. Prepare the area as follows: a. Neutralize the affected areas with baking soda (sodium bicarbonate) and water. b. Rinse the surface off with plain water. c. Wash the panel with a mild soapy detergent. d. Dry the panel completely. NOTE: IF THE DAMAGE IS THROUGH THE TOP COAT FINISH AND INTO THE PRIMERS, THE PANEL MUST BE SANDED DOWN TO BARE METAL OR PLASTIC AND THEN REFINISHED. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > 89133 > Jun > 89 > Paint - Cosmetic Damage From Airborn Materials > Page 6604 4. Apply a self-etching primer for metal surfaces only. NOTE: A FLEX ADDITIVE MAY BE NECESSARY WHEN WORKING WITH FLEXIBLE PLASTICS Then proceed as follows: a. Let dry per instructions. b. Apply a two component urethane primer surfacer. c. Sand the surface with 400 grit sandpaper to get to proper finish. d. Finish sanding with 600 grit sandpaper. 5. Solvent wash panel with wax and grease remover. Then, tack wipe it. 6. Apply base coat or top coat material per applicable paint system. NOTE: THE USE OF ACRYLIC URETHANE ENAMEL IS HIGHLY RECOMMENDED FOR THIS TYPE OF REPAIR. 7. Apply clear acrylic urethane if you are using a base/clear paint system. WAYS TO MINIMIZE EFFECTS OF AIRBORN MATERIAL DAMAGE During the past year, Ford Motor Company and major paint suppliers have participated in a survey to analyze the effects of airborn materials. This survey was conducted on foreign and domestic vehicles. It resulted in the following interesting conclusions. 1. Keeping the vehicles clean, washing frequently with de-ionized water and drying by hand or mechanical means will help minimize the effects of inorganic and organic materials. 2. Spray washing without rubbing will not totally remove all residue on the surface of the vehicle. Damage could possibly occur over a longer period of time. 3. Care should be taken to not allow any painted vehicle surface to become wet in direct sunlight. (A sprinkler system can cause damage if the vehicles are not dried.) Possible alkaline water or mineral deposit may be the cause. 4. The use of "Soft Lights" for lighting around storage lots and showing areas will minimize the attraction of insects and the possibility of organic damage. 5. Ford Motor Company is piloting a program for a transit/storage coating to be applied on the horizontal surfaces of all vehicles. These coatings have shown good protection to the paint surface. They are clear in color and should be left on the vehicles until they are sold. 6. We are testing many "permanent paint sealants" used by dealers. Until all testing is completed, we cannot give any recommendations for what products to use. Testing has shown that a sealant that allows water to bead up on the vehicle does not help to dissipate the materials on the paint surface. Sheeting of water on the vehicle is highly desirable. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 1100 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > 87151 > Jul > 87 > Paint - Difficulty Matching Production Colors Paint: All Technical Service Bulletins Paint - Difficulty Matching Production Colors PAINT - DIFFICULTY MATCHING AFTERMARKET Article No. COLORS WITH FORD PRODUCTION COLORS 87-15-1 FORD: 1986-88 ALL CAR LINES LINCOLN-MERCURY: 1986-88 ALL CAR LINES MERKUR: 1986-88 XR4Ti 1988 SCORPIO LIGHT TRUCK: 1986-88 ALL LIGHT TRUCK LINES ISSUE: Paint audits and field reports have indicated concerns in matching aftermarket paint colors to the Ford production paint colors. This matching concern seems to be greater when comparing the metallic paints. ACTION: To correct this, DuPont and PPG Aftermarket Divisions will supply color variance decks by August 1, 1987 to DuPont and PPG Distributors and District Offices for distribution to dealerships. Updated color variance decks will be sent during October, 1987 and will then continue to be sent on a regular basis. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service Bulletins > Seat Leather - Cleaning Procedure Tips Seat Cover: Technical Service Bulletins Seat Leather - Cleaning Procedure Tips Article No. 98-17-1 09/01/98 SEAT - LEATHER CLEANING PROCEDURE - SERVICE TIP FORD: 1984-94 TEMPO 1984-97 THUNDERBIRD 1984-98 CROWN VICTORIA, ESCORT, MUSTANG 1986-98 TAURUS 1989-97 PROBE 1994-97 ASPIRE 1995-98 CONTOUR LINCOLN-MERCURY: 1984-94 TOPAZ 1984-97 COUGAR 1984-98 GRAND MARQUIS, TRACER 1984-99 TOWN CAR 1986-98 SABLE 1993-98 MARK VIII 1995-98 MYSTIQUE 1995-99 CONTINENTAL 1999 COUGAR LIGHT TRUCK: 1983-98 RANGER 1984-96 BRONCO 1984-97 F-250 HD 1984-98 ECONOLINE, F-150, F-250 LD 1986-97 AEROSTAR 1991-98 EXPLORER 1993-98 VILLAGER 1996-98 WINDSTAR 1997-98 EXPEDITION, MOUNTAINEER 1998 NAVIGATOR 1999 SUPER DUTY F SERIES This TSB article is being republished in its entirety to include the latest level parts and to include a revised Service Procedure. ISSUE The following TSB contains information regarding the cleaning of interior leather seats and trim. Improper cleaning procedures may damage the leather. If seats are not cleaned on a regular basis (every 4-6 weeks), normal wear and tear can cause excessive soiling. ACTION Ford Motor Company has developed a new kit (Deluxe Leather Care Kit - F8AZ-19G253-AA) to clean soiled seats without damaging the top coat of the leather. The kit contains a leather and vinyl cleaner along with a specially formulated sponge. Refer to the text for cleaning leather seats and trim. The Deluxe Leather Care Kit has been tested and approved for use on all Ford and Lincoln/Mercury leather and vinyl seating surfaces, and if used as directed, should be used for service repairs. Many household cleaners and sponges are too harsh to be used on leather and may actually cause permanent damage to the surface. Use this material on leather and vinyl seats that: ^ show excessive soiling ^ have been stained with coffee, lipstick, etc. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service Bulletins > Seat Leather - Cleaning Procedure Tips > Page 6614 Refer to the instructions included in the kit for specific application procedures. After cleaning surface with cleaner and sponge, wipe area with water and a cotton cloth. NOTE AVOID EXCESSIVE APPLICATION OF CLEANER ALONG STITCHING. PART NUMBER PART NAME F8AZ-19G253-AA Deluxe Leather Care Kit OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 97-14-2 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 101000, 107000, 190000 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Locations Power Door Lock Switch: Locations In Respective Door Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Testing and Inspection Brake Switch (Cruise Control): Testing and Inspection Perform this test only when brake application will not disconnect the speed control system. 1. Check operation of stop lamps by applying approximately 6 lbs. of pressure to brake pedal. If more than 6 lbs. is required, check brake pedal actuation and stop lamp switch. 2. If stop lamps do not function properly, check bulbs, circuit fuse or stop lamp switch. 3. If stop lamps function properly, check for battery voltage at 6 way connector using black wire w/green stripe on 1980 models, 1981-83 E-100-350 and 1984-87 E-150-350 series, or white wire w/pink stripe on 1981-82 F-100-350 and Bronco series, or white wire w/purple stripe on 1983 F-100-350, Bronco and Ranger, 1984-87 F-150-350, Ranger, 1984-87 Bronco II and 1986-87 Aerostar. 4. Depress brake pedal until stop lamps are illuminated. Check voltage at red wire w/black stripe on 1980 models, 1981-83 E-100-350 and 1984-87 E-150-350 models, or the light green wire on 1981-83 F-100-350 and Bronco, 1984-87 F-150-350 and Bronco, 1983-87 Ranger, 1984-87 Bronco II and 1986-87 Aerostar. The difference between the two voltage readings must not exceed 1.5 volts. If voltage is greater, a high resistance exists in the circuit and must be found and corrected. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Service and Repair Clutch Switch: Service and Repair 1. Remove bracket mounting screw(s). 2. Disconnect electrical connector and remove switch and bracket assembly. 3. Remove switch from bracket. 4. Reverse procedure to install. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Cruise Control > Cruise Control Brush Assembly > Component Information > Technical Service Bulletins > Customer Interest for Cruise Control Brush Assembly: > 8934 > Feb > 89 > Speed Control - Abnormal Operation When Hot Cruise Control Brush Assembly: Customer Interest Speed Control - Abnormal Operation When Hot Article No. 89-3-4 SPEED CONTROL - COAST AND ACCELERATION MODES - ABNORMAL OPERATION IN HIGH AMBIENT TEMPERATURES FORD: 1986-89 ALL LINCOLN-MERCURY: 1986-89 ALL LIGHT TRUCK: 1986-89 ALL ISSUE: Abnormal speed control operation in the coast and acceleration modes may be caused by loss of electrical contact between the steering wheel slip rings and brush assembly. This condition usually occurs in high ambient temperatures when the steering wheel slip rings and brush assembly are warm. ACTION: Improve the electrical continuity of the steering wheel slip rings and brush assembly by applying a new service released grease on the contact area. Refer to the following procedure for service details. 1. Remove the steering wheel, Refer to the appropriate Car or Light Truck Shop Manual for service details. 2. Clean the old grease from the steering wheel slip rings and brush assembly contact areas. 3. Apply the new service released grease, (E8AZ-19590-A), on the steering wheel slip rings and brush assembly contact surfaces. This new grease can be identified by its bright orange/red color. 4. Reinstall steering wheel. PART NUMBER PART NAME CLASS E8AZ-19590-A Grease B OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION: 890304A TIME: 0.4 Hr. DLR. CODING: Basic Part No. 9C899 Condition Code: 53 OASIS CODES: 2900 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Cruise Control > Cruise Control Brush Assembly > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cruise Control Brush Assembly: > 8934 > Feb > 89 > Speed Control Abnormal Operation When Hot Cruise Control Brush Assembly: All Technical Service Bulletins Speed Control - Abnormal Operation When Hot Article No. 89-3-4 SPEED CONTROL - COAST AND ACCELERATION MODES - ABNORMAL OPERATION IN HIGH AMBIENT TEMPERATURES FORD: 1986-89 ALL LINCOLN-MERCURY: 1986-89 ALL LIGHT TRUCK: 1986-89 ALL ISSUE: Abnormal speed control operation in the coast and acceleration modes may be caused by loss of electrical contact between the steering wheel slip rings and brush assembly. This condition usually occurs in high ambient temperatures when the steering wheel slip rings and brush assembly are warm. ACTION: Improve the electrical continuity of the steering wheel slip rings and brush assembly by applying a new service released grease on the contact area. Refer to the following procedure for service details. 1. Remove the steering wheel, Refer to the appropriate Car or Light Truck Shop Manual for service details. 2. Clean the old grease from the steering wheel slip rings and brush assembly contact areas. 3. Apply the new service released grease, (E8AZ-19590-A), on the steering wheel slip rings and brush assembly contact surfaces. This new grease can be identified by its bright orange/red color. 4. Reinstall steering wheel. PART NUMBER PART NAME CLASS E8AZ-19590-A Grease B OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION: 890304A TIME: 0.4 Hr. DLR. CODING: Basic Part No. 9C899 Condition Code: 53 OASIS CODES: 2900 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Cruise Control > Cruise Control Module > Component Information > Locations Cruise Control Module: Locations Underneath LH Side Of I/P Behind I/P, To Right Of Steering Column Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Cruise Control > Cruise Control Module > Component Information > Locations > Page 6642 Cruise Control Module: Testing and Inspection Use only a multi-meter of 5000 ohm/volt rating or higher when performing amplifier test. ``On'' Circuit Test 1. Turn ignition ``On.'' 2. Connect a voltmeter between light blue wire w/black hash and ground on models exc. 1983-87 Ranger, 1984-87 Bronco II and 1986-87 Aerostar or white wire w/purple stripe and ground on 1983-87 Ranger, 1984-87 Bronco II and 1986-87 Aerostar. 3. Battery voltage should be indicated when ``On'' switch on steering column is depressed and held. If battery voltage is not indicated, check horn relay and perform control switch test. 4. Release ``On'' button. Voltmeter should indicate 7.8 volts indicating ``On'' circuit is engaged. If voltage does not remain, check amplifier ground, fuses or circuit breakers or replace amplifier with known good amplifier and repeat test. 5. Replace as necessary. ``Off'' Circuit Test 1. Turn ignition ``On.'' 2. Connect a voltmeter between light blue wire w/black hash and ground. 3. Depress ``Off'' button. Voltage should drop to zero indicating ``On'' circuit is de-energized. 4. If voltage does not drop to zero, perform ``Control Switch Test.'' ``Set-Accelerate'' Circuit Test 1. Turn ignition ``On.'' 2. Connect a voltmeter between light blue wire w/black hash and ground. 3. Depress ``On'' switch, then hold ``Set-Accel'' button on steering wheel. Voltmeter should indicate 4.5 volts. Rotate steering wheel back and forth and check for voltmeter fluctuations. If reading varies more than .5 volts, perform ``Control Switch Test.'' ``Coast'' Circuit Test 1. Turn ignition ``On.'' 2. Connect a voltmeter between light blue wire w/black hash and ground. 3. Depress ``On'' switch, then depress and hold ``Coast'' button on steering wheel. Voltmeter should indicate 1.5 volts. Rotate steering wheel back and forth and check for voltage fluctuations. If reading varies more than .5 volts, perform ``Control Switch Test.'' ``Resume'' Circuit Test 1. Turn ignition ``On.'' 2. Connect a voltmeter between light blue wire w/black hash and ground. 3. Depress and hold ``Resume'' button. Voltmeter should indicate 6.5 volts. If all circuits are functioning properly, perform ``Servo Assembly Test'' using a known good amplifier. Do not replace amplifier before performing servo test. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Technical Service Bulletins > Customer Interest for Cruise Control Servo: > 9278 > Mar > 92 > Speed Control - Intermittent or Inoperative Cruise Control Servo: Customer Interest Speed Control - Intermittent or Inoperative Article No. 92-7-8 03/25/92 ^ SPEED CONTROL - INTERMITTENT OR INOPERATIVE - DURING WET WEATHER CONDITIONS ^ WIRING - SPEED CONTROL INTERMITTENT OR INOPERATIVE - CONNECTOR CORROSION LIGHT TRUCK: 1986-90 BRONCO II 1986-91 BRONCO, ECONOLINE, F-150-350 SERIES, RANGER 1991 EXPLORER This TSB article is being republished in its entirety to correct the grease part number suffix which appeared in Step 5 of the service procedure. ISSUE: Intermittent or inoperative speed control operation may occur during wet weather operation. This may be caused by a corroded connector at the servo. ACTION: Inspect the connector at the servo for corrosion to determine if replacement is required. Refer to the following procedure for service details. 1. Disconnect the connector at the servo. 2. Blow dry the connector assembly with shop air. 3. Clean and inspect pins for corrosion. 4. Replace any damaged or corroded pins (D1AZ-14488-E). 5. Apply grease (F2AZ-19584-A) to both ends of the connector to prevent water entry. 6. Reconnect the connector at the servo. PART NUMBER PART NAME CLASS F2AZ-19684-A Grease C D1AZ-14488-E Pin Connector C SUPERSEDES: 92-1-7 WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION DESCRIPTION TIME 920708A Clean And Inspect Pins And 0.3 Hr. Apply Grease To Connectors 920708B Clean And Inspect Pins 0.4 Hr. Replace Damaged Pins As Necessary, Apply Grease To Connectors DEALER CODING BASIC PART NO. CONDITION CODE 14488 84 OASIS CODES: 203300, 205000 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cruise Control Servo: > 9278 > Mar > 92 > Speed Control - Intermittent or Inoperative Cruise Control Servo: All Technical Service Bulletins Speed Control - Intermittent or Inoperative Article No. 92-7-8 03/25/92 ^ SPEED CONTROL - INTERMITTENT OR INOPERATIVE - DURING WET WEATHER CONDITIONS ^ WIRING - SPEED CONTROL INTERMITTENT OR INOPERATIVE - CONNECTOR CORROSION LIGHT TRUCK: 1986-90 BRONCO II 1986-91 BRONCO, ECONOLINE, F-150-350 SERIES, RANGER 1991 EXPLORER This TSB article is being republished in its entirety to correct the grease part number suffix which appeared in Step 5 of the service procedure. ISSUE: Intermittent or inoperative speed control operation may occur during wet weather operation. This may be caused by a corroded connector at the servo. ACTION: Inspect the connector at the servo for corrosion to determine if replacement is required. Refer to the following procedure for service details. 1. Disconnect the connector at the servo. 2. Blow dry the connector assembly with shop air. 3. Clean and inspect pins for corrosion. 4. Replace any damaged or corroded pins (D1AZ-14488-E). 5. Apply grease (F2AZ-19584-A) to both ends of the connector to prevent water entry. 6. Reconnect the connector at the servo. PART NUMBER PART NAME CLASS F2AZ-19684-A Grease C D1AZ-14488-E Pin Connector C SUPERSEDES: 92-1-7 WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION DESCRIPTION TIME 920708A Clean And Inspect Pins And 0.3 Hr. Apply Grease To Connectors 920708B Clean And Inspect Pins 0.4 Hr. Replace Damaged Pins As Necessary, Apply Grease To Connectors DEALER CODING BASIC PART NO. CONDITION CODE 14488 84 OASIS CODES: 203300, 205000 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Technical Service Bulletins > Page 6656 Cruise Control Servo: Locations LH Side Of Engine Compartment In LH Inner Fender, Near Master Cylinder Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Technical Service Bulletins > Page 6657 Cruise Control Servo: Testing and Inspection 1981-83 F-100-350 & Bronco, 1984-87 F-150-350 & Bronco 1982-83 E-100-350 & 1984-87 E-150-350 Series 1. Disconnect ball chain from carburetor (if equipped), then the electrical connector at the amplifier. 2. Connect an ohmmeter between orange wire w/yellow hash and gray wire w/black hash at connector. A resistance of 40 to 125 ohms should be obtained. 3. Connect an ohmmeter between orange wire w/yellow hash and white wire w/pink hash. A resistance of 60 to 90 ohms should be obtained. 4. If equipped, connect ball chain to carburetor. 5. Start engine and ensure servo vacuum from engine exceeds 2.5 inches of Hg, then disconnect servo from amplifier. 6. Connect orange wire w/yellow hash of servo to battery positive terminal and white wire w/pink hash to ground, then momentarily touch gray wire w/black hash to ground. Servo throttle actuator should pull in and engine RPM should increase. Throttle should hold in position or slowly release chain tension. 7. Remove white wire w/pink hash and check for immediate release of chain tension from servo. 8. Replace servo if servo fails to function as described. Amplifier may need replacement if orange wire w/yellow hash is shorted to either white-pink hash lead or gray-black hash lead. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Technical Service Bulletins > Page 6658 Cruise Control Servo: Service and Repair Exc. 1986-87 Aerostar 1. Raise hood, then disconnect wiring harness connector at servo assembly. On some models, it may be necessary to disconnect servo assembly at the amplifier under the dash and carefully pull harness and connector through dash panel opening. 2. Disconnect ball chain at carburetor or adjuster from accelerator cable (as equipped), then remove vacuum hose from servo assembly. 3. Remove servo assembly retaining pins and nuts, then the servo assembly from mounting bracket. 4. Reverse procedure to install. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Service and Repair Cruise Control Servo Cable: Service and Repair 1. Remove servo assembly, then discard cable. 2. Attach new actuator cable to servo assembly. 3. Install servo assembly. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > Customer Interest for Cruise Control Switch: > 871615 > Aug > 87 > M/T - Gear Clash and Hard Shifting Cruise Control Switch: Customer Interest M/T - Gear Clash and Hard Shifting ^ CLUTCH (HYDRAULIC) - PEDAL DOES NOT Article No. FULLY RETURN - DIAGNOSTIC TIPS 87-16-15 ^ TRANSMISSION - MANUAL - GEAR CLASH AND HARD SHIFTING ^ SPEED CONTROL - INOPERATIVE - LOW CLUTCH PEDAL ALLOWS SWITCH CIRCUIT TO REMAIN OPEN LIGHT TRUCK: 1984-87 F-150/350, BRONCO ISSUE: A clutch pedal not fully returning to contact the rubber bumper at the "up" stop may result in any of the following conditions. ^ Transmission gear clash or hard shifting or failure to release into or from gear (particularly reverse and 1st gear) because clutch pedal stroke length is decreased, causing low pedal reserve. ^ Clutch pedal may sometimes stick near the TOP of the stroke, requiring driver to "tip" the pedal with his/her foot in order to get pedal to further return. ^ Speed control is inoperative, due to pedal not returning and permitting "shut off" switch circuit to remain in the open position, i.e., clutch disengaged mode. ACTION: To determine if a new cross-shaft lever is required, use the following diagnostic and servicing procedure. 1. Check under the dash area to be certain that the clutch pedal system has no wiring looms which interfere with pedal return, at the interlock switch rod and the end of the master cylinder pushrod. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > Customer Interest for Cruise Control Switch: > 871615 > Aug > 87 > M/T - Gear Clash and Hard Shifting > Page 6670 Figure 7 2. Determine if the clutch master cylinder pushrod and lever pin are correctly aligned by disconnecting the pushrod and seeing if it will reassemble to the pin WITHOUT DEPRESSING THE PUSHROD OR DEPRESSING THE CLUTCH PEDAL. (When the pushrod is disconnected from the pin, the clutch master cylinder piston is fully retracted (rearward) and the clutch pedal blade is contacting the rubber bumper stop), see Figure 7. 3. If the two components are not in alignment, perform the following IN THIS EXACT SEQUENCE: a. Loosen the clutch pedal attaching nut (left hand side). Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > Customer Interest for Cruise Control Switch: > 871615 > Aug > 87 > M/T - Gear Clash and Hard Shifting > Page 6671 b. Reinstall the clutch master cylinder pushrod to the cross-shaft lever pin. c. Tighten the clutch pedal attaching nut (left hand side). d. Stroke the clutch pedal several times to reset the position of the shaft to the pedal slot, THIS STEP IS REQUIRED! e. Again, remove the clutch master cylinder pushrod from the lever pin and check the alignment. If the two (2) components are still not in alignment, replace the crossshaft lever. NOTE: If the pushrod is aligned with the pin, no further action is required. Cross-Shaft Lever Replacement Removal 1. Disconnect the master cylinder pushrod from the cross-shaft lever pin. 1984-86 Vehicles Remove the clevis pin. Carefully pull the pushrod from the lever. 1987 Vehicles Disconnect the snap-in bushing by wedging a small screwdriver or putty knife between the lever and the bushing. When the bushing tangs are free at the pin groove, carefully pull the pushrod from the lever. 2. Remove the attaching nut. 3. Remove the lever from the cross-shaft, using a pry tool or puller. Installation NOTE: The proper position of clutch master cylinder pushrod relative to the crossshaft lever (7A554) pin is controlled by this installation PROCEDURE. Therefore, ONLY the following steps should be used. 1. Install the new lever (pin) to the clutch master cylinder pushrod bushing. 2. Install the lever onto the cross-shaft. 3. Install the attaching nut, finger tight. 4. Inspect pedal position to make sure it is against the "up" stop. 5. Tighten the attaching nut. This will permit the knurled teeth on the shaft to cut matching teeth in lever, which then results in the correct positioning of the two (2) components. NOTE: The above procedure is the preferred method of "adjusting" master cylinder pushrod length. Frequently, the master cylinder is replaced or adjustable pushrods are installed to obtain the required pushrod to lever positioning. Cross-shaft lever replacement is a more efficient method and eliminates the potential of pushrod mis-adjustment and introducing air or contamination into the hydraulic system. CROSS-SHAFT LEVER APPLICATION Model Year Truck Series Part Number 1984-86 F Series, Bronco E4TZ-7A554-A 1987 F Series, Bronco E7TZ-7A554-A PART NUMBER PART NAME CLASS E4TZ-7A554-A Cross-Shaft Lever B E7TZ-7A554-A Cross-Shaft Lever B OTHER APPLICABLE ARTICLES: 85-1-20, 85-5-24, 85-5-26 WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual OPERATION: SP871615A Align clutch master cylinder pushrod and cross-shaft lever pin Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > Customer Interest for Cruise Control Switch: > 871615 > Aug > 87 > M/T - Gear Clash and Hard Shifting > Page 6672 TIME: 0.4 Hr. - 6.9L diesel 0.3 Hr. - All others OPERATION: SP871615B - Replace cross-shaft lever (includes time to perform previous alignment) TIME: 0.6 Hr. - 6.9L diesel 0.5 Hr. - All others DLR. CODING: Basic Part No. 7A554 - Code: 07 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cruise Control Switch: > 871615 > Aug > 87 > M/T - Gear Clash and Hard Shifting Cruise Control Switch: All Technical Service Bulletins M/T - Gear Clash and Hard Shifting ^ CLUTCH (HYDRAULIC) - PEDAL DOES NOT Article No. FULLY RETURN - DIAGNOSTIC TIPS 87-16-15 ^ TRANSMISSION - MANUAL - GEAR CLASH AND HARD SHIFTING ^ SPEED CONTROL - INOPERATIVE - LOW CLUTCH PEDAL ALLOWS SWITCH CIRCUIT TO REMAIN OPEN LIGHT TRUCK: 1984-87 F-150/350, BRONCO ISSUE: A clutch pedal not fully returning to contact the rubber bumper at the "up" stop may result in any of the following conditions. ^ Transmission gear clash or hard shifting or failure to release into or from gear (particularly reverse and 1st gear) because clutch pedal stroke length is decreased, causing low pedal reserve. ^ Clutch pedal may sometimes stick near the TOP of the stroke, requiring driver to "tip" the pedal with his/her foot in order to get pedal to further return. ^ Speed control is inoperative, due to pedal not returning and permitting "shut off" switch circuit to remain in the open position, i.e., clutch disengaged mode. ACTION: To determine if a new cross-shaft lever is required, use the following diagnostic and servicing procedure. 1. Check under the dash area to be certain that the clutch pedal system has no wiring looms which interfere with pedal return, at the interlock switch rod and the end of the master cylinder pushrod. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cruise Control Switch: > 871615 > Aug > 87 > M/T - Gear Clash and Hard Shifting > Page 6678 Figure 7 2. Determine if the clutch master cylinder pushrod and lever pin are correctly aligned by disconnecting the pushrod and seeing if it will reassemble to the pin WITHOUT DEPRESSING THE PUSHROD OR DEPRESSING THE CLUTCH PEDAL. (When the pushrod is disconnected from the pin, the clutch master cylinder piston is fully retracted (rearward) and the clutch pedal blade is contacting the rubber bumper stop), see Figure 7. 3. If the two components are not in alignment, perform the following IN THIS EXACT SEQUENCE: a. Loosen the clutch pedal attaching nut (left hand side). Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cruise Control Switch: > 871615 > Aug > 87 > M/T - Gear Clash and Hard Shifting > Page 6679 b. Reinstall the clutch master cylinder pushrod to the cross-shaft lever pin. c. Tighten the clutch pedal attaching nut (left hand side). d. Stroke the clutch pedal several times to reset the position of the shaft to the pedal slot, THIS STEP IS REQUIRED! e. Again, remove the clutch master cylinder pushrod from the lever pin and check the alignment. If the two (2) components are still not in alignment, replace the crossshaft lever. NOTE: If the pushrod is aligned with the pin, no further action is required. Cross-Shaft Lever Replacement Removal 1. Disconnect the master cylinder pushrod from the cross-shaft lever pin. 1984-86 Vehicles Remove the clevis pin. Carefully pull the pushrod from the lever. 1987 Vehicles Disconnect the snap-in bushing by wedging a small screwdriver or putty knife between the lever and the bushing. When the bushing tangs are free at the pin groove, carefully pull the pushrod from the lever. 2. Remove the attaching nut. 3. Remove the lever from the cross-shaft, using a pry tool or puller. Installation NOTE: The proper position of clutch master cylinder pushrod relative to the crossshaft lever (7A554) pin is controlled by this installation PROCEDURE. Therefore, ONLY the following steps should be used. 1. Install the new lever (pin) to the clutch master cylinder pushrod bushing. 2. Install the lever onto the cross-shaft. 3. Install the attaching nut, finger tight. 4. Inspect pedal position to make sure it is against the "up" stop. 5. Tighten the attaching nut. This will permit the knurled teeth on the shaft to cut matching teeth in lever, which then results in the correct positioning of the two (2) components. NOTE: The above procedure is the preferred method of "adjusting" master cylinder pushrod length. Frequently, the master cylinder is replaced or adjustable pushrods are installed to obtain the required pushrod to lever positioning. Cross-shaft lever replacement is a more efficient method and eliminates the potential of pushrod mis-adjustment and introducing air or contamination into the hydraulic system. CROSS-SHAFT LEVER APPLICATION Model Year Truck Series Part Number 1984-86 F Series, Bronco E4TZ-7A554-A 1987 F Series, Bronco E7TZ-7A554-A PART NUMBER PART NAME CLASS E4TZ-7A554-A Cross-Shaft Lever B E7TZ-7A554-A Cross-Shaft Lever B OTHER APPLICABLE ARTICLES: 85-1-20, 85-5-24, 85-5-26 WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual OPERATION: SP871615A Align clutch master cylinder pushrod and cross-shaft lever pin Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cruise Control Switch: > 871615 > Aug > 87 > M/T - Gear Clash and Hard Shifting > Page 6680 TIME: 0.4 Hr. - 6.9L diesel 0.3 Hr. - All others OPERATION: SP871615B - Replace cross-shaft lever (includes time to perform previous alignment) TIME: 0.6 Hr. - 6.9L diesel 0.5 Hr. - All others DLR. CODING: Basic Part No. 7A554 - Code: 07 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Diagrams > Diagram Information and Instructions Cruise Control Switch: Diagram Information and Instructions Symbol Identification Wire Color Code Identification Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6683 NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6684 Cruise Control Switch: Electrical Diagrams Fig. 49 Speed Control System Wiring Circuit (Part 1 of 2) Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6685 Fig. 49 Speed Control System Wiring Circuit (Part 2 of 2) Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Diagrams > Page 6686 Cruise Control Switch: Testing and Inspection 1980-87 Models Exc. 1983-87 Ranger, 1984-87 Bronco II & 1986 Aerostar Disconnect 6 way connector from control switch at the amplifier, then perform the following checks: 1. Connect a voltmeter between light blue-black hash lead and ground, then depress the ``On'' button and check for battery voltage. 2. Turn ignition ``Off,'' then connect an ohmmeter between light blue-black hash lead and ground. 3. Rotate steering wheel throughout its full range while making the following checks: a. Depress ``Off'' button and check for a reading of 0-1 ohm. b. Depress ``Set'' button and check for a reading of 646-714 ohms. c. Depress and hold ``Coast'' switch and check for a reading of 114-126 ohms. d. On models with ``Resume,'' depress and hold ``Resume'' switch and check for a reading of approximately 2200 ohms. 4. If resistance values are not as specified, inspect wiring, slip rings, turn signal copper brushes, speed control switch and steering column for proper ground. Check for proper ground by connecting an ohmmeter between upper steering column flange and a suitable ground. Resistance should be less then 1/2 ohm. Rotate steering wheel throughout its full range and ensure flexible coupling has a resistance of less than 1 ohm. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Diagrams > Page 6687 Cruise Control Switch: Service and Repair 1. Remove steering wheel pad attaching screws from behind steering wheel. 2. While pulling pad away from steering wheel, disconnect horn and speed control wire connectors and remove pad. 3. Remove retaining nuts securing the speed control switches and trim plate retainer to the steering wheel pad. 4. Disconnect wiring connector on rear of steering wheel pad assembly, then remove switch and trim retainer assembly. 5. Remove speed control switches by snapping out of plastic retainer. 6. To remove the ground brush, remove steering wheel for access. 7. Snap the ground brush assembly out of the turn signal switch. 8. Reverse procedure to install. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Cruise Control > Cruise Control Vacuum Vent Solenoid > Component Information > Locations Cruise Control Vacuum Vent Solenoid: Locations Underneath LH Side Of I/P Under LH Side Of I/P Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Cruise Control > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Locations Cruise Control Module: Locations Underneath LH Side Of I/P Behind I/P, To Right Of Steering Column Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Cruise Control > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Locations > Page 6695 Cruise Control Module: Testing and Inspection Use only a multi-meter of 5000 ohm/volt rating or higher when performing amplifier test. ``On'' Circuit Test 1. Turn ignition ``On.'' 2. Connect a voltmeter between light blue wire w/black hash and ground on models exc. 1983-87 Ranger, 1984-87 Bronco II and 1986-87 Aerostar or white wire w/purple stripe and ground on 1983-87 Ranger, 1984-87 Bronco II and 1986-87 Aerostar. 3. Battery voltage should be indicated when ``On'' switch on steering column is depressed and held. If battery voltage is not indicated, check horn relay and perform control switch test. 4. Release ``On'' button. Voltmeter should indicate 7.8 volts indicating ``On'' circuit is engaged. If voltage does not remain, check amplifier ground, fuses or circuit breakers or replace amplifier with known good amplifier and repeat test. 5. Replace as necessary. ``Off'' Circuit Test 1. Turn ignition ``On.'' 2. Connect a voltmeter between light blue wire w/black hash and ground. 3. Depress ``Off'' button. Voltage should drop to zero indicating ``On'' circuit is de-energized. 4. If voltage does not drop to zero, perform ``Control Switch Test.'' ``Set-Accelerate'' Circuit Test 1. Turn ignition ``On.'' 2. Connect a voltmeter between light blue wire w/black hash and ground. 3. Depress ``On'' switch, then hold ``Set-Accel'' button on steering wheel. Voltmeter should indicate 4.5 volts. Rotate steering wheel back and forth and check for voltmeter fluctuations. If reading varies more than .5 volts, perform ``Control Switch Test.'' ``Coast'' Circuit Test 1. Turn ignition ``On.'' 2. Connect a voltmeter between light blue wire w/black hash and ground. 3. Depress ``On'' switch, then depress and hold ``Coast'' button on steering wheel. Voltmeter should indicate 1.5 volts. Rotate steering wheel back and forth and check for voltage fluctuations. If reading varies more than .5 volts, perform ``Control Switch Test.'' ``Resume'' Circuit Test 1. Turn ignition ``On.'' 2. Connect a voltmeter between light blue wire w/black hash and ground. 3. Depress and hold ``Resume'' button. Voltmeter should indicate 6.5 volts. If all circuits are functioning properly, perform ``Servo Assembly Test'' using a known good amplifier. Do not replace amplifier before performing servo test. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Testing and Inspection Brake Switch (Cruise Control): Testing and Inspection Perform this test only when brake application will not disconnect the speed control system. 1. Check operation of stop lamps by applying approximately 6 lbs. of pressure to brake pedal. If more than 6 lbs. is required, check brake pedal actuation and stop lamp switch. 2. If stop lamps do not function properly, check bulbs, circuit fuse or stop lamp switch. 3. If stop lamps function properly, check for battery voltage at 6 way connector using black wire w/green stripe on 1980 models, 1981-83 E-100-350 and 1984-87 E-150-350 series, or white wire w/pink stripe on 1981-82 F-100-350 and Bronco series, or white wire w/purple stripe on 1983 F-100-350, Bronco and Ranger, 1984-87 F-150-350, Ranger, 1984-87 Bronco II and 1986-87 Aerostar. 4. Depress brake pedal until stop lamps are illuminated. Check voltage at red wire w/black stripe on 1980 models, 1981-83 E-100-350 and 1984-87 E-150-350 models, or the light green wire on 1981-83 F-100-350 and Bronco, 1984-87 F-150-350 and Bronco, 1983-87 Ranger, 1984-87 Bronco II and 1986-87 Aerostar. The difference between the two voltage readings must not exceed 1.5 volts. If voltage is greater, a high resistance exists in the circuit and must be found and corrected. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Service and Repair Clutch Switch: Service and Repair 1. Remove bracket mounting screw(s). 2. Disconnect electrical connector and remove switch and bracket assembly. 3. Remove switch from bracket. 4. Reverse procedure to install. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > Customer Interest for Cruise Control Switch: > 871615 > Aug > 87 > M/T - Gear Clash and Hard Shifting Cruise Control Switch: Customer Interest M/T - Gear Clash and Hard Shifting ^ CLUTCH (HYDRAULIC) - PEDAL DOES NOT Article No. FULLY RETURN - DIAGNOSTIC TIPS 87-16-15 ^ TRANSMISSION - MANUAL - GEAR CLASH AND HARD SHIFTING ^ SPEED CONTROL - INOPERATIVE - LOW CLUTCH PEDAL ALLOWS SWITCH CIRCUIT TO REMAIN OPEN LIGHT TRUCK: 1984-87 F-150/350, BRONCO ISSUE: A clutch pedal not fully returning to contact the rubber bumper at the "up" stop may result in any of the following conditions. ^ Transmission gear clash or hard shifting or failure to release into or from gear (particularly reverse and 1st gear) because clutch pedal stroke length is decreased, causing low pedal reserve. ^ Clutch pedal may sometimes stick near the TOP of the stroke, requiring driver to "tip" the pedal with his/her foot in order to get pedal to further return. ^ Speed control is inoperative, due to pedal not returning and permitting "shut off" switch circuit to remain in the open position, i.e., clutch disengaged mode. ACTION: To determine if a new cross-shaft lever is required, use the following diagnostic and servicing procedure. 1. Check under the dash area to be certain that the clutch pedal system has no wiring looms which interfere with pedal return, at the interlock switch rod and the end of the master cylinder pushrod. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > Customer Interest for Cruise Control Switch: > 871615 > Aug > 87 > M/T - Gear Clash and Hard Shifting > Page 6711 Figure 7 2. Determine if the clutch master cylinder pushrod and lever pin are correctly aligned by disconnecting the pushrod and seeing if it will reassemble to the pin WITHOUT DEPRESSING THE PUSHROD OR DEPRESSING THE CLUTCH PEDAL. (When the pushrod is disconnected from the pin, the clutch master cylinder piston is fully retracted (rearward) and the clutch pedal blade is contacting the rubber bumper stop), see Figure 7. 3. If the two components are not in alignment, perform the following IN THIS EXACT SEQUENCE: a. Loosen the clutch pedal attaching nut (left hand side). Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > Customer Interest for Cruise Control Switch: > 871615 > Aug > 87 > M/T - Gear Clash and Hard Shifting > Page 6712 b. Reinstall the clutch master cylinder pushrod to the cross-shaft lever pin. c. Tighten the clutch pedal attaching nut (left hand side). d. Stroke the clutch pedal several times to reset the position of the shaft to the pedal slot, THIS STEP IS REQUIRED! e. Again, remove the clutch master cylinder pushrod from the lever pin and check the alignment. If the two (2) components are still not in alignment, replace the crossshaft lever. NOTE: If the pushrod is aligned with the pin, no further action is required. Cross-Shaft Lever Replacement Removal 1. Disconnect the master cylinder pushrod from the cross-shaft lever pin. 1984-86 Vehicles Remove the clevis pin. Carefully pull the pushrod from the lever. 1987 Vehicles Disconnect the snap-in bushing by wedging a small screwdriver or putty knife between the lever and the bushing. When the bushing tangs are free at the pin groove, carefully pull the pushrod from the lever. 2. Remove the attaching nut. 3. Remove the lever from the cross-shaft, using a pry tool or puller. Installation NOTE: The proper position of clutch master cylinder pushrod relative to the crossshaft lever (7A554) pin is controlled by this installation PROCEDURE. Therefore, ONLY the following steps should be used. 1. Install the new lever (pin) to the clutch master cylinder pushrod bushing. 2. Install the lever onto the cross-shaft. 3. Install the attaching nut, finger tight. 4. Inspect pedal position to make sure it is against the "up" stop. 5. Tighten the attaching nut. This will permit the knurled teeth on the shaft to cut matching teeth in lever, which then results in the correct positioning of the two (2) components. NOTE: The above procedure is the preferred method of "adjusting" master cylinder pushrod length. Frequently, the master cylinder is replaced or adjustable pushrods are installed to obtain the required pushrod to lever positioning. Cross-shaft lever replacement is a more efficient method and eliminates the potential of pushrod mis-adjustment and introducing air or contamination into the hydraulic system. CROSS-SHAFT LEVER APPLICATION Model Year Truck Series Part Number 1984-86 F Series, Bronco E4TZ-7A554-A 1987 F Series, Bronco E7TZ-7A554-A PART NUMBER PART NAME CLASS E4TZ-7A554-A Cross-Shaft Lever B E7TZ-7A554-A Cross-Shaft Lever B OTHER APPLICABLE ARTICLES: 85-1-20, 85-5-24, 85-5-26 WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual OPERATION: SP871615A Align clutch master cylinder pushrod and cross-shaft lever pin Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > Customer Interest for Cruise Control Switch: > 871615 > Aug > 87 > M/T - Gear Clash and Hard Shifting > Page 6713 TIME: 0.4 Hr. - 6.9L diesel 0.3 Hr. - All others OPERATION: SP871615B - Replace cross-shaft lever (includes time to perform previous alignment) TIME: 0.6 Hr. - 6.9L diesel 0.5 Hr. - All others DLR. CODING: Basic Part No. 7A554 - Code: 07 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cruise Control Switch: > 871615 > Aug > 87 > M/T - Gear Clash and Hard Shifting Cruise Control Switch: All Technical Service Bulletins M/T - Gear Clash and Hard Shifting ^ CLUTCH (HYDRAULIC) - PEDAL DOES NOT Article No. FULLY RETURN - DIAGNOSTIC TIPS 87-16-15 ^ TRANSMISSION - MANUAL - GEAR CLASH AND HARD SHIFTING ^ SPEED CONTROL - INOPERATIVE - LOW CLUTCH PEDAL ALLOWS SWITCH CIRCUIT TO REMAIN OPEN LIGHT TRUCK: 1984-87 F-150/350, BRONCO ISSUE: A clutch pedal not fully returning to contact the rubber bumper at the "up" stop may result in any of the following conditions. ^ Transmission gear clash or hard shifting or failure to release into or from gear (particularly reverse and 1st gear) because clutch pedal stroke length is decreased, causing low pedal reserve. ^ Clutch pedal may sometimes stick near the TOP of the stroke, requiring driver to "tip" the pedal with his/her foot in order to get pedal to further return. ^ Speed control is inoperative, due to pedal not returning and permitting "shut off" switch circuit to remain in the open position, i.e., clutch disengaged mode. ACTION: To determine if a new cross-shaft lever is required, use the following diagnostic and servicing procedure. 1. Check under the dash area to be certain that the clutch pedal system has no wiring looms which interfere with pedal return, at the interlock switch rod and the end of the master cylinder pushrod. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cruise Control Switch: > 871615 > Aug > 87 > M/T - Gear Clash and Hard Shifting > Page 6719 Figure 7 2. Determine if the clutch master cylinder pushrod and lever pin are correctly aligned by disconnecting the pushrod and seeing if it will reassemble to the pin WITHOUT DEPRESSING THE PUSHROD OR DEPRESSING THE CLUTCH PEDAL. (When the pushrod is disconnected from the pin, the clutch master cylinder piston is fully retracted (rearward) and the clutch pedal blade is contacting the rubber bumper stop), see Figure 7. 3. If the two components are not in alignment, perform the following IN THIS EXACT SEQUENCE: a. Loosen the clutch pedal attaching nut (left hand side). Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cruise Control Switch: > 871615 > Aug > 87 > M/T - Gear Clash and Hard Shifting > Page 6720 b. Reinstall the clutch master cylinder pushrod to the cross-shaft lever pin. c. Tighten the clutch pedal attaching nut (left hand side). d. Stroke the clutch pedal several times to reset the position of the shaft to the pedal slot, THIS STEP IS REQUIRED! e. Again, remove the clutch master cylinder pushrod from the lever pin and check the alignment. If the two (2) components are still not in alignment, replace the crossshaft lever. NOTE: If the pushrod is aligned with the pin, no further action is required. Cross-Shaft Lever Replacement Removal 1. Disconnect the master cylinder pushrod from the cross-shaft lever pin. 1984-86 Vehicles Remove the clevis pin. Carefully pull the pushrod from the lever. 1987 Vehicles Disconnect the snap-in bushing by wedging a small screwdriver or putty knife between the lever and the bushing. When the bushing tangs are free at the pin groove, carefully pull the pushrod from the lever. 2. Remove the attaching nut. 3. Remove the lever from the cross-shaft, using a pry tool or puller. Installation NOTE: The proper position of clutch master cylinder pushrod relative to the crossshaft lever (7A554) pin is controlled by this installation PROCEDURE. Therefore, ONLY the following steps should be used. 1. Install the new lever (pin) to the clutch master cylinder pushrod bushing. 2. Install the lever onto the cross-shaft. 3. Install the attaching nut, finger tight. 4. Inspect pedal position to make sure it is against the "up" stop. 5. Tighten the attaching nut. This will permit the knurled teeth on the shaft to cut matching teeth in lever, which then results in the correct positioning of the two (2) components. NOTE: The above procedure is the preferred method of "adjusting" master cylinder pushrod length. Frequently, the master cylinder is replaced or adjustable pushrods are installed to obtain the required pushrod to lever positioning. Cross-shaft lever replacement is a more efficient method and eliminates the potential of pushrod mis-adjustment and introducing air or contamination into the hydraulic system. CROSS-SHAFT LEVER APPLICATION Model Year Truck Series Part Number 1984-86 F Series, Bronco E4TZ-7A554-A 1987 F Series, Bronco E7TZ-7A554-A PART NUMBER PART NAME CLASS E4TZ-7A554-A Cross-Shaft Lever B E7TZ-7A554-A Cross-Shaft Lever B OTHER APPLICABLE ARTICLES: 85-1-20, 85-5-24, 85-5-26 WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual OPERATION: SP871615A Align clutch master cylinder pushrod and cross-shaft lever pin Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cruise Control Switch: > 871615 > Aug > 87 > M/T - Gear Clash and Hard Shifting > Page 6721 TIME: 0.4 Hr. - 6.9L diesel 0.3 Hr. - All others OPERATION: SP871615B - Replace cross-shaft lever (includes time to perform previous alignment) TIME: 0.6 Hr. - 6.9L diesel 0.5 Hr. - All others DLR. CODING: Basic Part No. 7A554 - Code: 07 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Diagrams > Diagram Information and Instructions Cruise Control Switch: Diagram Information and Instructions Symbol Identification Wire Color Code Identification Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6724 NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6725 Cruise Control Switch: Electrical Diagrams Fig. 49 Speed Control System Wiring Circuit (Part 1 of 2) Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6726 Fig. 49 Speed Control System Wiring Circuit (Part 2 of 2) Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Diagrams > Page 6727 Cruise Control Switch: Testing and Inspection 1980-87 Models Exc. 1983-87 Ranger, 1984-87 Bronco II & 1986 Aerostar Disconnect 6 way connector from control switch at the amplifier, then perform the following checks: 1. Connect a voltmeter between light blue-black hash lead and ground, then depress the ``On'' button and check for battery voltage. 2. Turn ignition ``Off,'' then connect an ohmmeter between light blue-black hash lead and ground. 3. Rotate steering wheel throughout its full range while making the following checks: a. Depress ``Off'' button and check for a reading of 0-1 ohm. b. Depress ``Set'' button and check for a reading of 646-714 ohms. c. Depress and hold ``Coast'' switch and check for a reading of 114-126 ohms. d. On models with ``Resume,'' depress and hold ``Resume'' switch and check for a reading of approximately 2200 ohms. 4. If resistance values are not as specified, inspect wiring, slip rings, turn signal copper brushes, speed control switch and steering column for proper ground. Check for proper ground by connecting an ohmmeter between upper steering column flange and a suitable ground. Resistance should be less then 1/2 ohm. Rotate steering wheel throughout its full range and ensure flexible coupling has a resistance of less than 1 ohm. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Diagrams > Page 6728 Cruise Control Switch: Service and Repair 1. Remove steering wheel pad attaching screws from behind steering wheel. 2. While pulling pad away from steering wheel, disconnect horn and speed control wire connectors and remove pad. 3. Remove retaining nuts securing the speed control switches and trim plate retainer to the steering wheel pad. 4. Disconnect wiring connector on rear of steering wheel pad assembly, then remove switch and trim retainer assembly. 5. Remove speed control switches by snapping out of plastic retainer. 6. To remove the ground brush, remove steering wheel for access. 7. Snap the ground brush assembly out of the turn signal switch. 8. Reverse procedure to install. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Vehicle Speed Sensor/Transducer Cruise Control > Component Information > Locations Vehicle Speed Sensor/Transducer - Cruise Control: Locations LH Side Of Engine Compartment Below LH Side Of Master Cylinder Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Vehicle Speed Sensor/Transducer Cruise Control > Component Information > Locations > Page 6732 Vehicle Speed Sensor/Transducer - Cruise Control: Testing and Inspection 1980-87 Models Exc. 1983-87 Ranger, 1984-87 Bronco II & 1986-87 Aerostar 1. Disconnect 6 way connector from amplifier assembly, then connect an ohmmeter between dark green wire w/white stripe and black wire on 1980 E-100-350, 1981-83 F-100-350 models and Bronco, and 1984-87 F-150-350 and Bronco, or green and black wire on 1980 F-100-350 and 1981-83 E-100-350 models and 1984-87 E-150-350 at the speed sensor end. A reading of 40 ohms should be obtained. A reading of 0 ohms indicates a shorted coil and an infinity reading indicates an open coil. 2. Replace sensor if a correct reading has not been obtained. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Cruise Control > Vacuum Vent Valve, Cruise Control > Component Information > Description and Operation Vacuum Vent Valve: Description and Operation Fig. 24 Solenoid vacuum valve assembly. Normally closed type Fig. 25 Solenoid vacuum valve assembly. Normally open & normally closed combination type Fig. 26 Solenoid vacuum valve assembly. One port normally open & two port normally closed combination type There are three types of solenoid vacuum valve assemblies, Figs. 24, 25 and 26. The normally closed solenoid vacuum valve assembly incorporates Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Cruise Control > Vacuum Vent Valve, Cruise Control > Component Information > Description and Operation > Page 6736 two vacuum ports and an atmospheric vent. When the solenoid is de-energized, the vacuum valve assembly outlet port is open to the atmospheric vent and closed to the inlet port. When the solenoid is energized, outlet port is open to the inlet port and closed to the atmospheric vent. Some normally closed solenoid vacuum valves also incorporate a control bleed to prevent contamination from the solenoid vacuum valve from entering the intake manifold. This solenoid valve assembly can be used in the exhaust heat control valve , throttle kicker, air dump or air diverter valve systems. The normally open and normally closed solenoid vacuum valve assembly, incorporates two solenoid valves which operate independently of each other, but are mounted to a single mounting bracket. Each solenoid valve controls a different device. This valve assembly is used to control the Thermactor air bypass and Thermactor diverter. The one port normally open and two port normally closed solenoid vacuum valve assembly also consist of two solenoid valve assemblies mounted to a single mounting bracket. This valve assembly is used to control the A/C throttle kicker and choke pulldown. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Cruise Control > Vacuum Vent Valve, Cruise Control > Component Information > Description and Operation > Page 6737 Vacuum Vent Valve: Testing and Inspection 1. Disconnect vacuum hose from the servo that leads to the dump valve. 2. Connect a hand vacuum pump to the hose, and draw vacuum. If vacuum cannot be obtained, the hose or dump valve is leaking, and should be replaced. 3. Step on brake pedal. The vacuum should be released. If not, adjust or replace the dump valve. 2.5 inches of Hg is minimum vacuum for normal servo operation. The vacuum source is a hose attached to a 5/16 inch engine vacuum fitting port on all except 6.9 diesel. On the 6.9 diesel, the vacuum source is the vacuum reservoir ``Vac'' port. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Cruise Control > Vacuum Vent Valve, Cruise Control > Component Information > Description and Operation > Page 6738 Vacuum Vent Valve: Service and Repair 1. Remove vacuum hose from valve and remove bracket mounting screw. 2. Remove valve and bracket assembly. 3. Remove valve from the bracket. 4. Reverse procedure to install. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Cruise Control > Vehicle Speed Sensor/Transducer - Cruise Control > Component Information > Locations Vehicle Speed Sensor/Transducer - Cruise Control: Locations LH Side Of Engine Compartment Below LH Side Of Master Cylinder Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Cruise Control > Vehicle Speed Sensor/Transducer - Cruise Control > Component Information > Locations > Page 6742 Vehicle Speed Sensor/Transducer - Cruise Control: Testing and Inspection 1980-87 Models Exc. 1983-87 Ranger, 1984-87 Bronco II & 1986-87 Aerostar 1. Disconnect 6 way connector from amplifier assembly, then connect an ohmmeter between dark green wire w/white stripe and black wire on 1980 E-100-350, 1981-83 F-100-350 models and Bronco, and 1984-87 F-150-350 and Bronco, or green and black wire on 1980 F-100-350 and 1981-83 E-100-350 models and 1984-87 E-150-350 at the speed sensor end. A reading of 40 ohms should be obtained. A reading of 0 ohms indicates a shorted coil and an infinity reading indicates an open coil. 2. Replace sensor if a correct reading has not been obtained. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Ammeter Gauge > Component Information > Testing and Inspection Ammeter Gauge: Testing and Inspection The ammeter is an instrument used to indicate current flow into and out of the battery. When electrical accessories in the vehicle draw more current than the alternator can supply, current flows from the battery and the ammeter indicates a discharge ( - ) condition. When electrical loads of the vehicle are less than alternator output, current is available to charge the battery, and the ammeter indicates a charge (+) condition. If battery is fully charged, the voltage regulator reduces alternator output to meet only immediate vehicle electrical loads. When this happens, ammeter reads zero. Fig. 1 Conventional type ammeter CONVENTIONAL AMMETER A conventional ammeter must be connected between the battery and alternator in order to indicate current flow. This type ammeter, Fig. 1, consists of a frame to which a permanent magnet is attached. The frame also supports an armature and pointer assembly. Current in this system flows from the alternator through the ammeter, then to the battery or from the battery through the ammeter into the vehicle electrical system, depending on vehicle operating conditions. When no current flows through the ammeter, the magnet holds the pointer armature so that the pointer stands at the center of the dial. When current passes in either direction through the ammeter, the resulting magnetic field attracts the armature away from the effect of the permanent magnet, thus giving a reading proportional to the strength of the current flowing. Troubleshooting When the ammeter apparently fails to register correctly, there may be trouble in the wiring which connects the ammeter to the alternator and battery or in the alternator or battery itself. To check the connections, first tighten the two terminal posts on the back of the ammeter. Then, following each wire from the ammeter, tighten all connections on the ignition switch, battery and alternator. Chafed, burned or broken insulation can be found by following each ammeter wire from end to end. All wires with chafed, burned or broken insulation should be repaired or replaced. After this is done, and all connections are tightened, connect the battery cable and turn on the ignition switch. The needle should point slightly to the discharge ( - ) side. Start the engine and run slightly above idling speed. The needle should move slowly to the charge side (+). If the pointer does not move as indicated, the ammeter is out of order and should be replaced. SHUNT TYPE AMMETER The shunt type ammeter is actually a specifically calibrated voltmeter. It is connected to read voltage drop across a resistance wire (shunt) between the battery and alternator. The shunt is located either in the vehicle wiring or within the ammeter itself. When voltage is higher at the alternator end of the shunt, the meter indicates a charge (+) condition. When voltage is higher at the battery end of the shunt, the meter indicates a discharge ( - ) condition. When voltage is equal at both ends of the shunt, the meter reads zero. Troubleshooting Ammeter accuracy can be determined by comparing reading with an ammeter of known accuracy. 1. With engine stopped and ignition switch in RUN position, switch on headlamps and heater fan. Meter should indicate a discharge ( - ) condition. 2. If ammeter pointer does not move, check ammeter terminals for proper connection and check for open circuit in wiring harness. If connections and wiring harness are satisfactory, ammeter is defective. 3. If ammeter indicates a charge (+) condition, wiring harness connections are reversed at ammeter. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Locations Audible Warning Device: Locations Back View Of I/P Behind RH Side Of I/P Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions Audible Warning Device: Diagram Information and Instructions Symbol Identification Wire Color Code Identification Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 6752 NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 6753 Audible Warning Device: Electrical Diagrams Fig. 51 Warning Indicator Wiring Circuit. Models W/Gasoline Engine Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 6754 Fig. 51 Warning Indicator Wiring Circuit. Models W/Gasoline Engine Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions Brake Warning Indicator: Diagram Information and Instructions Symbol Identification Wire Color Code Identification Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 6759 NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 6760 Fig. 51 Warning Indicator Wiring Circuit. Models W/Gasoline Engine Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions Cigarette Lighter: Diagram Information and Instructions Symbol Identification Wire Color Code Identification Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 6765 NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 6766 Fig. 13 Cigar Lighter & Horn Wiring Circuit Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Diagrams > Diagram Information and Instructions Clock: Diagram Information and Instructions Symbol Identification Wire Color Code Identification Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Diagrams > Diagram Information and Instructions > Page 6771 NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Diagrams > Diagram Information and Instructions > Page 6772 Fig. 14 Digital Clock Wiring Circuit Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Diagrams > Page 6773 Clock: Testing and Inspection Regulation of electric clocks is accomplished automatically by resetting the time. If the clock is running fast, the action of turning the hands back to correct the time will automatically cause the clock to run slightly slower. If the clock is running slow, the action of turning the hands forward to correct the time will automatically cause the clock to run slightly faster (10 to 15 seconds daily). A lockout feature prevents the clock regulator mechanism from being reset more than once per wind cycle, regardless of the number of times the time is reset. After the clock rewinds, if the time is then reset, automatic regulation will take place. If a clock varies over 10 minutes per day, it will never adjust properly and must be repaired or replaced. WINDING CLOCK WHEN CONNECTING BATTERY OR CLOCK WIRING The clock requires special attention when reconnecting a battery that has been disconnected for any reason, a clock that has been disconnected, or when replacing a blown clock fuse. It is very important that the initial wind be fully made. The procedure is as follows: 1. Make sure that all other instruments and lights are turned off. 2. Connect positive cable to battery. 3. Before connecting the negative cable, press the terminal to its post on the battery. Immediately afterward, strike the terminal against the battery post to see if there is a spark. If there is a spark, allow the clock to run down until it stops ticking, and repeat as above until there is no spark. Then immediately make the permanent connection before the clock can again run down. The clock will run down in approximately two minutes. 4. Reset clock after all connections have been made. The foregoing procedure should also be followed when reconnecting the clock after it has been disconnected, or if it has stopped because of a blown fuse. Be sure to disconnect battery before installing a new fuse. TROUBLESHOOTING If clock does not run, check for blown ``clock'' fuse. If fuse is blown, check for short in wiring. If fuse is not blown, check for open circuit. With an electric clock, the most frequent cause of clock fuse blowing is voltage at the clock which will prevent a complete wind and allow clock contacts to remain closed. This may be caused by any of the following: discharged battery, corrosion on contact surface of battery terminals, loose connections at battery terminals, at junction block, at fuse clips, or at terminal connection of clock. Therefore, if in reconnecting battery or clock it is noted that the clock is not ticking, always check for blown fuse, or examine the circuits at the points indicated above to determine and correct the cause. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Coolant Level Indicator Lamp > Component Information > Description and Operation Coolant Level Indicator Lamp: Description and Operation This lamp will be illuminated when engine coolant level in the radiator drops below a pre-determined level. To turn lamp off, check cooling system, then add coolant to bring system to proper level. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Component Information > Service and Repair Dashboard / Instrument Panel: Service and Repair Fig. 3 Exploded View Of Instrument Panel, 1986-87 Bronco & F-series. 1. Disconnect negative battery cable. 2. Remove screws from the lefthand and righthand defroster openings. A magnetic screwdriver should be used to avoid dropping the screws through the defroster openings. 3. Remove top instrument cluster finish panel to the instrument panel pad attaching screws. 4. Remove screws from center finish panel to instrument panel pad. 5. Remove instrument panel pad screws from above the glove compartment opening. 6. Lift rear edge of the instrument panel pad, then pull rearward to remove. 7. Reverse procedure to install. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > EGR Maintenance Light > Component Information > Locations EGR Maintenance Light: Locations Back View Of I/P On I/P, To Left Of Steering Column Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Emissions Maintenance Light > Component Information > Technical Service Bulletins > Emission Maintenance Warning Module - Service Emissions Maintenance Light: Technical Service Bulletins Emission Maintenance Warning Module - Service Article No. 89-22-8 ^ EMISSION MAINTENANCE WARNING MODULE SERVICE INFORMATION ^ LAMP - "EMISSIONS/CHECK ENGINE" - EMISSION MAINTENANCE WARNING MODULE SERVICE INFORMATION LIGHT TRUCK: 1985-89 BRONCO 1985-87 BRONCO II 1985-89 ECONOLINE, F-150, F-250, F-350 1985-88 RANGER 1986-87 AEROSTAR MEDIUM/HEAVY TRUCK: 1988-90 F & B SERIES ISSUE: The Emission Maintenance Warning "EMW" module operates a light that is located on the instrument panel. For 1985-87 model year vehicles, the light will display the word "EMISSIONS". For 1988-89 model year vehicles, the light will display the words "CHECK ENGINE". When the light is lit, it is indicating that the 60,000 mile emission maintenance should be performed. After the maintenance is performed the EMW module must be reset to zero time. Another type of module is the "IMS" module. This module is not part of the light circuit and does not require maintenance. At a predetermined time, the IMS module directs the EEC IV processor to make a strategy change. A third type of module is the "COMBO" module. This module combines the functions of the IMS and the EMW modules. ACTION: Refer to the following module application charts for the specific vehicle application and location of the different types of modules. NOTE: FOR APPLICATIONS NOT LOSTED IN THE FOLLOWING MODULE APPLICATION CHARTS, THE "CHECK ENGINE" LIGHT IS CONTROLLED BY THE EEC IV PROCESSOR. THESE VEHICLES DO NOT USE THE "EMW" MODULE. 1985 & 1986 MODULE APPLICATION CHART 1987 MODULE APPLICATION CHART Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Emissions Maintenance Light > Component Information > Technical Service Bulletins > Emission Maintenance Warning Module - Service > Page 6787 1988 MODULE APPLICATION CHART 1989 MODULE APPLICATION CHART 1990 MODULE APPLICATION CHART PART NUMBER PART NAME CLASS E5TZ-12B514-C EMW Module - 1000 Hr BM E5TZ-12B514-A EMW Module - 2000 Hr AM E7TZ-12B514-A COMBO Module BM OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 2300, 2500 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Four Wheel Drive Indicator Lamp > Component Information > Locations Four Wheel Drive Indicator Lamp: Locations LH Quarter Panel Area (F150-350) On Transfer Case Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Four Wheel Drive Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions Four Wheel Drive Indicator Lamp: Diagram Information and Instructions Symbol Identification Wire Color Code Identification Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Four Wheel Drive Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6793 NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Four Wheel Drive Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6794 Fig. 25 Four Wheel Drive Indicator Lamp Wiring Circuit Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Distance/Mileage Module > Component Information > Locations Right Hand Side of Instrument Panel Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Technical Service Bulletins > Fuel Pump/Sender - Erratic Operation Prevention Fuel Gauge: Technical Service Bulletins Fuel Pump/Sender - Erratic Operation Prevention Article No. 86-16-3 FUEL SYSTEM - FUEL PUMP/SENDER-APPLICATION OF GREASE TO ELECTRICAL TERMINALS FORD 1985-86 ESCORT, EXP, TEMPO, MUSTANG, LTD, THUNDERBIRD LINCOLN-MERCURY 1985-86 LYNX, TOPAZ, CAPRI, MARQUIS, COUGAR, MARK VII, CONTINENTAL LIGHT TRUCK 1985-86 RANGER, BRONCO II, AEROSTAR, BRONCO, E SERIES, F SERIES To prevent erratic operation of the fuel gauge or the in-tank fuel pump, a generous application of electrical grease should be applied to the terminals of the fuel pump/sender when service is required. The electrical grease will prevent corrosion and reduce the chance of a repeat repair. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions Fuel Gauge: Diagram Information and Instructions Symbol Identification Wire Color Code Identification Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 6804 NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 6805 Fuel Gauge: Electrical Diagrams Fig. 27 Fuel Tank Selector & Gauges Wiring Circuit. F150-350 W/V8-351 (5.8L) & V8-460 (7.5L) Engines & Dual Tanks (Less Electric Fuel Pumps) Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 6806 Fig. 26 Fuel Tank Selector & Gauges Wiring Circuit. Models W/6-300 (4.9L) & V8-351 (5.8L) Engines With 8,500 GVW Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 6807 Fig. 15 Electric Fuel Pump Control Wiring Circuit. All V8-302 (5.0L) EFI Engines W/Single Fuel Tank Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Page 6808 Fuel Gauge: Description and Operation DESCRIPTION AND OPERATION FUEL LEVEL INDICATING SYSTEM The fuel indicating system is a bimetal-resistance type system. It consists of an instrument voltage regulator, fuel indicator (gauge) mounted in the instrument cluster and a sender located in the fuel tank, INSTRUMENT VOLTAGE REGULATOR The instrument voltage regulator (IVR) used with the fuel indicator (gauge) controls and maintains an average pulsating voltage of 5.0 volts at the gauge terminals. FUEL INDICATOR (GAUGE) The fuel indicator gauge pointer is attached to a wire wound bimetal strip which when heated by the flow of electrical current controlled by the sender unit, produoes the appropriate indication. Fuel Indicating System Using A Bimetal Gauge - Typical FUEL SENDER The fuel sender consists of a variable screened resistor made up of a ceramic substrate. It is controlled by the action of an attached float in the fuel tank. When the fuel level is low, resistance in the sender is high and allows only a low current to flow through the indicator (gauge) windings, causing the pointer to move a short distance. When the fuel level is high, the resistance in the sender is low and allows a higher current flow and a greater heating effect causing the pointer to move a greater distance. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Page 6809 Fuel Gauge: Testing and Inspection DIAGNOSIS AND TESTING WARNING: DO NOT REMOVE THE NIPPLE ON THE END OF THE FUEL RETURN LINE. IT IS THERE TO PREVENT FUEL FROM DRAINING OUT OF THE TANK IN THE EVENT OF A ROLLOVER. NOTE: On vehicles equipped with diesel engines and dual fuel tanks, refer to the diagnosis guide in this Section before proceeding with the calibration testing. CAUTION: DO NOT INTERCHANGE SENDING UNITS BETWEEN GASOLINE-AND DIESEL-POWERED VEHICLES. DOING SO MAY CAUSE SEVERE ENGINE AND FUEL SYSTEM DAMAGE. CALIBRATION TEST (USING ROTUNDA TESTER MODEL 021-00034) Fuel Indicating System Test With Rotunda Tester Model 21-0015 Or Equivalent The Rotunda Instrument Gauge System Tester Model 021-00034 or equivalent is used to diagnose problems in all fuel indicating systems using the bimetal fuel indicator gauge and instrument voltage regulator (IVR). Prior to performing fuel system test the following tester checks should be made. 1. Set tester switch at IVR CHECK position. 2. Attach tester ground wire to the negative (-) terminal of 12-volt battery and touch one of the tester terminals marked with an arrow to the positive (+) battery terminal. 3. If the IVR check lamp does not come on, return tester for service or replacement. TEST SET-UP Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Page 6810 CAUTION: DURING IN-VEHICLE TESTS, Do NOT LET TESTER TERMINAL STUDS DESIGNATED BY ARROWS COME IN CONTACT WITH VEHICLE GROUND. THE FUEL GAUGE WILL BE SHORTED TO GROUND, PREVENTING AN ACCURATE TEST AND POSSIBLY DAMAGING THE IVR OR GAUGE. 1. Disconnect connector from fuel sender and hook onto the matching terminals on the tester (Fig. 4). 2. Turn vehicle ignition switch to ACC position. FUNCTIONAL TEST NOTE: The IVR also supplies a common regulated voltage for the temperature gauge indicating system and oil gauge indicating system (when applicable); therefore, the IVR can only be damaged if the other gauges exhibit similar problems (fluctuating movement or high or low indications at the upper calibration band). The IVR has little effect on the lower calibration band of the indicator. 1. Set test switch to IVR check position. 2. If IVR check lamp flashes on and off, the IVR and wiring are functional. Proceed to calibration check. 3. If IVR check lamp is on steady, check IVR ground screw. If ground screw is secure, replace IVR 4. If IVR check lamp does not come on, check for open circuit in gauge and/or circuit wiring. CALIBRATION CHECK With the tester switch in either the HIGH or LOW position, the center line of the gauge pointer should be within the "F" or "E" white band of the graphics for the fuel test function as shown on the tester. If the center line of the pointer registers in the white bands, the fuel indicating system is operating properly and replacement of the fuel sender is necessary. If the pointer center line falls outside the "E" white band, replace the fuel gauge. If the pointer center line falls outside the "F" white band, replace the IVR and retest. If still outside the upper white band, replace the fuel gauge reinstall the original IVR and retest for calibration. CALIBRATION TEST (WITHOUT TESTER) If only the fuel gauge is inoperative or appears to be out of calibration, a calibration test can be conducted on the vehicle fuel gauge system. The calibration test checks the fuel gauge and IVR simultaneously. The required test equipment consists of a 10 ohm resistor and a 73 ohm resistor. Disconnect the wiring connector at the sender unit. Connect one of the resistors between the lead wire terminal and ground, and turn the ignition switch to the ON or ACC position With the 10 ohm resistor, the gauge should indicate a full-scale reading. With the 73 ohm resistor, the gauge should read at the E graduation mark. Without any resistor (open circuit) the gauge reading should be the same as with the ignition switch in the OFF position. If reading is OK, replace wire connection to sender. If the gauge pointer does not move and stays below the E mark, check for an open circuit in the wiring assembly, the gauge windings, or the instrument cluster printed circuit. If the gauge pointer moves without any resistor connected, check for a short circuit in the lead to the sender unit. If the gauge reads out of calibration, replace IVR and retest. If still out of calibration, replace the gauge. GAUGE BENCH TEST FOR OPEN WINDINGS To test the gauge for open windings, remove the gauge from the vehicle. Connect the gauge to an ohmmeter and read the resistance. An upward movement of the needle from 10 to 14 ohms is normal, because the current increases the temperature of the gauge coil (windings). If the ohmmeter reads below 10 ohms or above 14 ohms, replace the gauge. FUEL TANK DAMAGE If fuel indicating system components are functioning properly and inaccurate indications continue, check the fuel tank for damage which may have changed the fuel sender mounting angle and/or damaged the fuel sender. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest: > 87717 > Apr > 87 > Fuel Gauge - Always Reads Full Fuel Gauge Sender: Customer Interest Fuel Gauge - Always Reads Full GAUGE - FUEL - ALWAYS READS "FULL" - Article No. 7.5L - MIDSHIP FUEL TANK 87-7-17 LIGHTTRUCK: 1985-86 F-250/350 Figure 15 - Article 87-7-17 ISSUE: A fuel gauge that always reads "full" may be caused by the float on the electric fuel pump sender catching on the internal fuel fill pipe inside the midship fuel tank. See Figure 15. ACTION: To correct this, install a new design fuel pump sender assembly, E5TZ- 9H307-L, with revised float travel that will not contact the internal fill pipe. PART NUMBER PART NAME CLASS E5TZ-9H307-L Sender and Fuel Pump A Assembly OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual OPERATION: SP870717A TIME: 0.9 Hr. DLR. CODING: Basic Part No. 9H307 - Code: 09 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 89146 > Jul > 89 > Fuel Tank Sending Unit - Connector Replacement Fuel Gauge Sender: All Technical Service Bulletins Fuel Tank Sending Unit - Connector Replacement FUEL SYSTEM-FUEL TANK SENDING UNIT-WIRE HARNESS CONNECTOR REPLACEMENT WIRING-FUEL TANK SENDING UNIT-CONNECTOR REPLACEMENT Article No. 89-14-6 FORD: 1985-89 CROWN VICTORIA, ESCORT 1985-88 EXP 1985-89 MUSTANG, TEMPO, THUNDERBIRD 1986-89 TAURUS LINCOLN-MERCURY: 1985-89 CONTINENTAL, COUGAR, GRAND MARQUIS 1985-87 LYNX 1985-89 MARK VII, TOPAZ, TOWN CAR 1986-89 SABLE LIGHT TRUCK: 1985-89 BRONCO II, ECONOLINE, F-150, F-250, F-350, RANGER Figure 1 ISSUE: Damaged fuel tank sending unit connectors can be serviced by splicing in a new wire harness connector. The new connector can be obtained by ordering the fuel tank sending unit wire harness and cutting off the connector. ACTION: Splice the new fuel tank sending unit connector to the existing wire harness. Refer to the following procedure for service details. 1. Disconnect the battery ground. 2. Cut the connector from the new harness. 3. Leave 6-8 inches of wiring lead on the connector. 4. Remove the old connector from the fuel tank sending unit. 5. Cut the connector off the vehicle's wire harness about 6-8 inches from the old connector. 6. Match the wire colors. 7. Install the new connector. Use a "Duraseal" butt splice connector, Figure 1. 8. Using a heat gun, seal the splice. CAUTION: DO NOT USE AN OPEN FLAME. 9. Connect the battery ground. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 89146 > Jul > 89 > Fuel Tank Sending Unit - Connector Replacement > Page 6824 10. Check the operation of the fuel gauge. PART NUMBER PART NAME CLASS E9FZ-9A400-A Wire Harness - Fuel Pump C OTHER APPLICABLE ARTICLES: 86-3-11 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 2300, 2310, 2400, 2770, 4500 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 87717 > Apr > 87 > Fuel Gauge - Always Reads Full Fuel Gauge Sender: All Technical Service Bulletins Fuel Gauge - Always Reads Full GAUGE - FUEL - ALWAYS READS "FULL" - Article No. 7.5L - MIDSHIP FUEL TANK 87-7-17 LIGHTTRUCK: 1985-86 F-250/350 Figure 15 - Article 87-7-17 ISSUE: A fuel gauge that always reads "full" may be caused by the float on the electric fuel pump sender catching on the internal fuel fill pipe inside the midship fuel tank. See Figure 15. ACTION: To correct this, install a new design fuel pump sender assembly, E5TZ- 9H307-L, with revised float travel that will not contact the internal fill pipe. PART NUMBER PART NAME CLASS E5TZ-9H307-L Sender and Fuel Pump A Assembly OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual OPERATION: SP870717A TIME: 0.9 Hr. DLR. CODING: Basic Part No. 9H307 - Code: 09 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 86163 > Aug > 86 > Fuel Pump/Sender - Erratic Operation Prevention Fuel Gauge Sender: All Technical Service Bulletins Fuel Pump/Sender - Erratic Operation Prevention Article No. 86-16-3 FUEL SYSTEM - FUEL PUMP/SENDER-APPLICATION OF GREASE TO ELECTRICAL TERMINALS FORD 1985-86 ESCORT, EXP, TEMPO, MUSTANG, LTD, THUNDERBIRD LINCOLN-MERCURY 1985-86 LYNX, TOPAZ, CAPRI, MARQUIS, COUGAR, MARK VII, CONTINENTAL LIGHT TRUCK 1985-86 RANGER, BRONCO II, AEROSTAR, BRONCO, E SERIES, F SERIES To prevent erratic operation of the fuel gauge or the in-tank fuel pump, a generous application of electrical grease should be applied to the terminals of the fuel pump/sender when service is required. The electrical grease will prevent corrosion and reduce the chance of a repeat repair. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge Sender: > 89146 > Jul > 89 > Fuel Tank Sending Unit - Connector Replacement Fuel Gauge Sender: All Technical Service Bulletins Fuel Tank Sending Unit - Connector Replacement FUEL SYSTEM-FUEL TANK SENDING UNIT-WIRE HARNESS CONNECTOR REPLACEMENT WIRING-FUEL TANK SENDING UNIT-CONNECTOR REPLACEMENT Article No. 89-14-6 FORD: 1985-89 CROWN VICTORIA, ESCORT 1985-88 EXP 1985-89 MUSTANG, TEMPO, THUNDERBIRD 1986-89 TAURUS LINCOLN-MERCURY: 1985-89 CONTINENTAL, COUGAR, GRAND MARQUIS 1985-87 LYNX 1985-89 MARK VII, TOPAZ, TOWN CAR 1986-89 SABLE LIGHT TRUCK: 1985-89 BRONCO II, ECONOLINE, F-150, F-250, F-350, RANGER Figure 1 ISSUE: Damaged fuel tank sending unit connectors can be serviced by splicing in a new wire harness connector. The new connector can be obtained by ordering the fuel tank sending unit wire harness and cutting off the connector. ACTION: Splice the new fuel tank sending unit connector to the existing wire harness. Refer to the following procedure for service details. 1. Disconnect the battery ground. 2. Cut the connector from the new harness. 3. Leave 6-8 inches of wiring lead on the connector. 4. Remove the old connector from the fuel tank sending unit. 5. Cut the connector off the vehicle's wire harness about 6-8 inches from the old connector. 6. Match the wire colors. 7. Install the new connector. Use a "Duraseal" butt splice connector, Figure 1. 8. Using a heat gun, seal the splice. CAUTION: DO NOT USE AN OPEN FLAME. 9. Connect the battery ground. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge Sender: > 89146 > Jul > 89 > Fuel Tank Sending Unit - Connector Replacement > Page 6838 10. Check the operation of the fuel gauge. PART NUMBER PART NAME CLASS E9FZ-9A400-A Wire Harness - Fuel Pump C OTHER APPLICABLE ARTICLES: 86-3-11 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 2300, 2310, 2400, 2770, 4500 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge Sender: > 86163 > Aug > 86 > Fuel Pump/Sender - Erratic Operation Prevention Fuel Gauge Sender: All Technical Service Bulletins Fuel Pump/Sender - Erratic Operation Prevention Article No. 86-16-3 FUEL SYSTEM - FUEL PUMP/SENDER-APPLICATION OF GREASE TO ELECTRICAL TERMINALS FORD 1985-86 ESCORT, EXP, TEMPO, MUSTANG, LTD, THUNDERBIRD LINCOLN-MERCURY 1985-86 LYNX, TOPAZ, CAPRI, MARQUIS, COUGAR, MARK VII, CONTINENTAL LIGHT TRUCK 1985-86 RANGER, BRONCO II, AEROSTAR, BRONCO, E SERIES, F SERIES To prevent erratic operation of the fuel gauge or the in-tank fuel pump, a generous application of electrical grease should be applied to the terminals of the fuel pump/sender when service is required. The electrical grease will prevent corrosion and reduce the chance of a repeat repair. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Page 6843 Fuel Gauge Sender: Locations Top Of Fuel Tank Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Page 6844 Fuel Gauge Sender: Description and Operation DESCRIPTION AND OPERATION FUEL LEVEL INDICATING SYSTEM The fuel indicating system is a bimetal-resistance type system. It consists of an instrument voltage regulator, fuel indicator (gauge) mounted in the instrument cluster and a sender located in the fuel tank, INSTRUMENT VOLTAGE REGULATOR The instrument voltage regulator (IVR) used with the fuel indicator (gauge) controls and maintains an average pulsating voltage of 5.0 volts at the gauge terminals. FUEL INDICATOR (GAUGE) The fuel indicator gauge pointer is attached to a wire wound bimetal strip which when heated by the flow of electrical current controlled by the sender unit, produoes the appropriate indication. Fuel Indicating System Using A Bimetal Gauge - Typical FUEL SENDER The fuel sender consists of a variable screened resistor made up of a ceramic substrate. It is controlled by the action of an attached float in the fuel tank. When the fuel level is low, resistance in the sender is high and allows only a low current to flow through the indicator (gauge) windings, causing the pointer to move a short distance. When the fuel level is high, the resistance in the sender is low and allows a higher current flow and a greater heating effect causing the pointer to move a greater distance. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Page 6845 Fuel Gauge Sender: Testing and Inspection DIAGNOSIS AND TESTING WARNING: DO NOT REMOVE THE NIPPLE ON THE END OF THE FUEL RETURN LINE. IT IS THERE TO PREVENT FUEL FROM DRAINING OUT OF THE TANK IN THE EVENT OF A ROLLOVER. NOTE: On vehicles equipped with diesel engines and dual fuel tanks, refer to the diagnosis guide in this Section before proceeding with the calibration testing. CAUTION: DO NOT INTERCHANGE SENDING UNITS BETWEEN GASOLINE-AND DIESEL-POWERED VEHICLES. DOING SO MAY CAUSE SEVERE ENGINE AND FUEL SYSTEM DAMAGE. CALIBRATION TEST (USING ROTUNDA TESTER MODEL 021-00034) Fuel Indicating System Test With Rotunda Tester Model 21-0015 Or Equivalent The Rotunda Instrument Gauge System Tester Model 021-00034 or equivalent is used to diagnose problems in all fuel indicating systems using the bimetal fuel indicator gauge and instrument voltage regulator (IVR). Prior to performing fuel system test the following tester checks should be made. 1. Set tester switch at IVR CHECK position. 2. Attach tester ground wire to the negative (-) terminal of 12-volt battery and touch one of the tester terminals marked with an arrow to the positive (+) battery terminal. 3. If the IVR check lamp does not come on, return tester for service or replacement. TEST SET-UP Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Page 6846 CAUTION: DURING IN-VEHICLE TESTS, Do NOT LET TESTER TERMINAL STUDS DESIGNATED BY ARROWS COME IN CONTACT WITH VEHICLE GROUND. THE FUEL GAUGE WILL BE SHORTED TO GROUND, PREVENTING AN ACCURATE TEST AND POSSIBLY DAMAGING THE IVR OR GAUGE. 1. Disconnect connector from fuel sender and hook onto the matching terminals on the tester (Fig. 4). 2. Turn vehicle ignition switch to ACC position. FUNCTIONAL TEST NOTE: The IVR also supplies a common regulated voltage for the temperature gauge indicating system and oil gauge indicating system (when applicable); therefore, the IVR can only be damaged if the other gauges exhibit similar problems (fluctuating movement or high or low indications at the upper calibration band). The IVR has little effect on the lower calibration band of the indicator. 1. Set test switch to IVR check position. 2. If IVR check lamp flashes on and off, the IVR and wiring are functional. Proceed to calibration check. 3. If IVR check lamp is on steady, check IVR ground screw. If ground screw is secure, replace IVR 4. If IVR check lamp does not come on, check for open circuit in gauge and/or circuit wiring. CALIBRATION CHECK With the tester switch in either the HIGH or LOW position, the center line of the gauge pointer should be within the "F" or "E" white band of the graphics for the fuel test function as shown on the tester. If the center line of the pointer registers in the white bands, the fuel indicating system is operating properly and replacement of the fuel sender is necessary. If the pointer center line falls outside the "E" white band, replace the fuel gauge. If the pointer center line falls outside the "F" white band, replace the IVR and retest. If still outside the upper white band, replace the fuel gauge reinstall the original IVR and retest for calibration. CALIBRATION TEST (WITHOUT TESTER) If only the fuel gauge is inoperative or appears to be out of calibration, a calibration test can be conducted on the vehicle fuel gauge system. The calibration test checks the fuel gauge and IVR simultaneously. The required test equipment consists of a 10 ohm resistor and a 73 ohm resistor. Disconnect the wiring connector at the sender unit. Connect one of the resistors between the lead wire terminal and ground, and turn the ignition switch to the ON or ACC position With the 10 ohm resistor, the gauge should indicate a full-scale reading. With the 73 ohm resistor, the gauge should read at the E graduation mark. Without any resistor (open circuit) the gauge reading should be the same as with the ignition switch in the OFF position. If reading is OK, replace wire connection to sender. If the gauge pointer does not move and stays below the E mark, check for an open circuit in the wiring assembly, the gauge windings, or the instrument cluster printed circuit. If the gauge pointer moves without any resistor connected, check for a short circuit in the lead to the sender unit. If the gauge reads out of calibration, replace IVR and retest. If still out of calibration, replace the gauge. GAUGE BENCH TEST FOR OPEN WINDINGS To test the gauge for open windings, remove the gauge from the vehicle. Connect the gauge to an ohmmeter and read the resistance. An upward movement of the needle from 10 to 14 ohms is normal, because the current increases the temperature of the gauge coil (windings). If the ohmmeter reads below 10 ohms or above 14 ohms, replace the gauge. FUEL TANK DAMAGE If fuel indicating system components are functioning properly and inaccurate indications continue, check the fuel tank for damage which may have changed the fuel sender mounting angle and/or damaged the fuel sender. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Component Information > Technical Service Bulletins > Customer Interest: > 932410 > Nov > 93 > Instrument Cluster Warning Lights Dimly Lit Instrument Cluster / Carrier: Customer Interest Instrument Cluster Warning Lights - Dimly Lit Article No. 93-24-10 11/24/93 ^ LAMP - MALFUNCTION OF FOUR PIN LOW OIL LEVEL RELAY - VEHICLES BUILT AFTER 8/1/92 OR 1983-1993 VEHICLES THAT HAVE HAD SERVICE REPLACEMENT IGNITION SWITCHES AFTER 8/1/92 ^ LAMPS - INSTRUMENT CLUSTER WARNING LIGHTS DIMLY LIT - VEHICLES BUILT AFTER 8/1/92 OR 1983-1993 VEHICLES THAT HAVE HAD SERVICE REPLACEMENT IGNITION SWITCHES AFTER 8/1/92 FORD: 1983 FAIRMONT 1983-89 CROWN VICTORIA, ESCORT 1983-93 MUSTANG, THUNDERBIRD 1983-94 PROBE 1984-86 LTD 1984-94 TEMPO LINCOLN-MERCURY: 1983 LN7, ZEPHYR 1983-87 CONTINENTAL, LYNX 1983-89 GRAND MARQUIS, TOWN CAR 1983-93 COUGAR 1984-86 CAPRI, MARQUIS 1984-94 TOPAZ LIGHT TRUCK: 1983-91 BRONCO 1983-93 ECONOLINE, F-150-350 SERIES, RANGER 1986-91 AEROSTAR 1991-93 EXPLORER ISSUE: The instrument cluster warning light(s) may be dimly lit or there may be a malfunction of the four pin low oil relay on vehicles so equipped. This could be due to the ignition switch. ACTION: If the vehicle displays the subject symptoms and meets the following conditions, replace the ignition switch. Refer to the appropriate Car or Light Truck Service Manual (Section 13-04 for 1983-1990 Cars, Section 11-04 for 1991-1993 Cars and Section 13-05 for 1983-1990 Light Trucks, Section 11-05 for 1991-1993 Light Trucks) for removal and installation procedures. Refer to the Parts Block in this article for correct parts usage. CONDITIONS ^ The vehicle has 14401 wiring attached to the P2 terminal of the ignition switch. Refer to the wiring schematic and/or Electrical And Vacuum Troubleshooting Manual (EVTM) for the concern vehicle. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Component Information > Technical Service Bulletins > Customer Interest: > 932410 > Nov > 93 > Instrument Cluster Warning Lights Dimly Lit > Page 6855 ^ The vehicle is equipped with one of the ignition switches identified in the Ignition Switch Part Number Chart. NOTE: THE SERVICE PART NUMBERS FOR THE REPLACEMENT IGNITION SWITCHES WILL HAVE THE SAME PART NUMBERS AS THOSE REPLACED. THE NEW SWITCH HAS BEEN IMPROVED TO CORRECT THE SUBJECT ISSUE. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of The Bumper To Bumper For 1992/93 Models, Basic Warranty Coverage For All Other Models Except Lincolns. Major Component Warranty Coverage For Lincolns OPERATION DESCRIPTION TIME 932410A Replace Ignition Switch - 0.5 Hr. All Light and Compact Trucks DEALER CODING BASIC PART NO. CONDITION CODE 11572 X1 OASIS CODES: 201000, 201100, 206000 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 932410 > Nov > 93 > Instrument Cluster Warning Lights - Dimly Lit Instrument Cluster / Carrier: All Technical Service Bulletins Instrument Cluster Warning Lights Dimly Lit Article No. 93-24-10 11/24/93 ^ LAMP - MALFUNCTION OF FOUR PIN LOW OIL LEVEL RELAY - VEHICLES BUILT AFTER 8/1/92 OR 1983-1993 VEHICLES THAT HAVE HAD SERVICE REPLACEMENT IGNITION SWITCHES AFTER 8/1/92 ^ LAMPS - INSTRUMENT CLUSTER WARNING LIGHTS DIMLY LIT - VEHICLES BUILT AFTER 8/1/92 OR 1983-1993 VEHICLES THAT HAVE HAD SERVICE REPLACEMENT IGNITION SWITCHES AFTER 8/1/92 FORD: 1983 FAIRMONT 1983-89 CROWN VICTORIA, ESCORT 1983-93 MUSTANG, THUNDERBIRD 1983-94 PROBE 1984-86 LTD 1984-94 TEMPO LINCOLN-MERCURY: 1983 LN7, ZEPHYR 1983-87 CONTINENTAL, LYNX 1983-89 GRAND MARQUIS, TOWN CAR 1983-93 COUGAR 1984-86 CAPRI, MARQUIS 1984-94 TOPAZ LIGHT TRUCK: 1983-91 BRONCO 1983-93 ECONOLINE, F-150-350 SERIES, RANGER 1986-91 AEROSTAR 1991-93 EXPLORER ISSUE: The instrument cluster warning light(s) may be dimly lit or there may be a malfunction of the four pin low oil relay on vehicles so equipped. This could be due to the ignition switch. ACTION: If the vehicle displays the subject symptoms and meets the following conditions, replace the ignition switch. Refer to the appropriate Car or Light Truck Service Manual (Section 13-04 for 1983-1990 Cars, Section 11-04 for 1991-1993 Cars and Section 13-05 for 1983-1990 Light Trucks, Section 11-05 for 1991-1993 Light Trucks) for removal and installation procedures. Refer to the Parts Block in this article for correct parts usage. CONDITIONS ^ The vehicle has 14401 wiring attached to the P2 terminal of the ignition switch. Refer to the wiring schematic and/or Electrical And Vacuum Troubleshooting Manual (EVTM) for the concern vehicle. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 932410 > Nov > 93 > Instrument Cluster Warning Lights - Dimly Lit > Page 6861 ^ The vehicle is equipped with one of the ignition switches identified in the Ignition Switch Part Number Chart. NOTE: THE SERVICE PART NUMBERS FOR THE REPLACEMENT IGNITION SWITCHES WILL HAVE THE SAME PART NUMBERS AS THOSE REPLACED. THE NEW SWITCH HAS BEEN IMPROVED TO CORRECT THE SUBJECT ISSUE. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of The Bumper To Bumper For 1992/93 Models, Basic Warranty Coverage For All Other Models Except Lincolns. Major Component Warranty Coverage For Lincolns OPERATION DESCRIPTION TIME 932410A Replace Ignition Switch - 0.5 Hr. All Light and Compact Trucks DEALER CODING BASIC PART NO. CONDITION CODE 11572 X1 OASIS CODES: 201000, 201100, 206000 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Component Information > Technical Service Bulletins > All Other Service Bulletins for Instrument Cluster / Carrier: > 871615 > Aug > 87 > M/T - Gear Clash and Hard Shifting Clutch Pedal Assembly: All Technical Service Bulletins M/T - Gear Clash and Hard Shifting ^ CLUTCH (HYDRAULIC) - PEDAL DOES NOT Article No. FULLY RETURN - DIAGNOSTIC TIPS 87-16-15 ^ TRANSMISSION - MANUAL - GEAR CLASH AND HARD SHIFTING ^ SPEED CONTROL - INOPERATIVE - LOW CLUTCH PEDAL ALLOWS SWITCH CIRCUIT TO REMAIN OPEN LIGHT TRUCK: 1984-87 F-150/350, BRONCO ISSUE: A clutch pedal not fully returning to contact the rubber bumper at the "up" stop may result in any of the following conditions. ^ Transmission gear clash or hard shifting or failure to release into or from gear (particularly reverse and 1st gear) because clutch pedal stroke length is decreased, causing low pedal reserve. ^ Clutch pedal may sometimes stick near the TOP of the stroke, requiring driver to "tip" the pedal with his/her foot in order to get pedal to further return. ^ Speed control is inoperative, due to pedal not returning and permitting "shut off" switch circuit to remain in the open position, i.e., clutch disengaged mode. ACTION: To determine if a new cross-shaft lever is required, use the following diagnostic and servicing procedure. 1. Check under the dash area to be certain that the clutch pedal system has no wiring looms which interfere with pedal return, at the interlock switch rod and the end of the master cylinder pushrod. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Component Information > Technical Service Bulletins > All Other Service Bulletins for Instrument Cluster / Carrier: > 871615 > Aug > 87 > M/T - Gear Clash and Hard Shifting > Page 6867 Figure 7 2. Determine if the clutch master cylinder pushrod and lever pin are correctly aligned by disconnecting the pushrod and seeing if it will reassemble to the pin WITHOUT DEPRESSING THE PUSHROD OR DEPRESSING THE CLUTCH PEDAL. (When the pushrod is disconnected from the pin, the clutch master cylinder piston is fully retracted (rearward) and the clutch pedal blade is contacting the rubber bumper stop), see Figure 7. 3. If the two components are not in alignment, perform the following IN THIS EXACT SEQUENCE: a. Loosen the clutch pedal attaching nut (left hand side). Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Component Information > Technical Service Bulletins > All Other Service Bulletins for Instrument Cluster / Carrier: > 871615 > Aug > 87 > M/T - Gear Clash and Hard Shifting > Page 6868 b. Reinstall the clutch master cylinder pushrod to the cross-shaft lever pin. c. Tighten the clutch pedal attaching nut (left hand side). d. Stroke the clutch pedal several times to reset the position of the shaft to the pedal slot, THIS STEP IS REQUIRED! e. Again, remove the clutch master cylinder pushrod from the lever pin and check the alignment. If the two (2) components are still not in alignment, replace the crossshaft lever. NOTE: If the pushrod is aligned with the pin, no further action is required. Cross-Shaft Lever Replacement Removal 1. Disconnect the master cylinder pushrod from the cross-shaft lever pin. 1984-86 Vehicles Remove the clevis pin. Carefully pull the pushrod from the lever. 1987 Vehicles Disconnect the snap-in bushing by wedging a small screwdriver or putty knife between the lever and the bushing. When the bushing tangs are free at the pin groove, carefully pull the pushrod from the lever. 2. Remove the attaching nut. 3. Remove the lever from the cross-shaft, using a pry tool or puller. Installation NOTE: The proper position of clutch master cylinder pushrod relative to the crossshaft lever (7A554) pin is controlled by this installation PROCEDURE. Therefore, ONLY the following steps should be used. 1. Install the new lever (pin) to the clutch master cylinder pushrod bushing. 2. Install the lever onto the cross-shaft. 3. Install the attaching nut, finger tight. 4. Inspect pedal position to make sure it is against the "up" stop. 5. Tighten the attaching nut. This will permit the knurled teeth on the shaft to cut matching teeth in lever, which then results in the correct positioning of the two (2) components. NOTE: The above procedure is the preferred method of "adjusting" master cylinder pushrod length. Frequently, the master cylinder is replaced or adjustable pushrods are installed to obtain the required pushrod to lever positioning. Cross-shaft lever replacement is a more efficient method and eliminates the potential of pushrod mis-adjustment and introducing air or contamination into the hydraulic system. CROSS-SHAFT LEVER APPLICATION Model Year Truck Series Part Number 1984-86 F Series, Bronco E4TZ-7A554-A 1987 F Series, Bronco E7TZ-7A554-A PART NUMBER PART NAME CLASS E4TZ-7A554-A Cross-Shaft Lever B E7TZ-7A554-A Cross-Shaft Lever B OTHER APPLICABLE ARTICLES: 85-1-20, 85-5-24, 85-5-26 WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual OPERATION: SP871615A Align clutch master cylinder pushrod and cross-shaft lever pin Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Component Information > Technical Service Bulletins > All Other Service Bulletins for Instrument Cluster / Carrier: > 871615 > Aug > 87 > M/T - Gear Clash and Hard Shifting > Page 6869 TIME: 0.4 Hr. - 6.9L diesel 0.3 Hr. - All others OPERATION: SP871615B - Replace cross-shaft lever (includes time to perform previous alignment) TIME: 0.6 Hr. - 6.9L diesel 0.5 Hr. - All others DLR. CODING: Basic Part No. 7A554 - Code: 07 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Component Information > Technical Service Bulletins > All Other Service Bulletins for Instrument Cluster / Carrier: > 871615 > Aug > 87 > M/T - Gear Clash and Hard Shifting > Page 6875 Figure 7 2. Determine if the clutch master cylinder pushrod and lever pin are correctly aligned by disconnecting the pushrod and seeing if it will reassemble to the pin WITHOUT DEPRESSING THE PUSHROD OR DEPRESSING THE CLUTCH PEDAL. (When the pushrod is disconnected from the pin, the clutch master cylinder piston is fully retracted (rearward) and the clutch pedal blade is contacting the rubber bumper stop), see Figure 7. 3. If the two components are not in alignment, perform the following IN THIS EXACT SEQUENCE: a. Loosen the clutch pedal attaching nut (left hand side). Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Component Information > Technical Service Bulletins > All Other Service Bulletins for Instrument Cluster / Carrier: > 871615 > Aug > 87 > M/T - Gear Clash and Hard Shifting > Page 6876 b. Reinstall the clutch master cylinder pushrod to the cross-shaft lever pin. c. Tighten the clutch pedal attaching nut (left hand side). d. Stroke the clutch pedal several times to reset the position of the shaft to the pedal slot, THIS STEP IS REQUIRED! e. Again, remove the clutch master cylinder pushrod from the lever pin and check the alignment. If the two (2) components are still not in alignment, replace the crossshaft lever. NOTE: If the pushrod is aligned with the pin, no further action is required. Cross-Shaft Lever Replacement Removal 1. Disconnect the master cylinder pushrod from the cross-shaft lever pin. 1984-86 Vehicles Remove the clevis pin. Carefully pull the pushrod from the lever. 1987 Vehicles Disconnect the snap-in bushing by wedging a small screwdriver or putty knife between the lever and the bushing. When the bushing tangs are free at the pin groove, carefully pull the pushrod from the lever. 2. Remove the attaching nut. 3. Remove the lever from the cross-shaft, using a pry tool or puller. Installation NOTE: The proper position of clutch master cylinder pushrod relative to the crossshaft lever (7A554) pin is controlled by this installation PROCEDURE. Therefore, ONLY the following steps should be used. 1. Install the new lever (pin) to the clutch master cylinder pushrod bushing. 2. Install the lever onto the cross-shaft. 3. Install the attaching nut, finger tight. 4. Inspect pedal position to make sure it is against the "up" stop. 5. Tighten the attaching nut. This will permit the knurled teeth on the shaft to cut matching teeth in lever, which then results in the correct positioning of the two (2) components. NOTE: The above procedure is the preferred method of "adjusting" master cylinder pushrod length. Frequently, the master cylinder is replaced or adjustable pushrods are installed to obtain the required pushrod to lever positioning. Cross-shaft lever replacement is a more efficient method and eliminates the potential of pushrod mis-adjustment and introducing air or contamination into the hydraulic system. CROSS-SHAFT LEVER APPLICATION Model Year Truck Series Part Number 1984-86 F Series, Bronco E4TZ-7A554-A 1987 F Series, Bronco E7TZ-7A554-A PART NUMBER PART NAME CLASS E4TZ-7A554-A Cross-Shaft Lever B E7TZ-7A554-A Cross-Shaft Lever B OTHER APPLICABLE ARTICLES: 85-1-20, 85-5-24, 85-5-26 WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual OPERATION: SP871615A Align clutch master cylinder pushrod and cross-shaft lever pin Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Component Information > Technical Service Bulletins > All Other Service Bulletins for Instrument Cluster / Carrier: > 871615 > Aug > 87 > M/T - Gear Clash and Hard Shifting > Page 6877 TIME: 0.4 Hr. - 6.9L diesel 0.3 Hr. - All others OPERATION: SP871615B - Replace cross-shaft lever (includes time to perform previous alignment) TIME: 0.6 Hr. - 6.9L diesel 0.5 Hr. - All others DLR. CODING: Basic Part No. 7A554 - Code: 07 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Component Information > Technical Service Bulletins > Page 6878 Instrument Cluster / Carrier: Service and Repair Fig. 10 Instrument Cluster F-100---350 & BRONCO 1. Disconnect battery ground cable. 2. Remove wiper/washer knob, and on equipped 1980 models, the fuel gauge switch knob. Use a suitable hook tool to release each knob lock tab. 3. Remove light switch knob, windshield wiper switch knob and fog light switch knob, if equipped. 4. Remove steering column shroud, using care not to damage transmission selector indicator cables on models equipped with automatic transmission. 5. On models equipped with automatic transmission, release shift lever indicator cable retaining clip(s), then remove cable loop from retainer pin. Remove cable bracket attaching screw and slide bracket out of slot in tube. 6. On all models, remove cluster finish panel and the 4 cluster attaching screws, Fig. 10. 7. Pull cluster back from panel and disconnect speedometer cable, printed circuit electrical connector and 4 x 4 indicator light electrical connector, if equipped. 8. Remove cluster from vehicle, Fig. 10. 9. Reverse procedure to install. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Maintenance Required Lamp/Indicator > Component Information > Description and Operation Maintenance Required Lamp/Indicator: Description and Operation NOTE: This lamp is used only on models with Federal emissions systems. The lamp will be illuminated after approximately 60,000 miles of operation. The amber lens is located on the instrument panel and has the word Emissions, Emiss or EGR printed on it. On 1988 Ranger models with 2.0L/4-122 engine, the lamp lens will indicate Check Engine. After performing the required emission control maintenance, the module must be replaced or reset, depending on type of module used. On module equipped with reset feature, reset the module as follows: 1. Place ignition switch in the Off position. 2. On Aerostar models, the module is located under the instrument panel near the bulkhead connector. On Bronco and F-Series, the module is attached to the instrument cluster to the left of the steering column. On Bronco II and Ranger models, the module is located on the righthand side of the instrument panel below the glove compartment. On E Series models, the module is located under the lefthand side of the instrument panel. 3. On all models, insert a suitable phillips head screwdriver through .2 inch diameter hole located on module near the reset sticker and lightly press down and hold. 4. While still lightly pressing down on screwdriver, turn ignition switch to Run position. The emissions maintenance lamp should remain illuminated for as long as the screwdriver is pressing down. Hold screwdriver in position for approximately five seconds. 5. Remove screwdriver, lamp should go out after approximately two to five seconds, indicating the module has been reset. If lamp fails to go out, repeat reset procedure. Place ignition switch in the Off position. 6. Turn ignition switch to Run position and check to ensure emission maintenance lamp is illuminated for two to five seconds. After approximately two to five seconds the lamp should turn off. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Technical Service Bulletins > Speedometer/Odometer - Inaccurate Readings Odometer: Technical Service Bulletins Speedometer/Odometer - Inaccurate Readings SPEEDOMETER - MECHANICAL/ELECTRONIC - INACCURATE SPEED READINGS AND ODOMETER READINGS Article No. 89-2-7 FORD: 1989 AND PRIOR ALL CAR LINES LINCOLN-MERCURY: 1989 AND PRIOR ALL CAR LINES LIGHT TRUCK: 1989 AND PRIOR ALL TRUCK LINES ISSUE: The accuracy of speedometer/odometer readings may be influenced by several vehicle components or systems. The information in this TSB article is intended to assist technicians in speedometer/odometer concern diagnosis. ACTION: Use the following supplemental information below to assist in speedometer/odometer diagnostics. OPERATION A mechanical analog speedometer displays vehicle speed and the odometer displays total distance traveled. The speedometer/odometer assembly is cable driven by either a transmission or a transaxle. All speedometer/odometer assemblies, except for police vehicles are the same with respect to the speed accuracy tolerance used during calibration. The odometer gear ratio is fixed so that all are identical and have no error in the speedometer head. Electronic digital operation is similar. It could use a drive cable or a speed sensor to drive the speedometer/odometer. An electronic signal is sent from a speed sensor to the digital speedometer/ odometer assembly. The speed sensor is driven by a transmission or a transaxle, similar to a cable. Several areas of concern that may affect speedometer/ odometer readings are tires, axle gear ratio and speedometer/odometer drive and driven gears. TIRES Improper tire rolling radius and inflation pressure, temperature and size may contribute to inaccurate system readings. System accuracy testing should be performed after the tires are set at the correct pressure as shown on the safety compliance certification label. The tires should be warmed for a short period. Best results are obtained on smooth, dry pavement while driving at a constant speed within the posted speed limit. AXLE/TRANSAXLE RATIO The gear ratio of the rear axle or the final drive ratio of the transaxle must be known to select or check if the proper speedometer/odometer drive and driven gears are present. Various gear ratios are available, but usually are not a concern when dealing with speedometer/odometer concerns unless the gear ratio has been changed. WARNING: NEVER CORRECT SPEEDOMETER READINGS BY CHANGING GEARS UNLESS THE ODOMETER IS ALSO OFF. DRIVE/DRIVEN GEARS The speedometer/odometer drive gear is located inside the transmission, transaxle or transfer case and is not easily accessed for change. The driven gear rotates the speedometer cable. Rear wheel drive vehicles have several driven gears with various numbers of teeth available to correct input to the speedometer/odometer head. Front wheel drive vehicles generally do not offer different gears for correction. GENERAL DESCRIPTION The maximum allowable odometer system accuracy error is +/- 3.75% of the actual distance traveled. Ford Motor vehicles are well within those limits. The speed indication is biased high, except on police vehicles with certified calibration speedometers/ odometers. As a general rule, the indicated speed is equal to or greater than the actual speed. This is intended to protect the consumer against violating speed laws. Most customer concerns are related to speedometers reading too high at true speeds between 50 MPH and 65 MPH (80 - 105 Km/h). At that speed range, the worst case errors may indicate a speed that is 10% greater than true speed. The speedometer head is an instrument which processes information sent to it by the rotating speedometer cable. If the system components send the Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Technical Service Bulletins > Speedometer/Odometer - Inaccurate Readings > Page 6886 wrong number of revolution per mile to the speedometer head, an inaccurate speed reading and amount of distanced traveled will be displayed. Since there is no error in the fixed gear ratio of the speedometer head odometer, start by checking the accuracy of the odometer even if the customer concern indicates a speed accuracy problem. Odometer accuracy can be checked by using roads established at mile increments or a known local course. If roads with mile markers are used, a five mile stretch is recommended to allow for inaccuracies. If an error is greater than 3.75%, a change to the transmission drive/driven gear selection, tire size, or tire inflation may need attention. The odometer should be checked again to verify any corrective action. If the indicated speed error exceeds 10% between 50 MPH and 60 MPH (80 - 105 Km/h), replace the speedometer/odometer assembly. Vehicles with transfer cases that have fluctuating readings may be due to slippage of drive gears, parts not splined or loose yoke nuts. If the vehicle has speed control, the speed accuracy can be checked using the verified odometer vs. time. The formula is as follows: 3600 divided by TIME (seconds to cover one mile) = TRUE MPH (Km/h) EXAMPLES: 60 MPH (96 Km/h) requires 60 seconds to cover one mile 55 MPH (88 Km/h) requires 65 and 3/4 seconds to cover one mile 50 MPH (80 Km/h) requires 72 seconds to cover one mile ARTICLE SUPERSEDED: 84-14-6, date 7/3/84 WARRANTY STATUS: "INFORMATION ONLY" OASIS CODES: 2300, 2310, 2400, 2500 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Level Warning Indicator > Component Information > Technical Service Bulletins > Customer Interest for Oil Level Warning Indicator: > 932410 > Nov > 93 > Instrument Cluster Warning Lights - Dimly Lit Oil Level Warning Indicator: Customer Interest Instrument Cluster Warning Lights - Dimly Lit Article No. 93-24-10 11/24/93 ^ LAMP - MALFUNCTION OF FOUR PIN LOW OIL LEVEL RELAY - VEHICLES BUILT AFTER 8/1/92 OR 1983-1993 VEHICLES THAT HAVE HAD SERVICE REPLACEMENT IGNITION SWITCHES AFTER 8/1/92 ^ LAMPS - INSTRUMENT CLUSTER WARNING LIGHTS DIMLY LIT - VEHICLES BUILT AFTER 8/1/92 OR 1983-1993 VEHICLES THAT HAVE HAD SERVICE REPLACEMENT IGNITION SWITCHES AFTER 8/1/92 FORD: 1983 FAIRMONT 1983-89 CROWN VICTORIA, ESCORT 1983-93 MUSTANG, THUNDERBIRD 1983-94 PROBE 1984-86 LTD 1984-94 TEMPO LINCOLN-MERCURY: 1983 LN7, ZEPHYR 1983-87 CONTINENTAL, LYNX 1983-89 GRAND MARQUIS, TOWN CAR 1983-93 COUGAR 1984-86 CAPRI, MARQUIS 1984-94 TOPAZ LIGHT TRUCK: 1983-91 BRONCO 1983-93 ECONOLINE, F-150-350 SERIES, RANGER 1986-91 AEROSTAR 1991-93 EXPLORER ISSUE: The instrument cluster warning light(s) may be dimly lit or there may be a malfunction of the four pin low oil relay on vehicles so equipped. This could be due to the ignition switch. ACTION: If the vehicle displays the subject symptoms and meets the following conditions, replace the ignition switch. Refer to the appropriate Car or Light Truck Service Manual (Section 13-04 for 1983-1990 Cars, Section 11-04 for 1991-1993 Cars and Section 13-05 for 1983-1990 Light Trucks, Section 11-05 for 1991-1993 Light Trucks) for removal and installation procedures. Refer to the Parts Block in this article for correct parts usage. CONDITIONS ^ The vehicle has 14401 wiring attached to the P2 terminal of the ignition switch. Refer to the wiring schematic and/or Electrical And Vacuum Troubleshooting Manual (EVTM) for the concern vehicle. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Level Warning Indicator > Component Information > Technical Service Bulletins > Customer Interest for Oil Level Warning Indicator: > 932410 > Nov > 93 > Instrument Cluster Warning Lights - Dimly Lit > Page 6895 ^ The vehicle is equipped with one of the ignition switches identified in the Ignition Switch Part Number Chart. NOTE: THE SERVICE PART NUMBERS FOR THE REPLACEMENT IGNITION SWITCHES WILL HAVE THE SAME PART NUMBERS AS THOSE REPLACED. THE NEW SWITCH HAS BEEN IMPROVED TO CORRECT THE SUBJECT ISSUE. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of The Bumper To Bumper For 1992/93 Models, Basic Warranty Coverage For All Other Models Except Lincolns. Major Component Warranty Coverage For Lincolns OPERATION DESCRIPTION TIME 932410A Replace Ignition Switch - 0.5 Hr. All Light and Compact Trucks DEALER CODING BASIC PART NO. CONDITION CODE 11572 X1 OASIS CODES: 201000, 201100, 206000 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Level Warning Indicator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oil Level Warning Indicator: > 932410 > Nov > 93 > Instrument Cluster Warning Lights - Dimly Lit Oil Level Warning Indicator: All Technical Service Bulletins Instrument Cluster Warning Lights Dimly Lit Article No. 93-24-10 11/24/93 ^ LAMP - MALFUNCTION OF FOUR PIN LOW OIL LEVEL RELAY - VEHICLES BUILT AFTER 8/1/92 OR 1983-1993 VEHICLES THAT HAVE HAD SERVICE REPLACEMENT IGNITION SWITCHES AFTER 8/1/92 ^ LAMPS - INSTRUMENT CLUSTER WARNING LIGHTS DIMLY LIT - VEHICLES BUILT AFTER 8/1/92 OR 1983-1993 VEHICLES THAT HAVE HAD SERVICE REPLACEMENT IGNITION SWITCHES AFTER 8/1/92 FORD: 1983 FAIRMONT 1983-89 CROWN VICTORIA, ESCORT 1983-93 MUSTANG, THUNDERBIRD 1983-94 PROBE 1984-86 LTD 1984-94 TEMPO LINCOLN-MERCURY: 1983 LN7, ZEPHYR 1983-87 CONTINENTAL, LYNX 1983-89 GRAND MARQUIS, TOWN CAR 1983-93 COUGAR 1984-86 CAPRI, MARQUIS 1984-94 TOPAZ LIGHT TRUCK: 1983-91 BRONCO 1983-93 ECONOLINE, F-150-350 SERIES, RANGER 1986-91 AEROSTAR 1991-93 EXPLORER ISSUE: The instrument cluster warning light(s) may be dimly lit or there may be a malfunction of the four pin low oil relay on vehicles so equipped. This could be due to the ignition switch. ACTION: If the vehicle displays the subject symptoms and meets the following conditions, replace the ignition switch. Refer to the appropriate Car or Light Truck Service Manual (Section 13-04 for 1983-1990 Cars, Section 11-04 for 1991-1993 Cars and Section 13-05 for 1983-1990 Light Trucks, Section 11-05 for 1991-1993 Light Trucks) for removal and installation procedures. Refer to the Parts Block in this article for correct parts usage. CONDITIONS ^ The vehicle has 14401 wiring attached to the P2 terminal of the ignition switch. Refer to the wiring schematic and/or Electrical And Vacuum Troubleshooting Manual (EVTM) for the concern vehicle. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Level Warning Indicator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oil Level Warning Indicator: > 932410 > Nov > 93 > Instrument Cluster Warning Lights - Dimly Lit > Page 6901 ^ The vehicle is equipped with one of the ignition switches identified in the Ignition Switch Part Number Chart. NOTE: THE SERVICE PART NUMBERS FOR THE REPLACEMENT IGNITION SWITCHES WILL HAVE THE SAME PART NUMBERS AS THOSE REPLACED. THE NEW SWITCH HAS BEEN IMPROVED TO CORRECT THE SUBJECT ISSUE. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of The Bumper To Bumper For 1992/93 Models, Basic Warranty Coverage For All Other Models Except Lincolns. Major Component Warranty Coverage For Lincolns OPERATION DESCRIPTION TIME 932410A Replace Ignition Switch - 0.5 Hr. All Light and Compact Trucks DEALER CODING BASIC PART NO. CONDITION CODE 11572 X1 OASIS CODES: 201000, 201100, 206000 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Level Warning Indicator > Component Information > Technical Service Bulletins > Page 6902 Oil Level Warning Indicator: Description and Operation This system is used to indicate a low engine oil level condition. The lamp will be illuminated during engine starting. If oil level is sufficient, the lamp will go off when engine is operating. If oil level is low the lamp will remain on until engine oil is added and the ignition switch is placed in the Off position. The module may take a few minutes to reset. If the engine is started during this period, the last recorded reading will be displayed. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Gauge > Component Information > Testing and Inspection Oil Pressure Gauge: Testing and Inspection This oil pressure indicating system incorporates an instrument voltage regulator, electrical oil pressure gauge and a sending unit which are connected in series. The sending unit consists of a diaphragm, contact and a variable resistor. As oil pressure increases or decreases, the diaphragm actuated the contact on the variable resistor, in turn controlling current flow to the gauge. When oil pressure is low, the resistance of the variable resistor is high, restricting current flow to the gauge, in turn indicating low oil pressure. As oil pressure increases, the resistance of the variable resistor is lowered, permitting an increased current flow to the gauge, resulting in an increased gauge reading. TROUBLESHOOTING A special tester is required to diagnose this type gauge. Follow instructions included with the tester. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Switch <--> [Oil Pressure Sender] > Component Information > Locations Oil Pressure Switch: Locations LH Side Of V8-351/5. LH Front Of Engine Applicable to: 8L Engine Less EEC-IV Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Warning Lamp/Indicator > Component Information > Testing and Inspection Oil Pressure Warning Lamp/Indicator: Testing and Inspection Many trucks utilize a warning light on the instrument panel in place of the conventional dash indicating gauge to warn the driver when the oil pressure is dangerously low. The warning light is wired in series with the ignition switch and the engine unit--which is an oil pressure switch. The oil pressure switch contains a diaphragm and a set of contacts. When the ignition switch is turned on, the warning light circuit is energized and the circuit is completed through the closed contacts in the pressure switch. When the engine is started, build-up of oil pressure compresses the diaphragm, opening the contacts, thereby breaking the circuit and putting out the light. TROUBLESHOOTING The oil pressure warning light should go on when the ignition is turned on. If it does not light, disconnect the wire from the engine unit and ground the wire to the frame or cylinder block. Then if the warning light still does not go on with the ignition switch on, replace the bulb. If the warning light goes on when the wire is grounded to the frame or cylinder block, the engine unit should be checked for being loose or poorly grounded. If the unit is found to be tight and properly grounded, it should be removed and a new one installed. (The presence of sealing compound on the threads of the engine unit will cause a poor ground). If the warning light remains lit when it normally should be out, replace the engine unit before proceeding further to determine the cause for a low pressure indication. The warning light will sometimes light up or flicker when the engine is idling, even though the oil pressure is adequate. However, the light should go out when the engine speed is increased. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Brake Warning Switch > Component Information > Locations Parking Brake Warning Switch: Locations On Parking Brake Bracket Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Fuel Distance/Mileage Module > Component Information > Locations Right Hand Side of Instrument Panel Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest: > 87717 > Apr > 87 > Fuel Gauge - Always Reads Full Fuel Gauge Sender: Customer Interest Fuel Gauge - Always Reads Full GAUGE - FUEL - ALWAYS READS "FULL" - Article No. 7.5L - MIDSHIP FUEL TANK 87-7-17 LIGHTTRUCK: 1985-86 F-250/350 Figure 15 - Article 87-7-17 ISSUE: A fuel gauge that always reads "full" may be caused by the float on the electric fuel pump sender catching on the internal fuel fill pipe inside the midship fuel tank. See Figure 15. ACTION: To correct this, install a new design fuel pump sender assembly, E5TZ- 9H307-L, with revised float travel that will not contact the internal fill pipe. PART NUMBER PART NAME CLASS E5TZ-9H307-L Sender and Fuel Pump A Assembly OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual OPERATION: SP870717A TIME: 0.9 Hr. DLR. CODING: Basic Part No. 9H307 - Code: 09 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 89146 > Jul > 89 > Fuel Tank Sending Unit - Connector Replacement Fuel Gauge Sender: All Technical Service Bulletins Fuel Tank Sending Unit - Connector Replacement FUEL SYSTEM-FUEL TANK SENDING UNIT-WIRE HARNESS CONNECTOR REPLACEMENT WIRING-FUEL TANK SENDING UNIT-CONNECTOR REPLACEMENT Article No. 89-14-6 FORD: 1985-89 CROWN VICTORIA, ESCORT 1985-88 EXP 1985-89 MUSTANG, TEMPO, THUNDERBIRD 1986-89 TAURUS LINCOLN-MERCURY: 1985-89 CONTINENTAL, COUGAR, GRAND MARQUIS 1985-87 LYNX 1985-89 MARK VII, TOPAZ, TOWN CAR 1986-89 SABLE LIGHT TRUCK: 1985-89 BRONCO II, ECONOLINE, F-150, F-250, F-350, RANGER Figure 1 ISSUE: Damaged fuel tank sending unit connectors can be serviced by splicing in a new wire harness connector. The new connector can be obtained by ordering the fuel tank sending unit wire harness and cutting off the connector. ACTION: Splice the new fuel tank sending unit connector to the existing wire harness. Refer to the following procedure for service details. 1. Disconnect the battery ground. 2. Cut the connector from the new harness. 3. Leave 6-8 inches of wiring lead on the connector. 4. Remove the old connector from the fuel tank sending unit. 5. Cut the connector off the vehicle's wire harness about 6-8 inches from the old connector. 6. Match the wire colors. 7. Install the new connector. Use a "Duraseal" butt splice connector, Figure 1. 8. Using a heat gun, seal the splice. CAUTION: DO NOT USE AN OPEN FLAME. 9. Connect the battery ground. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 89146 > Jul > 89 > Fuel Tank Sending Unit - Connector Replacement > Page 6933 10. Check the operation of the fuel gauge. PART NUMBER PART NAME CLASS E9FZ-9A400-A Wire Harness - Fuel Pump C OTHER APPLICABLE ARTICLES: 86-3-11 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 2300, 2310, 2400, 2770, 4500 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 87717 > Apr > 87 > Fuel Gauge - Always Reads Full Fuel Gauge Sender: All Technical Service Bulletins Fuel Gauge - Always Reads Full GAUGE - FUEL - ALWAYS READS "FULL" - Article No. 7.5L - MIDSHIP FUEL TANK 87-7-17 LIGHTTRUCK: 1985-86 F-250/350 Figure 15 - Article 87-7-17 ISSUE: A fuel gauge that always reads "full" may be caused by the float on the electric fuel pump sender catching on the internal fuel fill pipe inside the midship fuel tank. See Figure 15. ACTION: To correct this, install a new design fuel pump sender assembly, E5TZ- 9H307-L, with revised float travel that will not contact the internal fill pipe. PART NUMBER PART NAME CLASS E5TZ-9H307-L Sender and Fuel Pump A Assembly OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual OPERATION: SP870717A TIME: 0.9 Hr. DLR. CODING: Basic Part No. 9H307 - Code: 09 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 86163 > Aug > 86 > Fuel Pump/Sender - Erratic Operation Prevention Fuel Gauge Sender: All Technical Service Bulletins Fuel Pump/Sender - Erratic Operation Prevention Article No. 86-16-3 FUEL SYSTEM - FUEL PUMP/SENDER-APPLICATION OF GREASE TO ELECTRICAL TERMINALS FORD 1985-86 ESCORT, EXP, TEMPO, MUSTANG, LTD, THUNDERBIRD LINCOLN-MERCURY 1985-86 LYNX, TOPAZ, CAPRI, MARQUIS, COUGAR, MARK VII, CONTINENTAL LIGHT TRUCK 1985-86 RANGER, BRONCO II, AEROSTAR, BRONCO, E SERIES, F SERIES To prevent erratic operation of the fuel gauge or the in-tank fuel pump, a generous application of electrical grease should be applied to the terminals of the fuel pump/sender when service is required. The electrical grease will prevent corrosion and reduce the chance of a repeat repair. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge Sender: > 89146 > Jul > 89 > Fuel Tank Sending Unit - Connector Replacement Fuel Gauge Sender: All Technical Service Bulletins Fuel Tank Sending Unit - Connector Replacement FUEL SYSTEM-FUEL TANK SENDING UNIT-WIRE HARNESS CONNECTOR REPLACEMENT WIRING-FUEL TANK SENDING UNIT-CONNECTOR REPLACEMENT Article No. 89-14-6 FORD: 1985-89 CROWN VICTORIA, ESCORT 1985-88 EXP 1985-89 MUSTANG, TEMPO, THUNDERBIRD 1986-89 TAURUS LINCOLN-MERCURY: 1985-89 CONTINENTAL, COUGAR, GRAND MARQUIS 1985-87 LYNX 1985-89 MARK VII, TOPAZ, TOWN CAR 1986-89 SABLE LIGHT TRUCK: 1985-89 BRONCO II, ECONOLINE, F-150, F-250, F-350, RANGER Figure 1 ISSUE: Damaged fuel tank sending unit connectors can be serviced by splicing in a new wire harness connector. The new connector can be obtained by ordering the fuel tank sending unit wire harness and cutting off the connector. ACTION: Splice the new fuel tank sending unit connector to the existing wire harness. Refer to the following procedure for service details. 1. Disconnect the battery ground. 2. Cut the connector from the new harness. 3. Leave 6-8 inches of wiring lead on the connector. 4. Remove the old connector from the fuel tank sending unit. 5. Cut the connector off the vehicle's wire harness about 6-8 inches from the old connector. 6. Match the wire colors. 7. Install the new connector. Use a "Duraseal" butt splice connector, Figure 1. 8. Using a heat gun, seal the splice. CAUTION: DO NOT USE AN OPEN FLAME. 9. Connect the battery ground. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge Sender: > 89146 > Jul > 89 > Fuel Tank Sending Unit - Connector Replacement > Page 6947 10. Check the operation of the fuel gauge. PART NUMBER PART NAME CLASS E9FZ-9A400-A Wire Harness - Fuel Pump C OTHER APPLICABLE ARTICLES: 86-3-11 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 2300, 2310, 2400, 2770, 4500 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge Sender: > 86163 > Aug > 86 > Fuel Pump/Sender - Erratic Operation Prevention Fuel Gauge Sender: All Technical Service Bulletins Fuel Pump/Sender - Erratic Operation Prevention Article No. 86-16-3 FUEL SYSTEM - FUEL PUMP/SENDER-APPLICATION OF GREASE TO ELECTRICAL TERMINALS FORD 1985-86 ESCORT, EXP, TEMPO, MUSTANG, LTD, THUNDERBIRD LINCOLN-MERCURY 1985-86 LYNX, TOPAZ, CAPRI, MARQUIS, COUGAR, MARK VII, CONTINENTAL LIGHT TRUCK 1985-86 RANGER, BRONCO II, AEROSTAR, BRONCO, E SERIES, F SERIES To prevent erratic operation of the fuel gauge or the in-tank fuel pump, a generous application of electrical grease should be applied to the terminals of the fuel pump/sender when service is required. The electrical grease will prevent corrosion and reduce the chance of a repeat repair. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Page 6952 Fuel Gauge Sender: Locations Top Of Fuel Tank Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Page 6953 Fuel Gauge Sender: Description and Operation DESCRIPTION AND OPERATION FUEL LEVEL INDICATING SYSTEM The fuel indicating system is a bimetal-resistance type system. It consists of an instrument voltage regulator, fuel indicator (gauge) mounted in the instrument cluster and a sender located in the fuel tank, INSTRUMENT VOLTAGE REGULATOR The instrument voltage regulator (IVR) used with the fuel indicator (gauge) controls and maintains an average pulsating voltage of 5.0 volts at the gauge terminals. FUEL INDICATOR (GAUGE) The fuel indicator gauge pointer is attached to a wire wound bimetal strip which when heated by the flow of electrical current controlled by the sender unit, produoes the appropriate indication. Fuel Indicating System Using A Bimetal Gauge - Typical FUEL SENDER The fuel sender consists of a variable screened resistor made up of a ceramic substrate. It is controlled by the action of an attached float in the fuel tank. When the fuel level is low, resistance in the sender is high and allows only a low current to flow through the indicator (gauge) windings, causing the pointer to move a short distance. When the fuel level is high, the resistance in the sender is low and allows a higher current flow and a greater heating effect causing the pointer to move a greater distance. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Page 6954 Fuel Gauge Sender: Testing and Inspection DIAGNOSIS AND TESTING WARNING: DO NOT REMOVE THE NIPPLE ON THE END OF THE FUEL RETURN LINE. IT IS THERE TO PREVENT FUEL FROM DRAINING OUT OF THE TANK IN THE EVENT OF A ROLLOVER. NOTE: On vehicles equipped with diesel engines and dual fuel tanks, refer to the diagnosis guide in this Section before proceeding with the calibration testing. CAUTION: DO NOT INTERCHANGE SENDING UNITS BETWEEN GASOLINE-AND DIESEL-POWERED VEHICLES. DOING SO MAY CAUSE SEVERE ENGINE AND FUEL SYSTEM DAMAGE. CALIBRATION TEST (USING ROTUNDA TESTER MODEL 021-00034) Fuel Indicating System Test With Rotunda Tester Model 21-0015 Or Equivalent The Rotunda Instrument Gauge System Tester Model 021-00034 or equivalent is used to diagnose problems in all fuel indicating systems using the bimetal fuel indicator gauge and instrument voltage regulator (IVR). Prior to performing fuel system test the following tester checks should be made. 1. Set tester switch at IVR CHECK position. 2. Attach tester ground wire to the negative (-) terminal of 12-volt battery and touch one of the tester terminals marked with an arrow to the positive (+) battery terminal. 3. If the IVR check lamp does not come on, return tester for service or replacement. TEST SET-UP Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Page 6955 CAUTION: DURING IN-VEHICLE TESTS, Do NOT LET TESTER TERMINAL STUDS DESIGNATED BY ARROWS COME IN CONTACT WITH VEHICLE GROUND. THE FUEL GAUGE WILL BE SHORTED TO GROUND, PREVENTING AN ACCURATE TEST AND POSSIBLY DAMAGING THE IVR OR GAUGE. 1. Disconnect connector from fuel sender and hook onto the matching terminals on the tester (Fig. 4). 2. Turn vehicle ignition switch to ACC position. FUNCTIONAL TEST NOTE: The IVR also supplies a common regulated voltage for the temperature gauge indicating system and oil gauge indicating system (when applicable); therefore, the IVR can only be damaged if the other gauges exhibit similar problems (fluctuating movement or high or low indications at the upper calibration band). The IVR has little effect on the lower calibration band of the indicator. 1. Set test switch to IVR check position. 2. If IVR check lamp flashes on and off, the IVR and wiring are functional. Proceed to calibration check. 3. If IVR check lamp is on steady, check IVR ground screw. If ground screw is secure, replace IVR 4. If IVR check lamp does not come on, check for open circuit in gauge and/or circuit wiring. CALIBRATION CHECK With the tester switch in either the HIGH or LOW position, the center line of the gauge pointer should be within the "F" or "E" white band of the graphics for the fuel test function as shown on the tester. If the center line of the pointer registers in the white bands, the fuel indicating system is operating properly and replacement of the fuel sender is necessary. If the pointer center line falls outside the "E" white band, replace the fuel gauge. If the pointer center line falls outside the "F" white band, replace the IVR and retest. If still outside the upper white band, replace the fuel gauge reinstall the original IVR and retest for calibration. CALIBRATION TEST (WITHOUT TESTER) If only the fuel gauge is inoperative or appears to be out of calibration, a calibration test can be conducted on the vehicle fuel gauge system. The calibration test checks the fuel gauge and IVR simultaneously. The required test equipment consists of a 10 ohm resistor and a 73 ohm resistor. Disconnect the wiring connector at the sender unit. Connect one of the resistors between the lead wire terminal and ground, and turn the ignition switch to the ON or ACC position With the 10 ohm resistor, the gauge should indicate a full-scale reading. With the 73 ohm resistor, the gauge should read at the E graduation mark. Without any resistor (open circuit) the gauge reading should be the same as with the ignition switch in the OFF position. If reading is OK, replace wire connection to sender. If the gauge pointer does not move and stays below the E mark, check for an open circuit in the wiring assembly, the gauge windings, or the instrument cluster printed circuit. If the gauge pointer moves without any resistor connected, check for a short circuit in the lead to the sender unit. If the gauge reads out of calibration, replace IVR and retest. If still out of calibration, replace the gauge. GAUGE BENCH TEST FOR OPEN WINDINGS To test the gauge for open windings, remove the gauge from the vehicle. Connect the gauge to an ohmmeter and read the resistance. An upward movement of the needle from 10 to 14 ohms is normal, because the current increases the temperature of the gauge coil (windings). If the ohmmeter reads below 10 ohms or above 14 ohms, replace the gauge. FUEL TANK DAMAGE If fuel indicating system components are functioning properly and inaccurate indications continue, check the fuel tank for damage which may have changed the fuel sender mounting angle and/or damaged the fuel sender. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Locations Parking Brake Warning Switch: Locations On Parking Brake Bracket Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Cable > Component Information > Testing and Inspection Speedometer Cable: Testing and Inspection The following material covers only that service on speedometers which is feasible to perform. Repairs on the units themselves are not included as they require special tools and extreme care when making repairs and adjustments that only an experienced speedometer mechanic should attempt. The speedometer has two main parts, the speedometer head and the speedometer drive cable. When the speedometer fails to indicate speed or mileage, the cable or cable housing is probably broken. On vehicles are equipped with speed control, there is a speed sensor attached to the transmission. This is used to sense the revolutions of cable assembly and to regulate speed control. SPEEDOMETER CABLE Most cables are broken due to lack of lubrication, or a sharp bend or kink in the housing. A cable might break because of the speedometer head mechanism binds. In such cases, the speedometer head should be repaired or replaced before a new cable or housing is installed. A ``jumpy'' pointer condition, together with a scraping noise, is due, in most instances, to a dry or kinked speedometer cable. The kinked cable rubs on the housing and winds up, slowing down the pointer. The cable then unwinds and the pointer ``jumps.'' To check for kinks, remove the cable, lay it on a flat surface and twist one end with the fingers. If it turns over smoothly the cable is not kinked. But if part of the cable flops over as it is twisted, the cable is kinked and should be replaced. LUBRICATION The speedometer cable should be lubricated with special cable lubricant. Fill the ferrule on the upper end of the housing with the cable lubricant. Insert the cable in the housing, starting at the upper end. Turn the cable around carefully while feeding it into the housing. Repeat filling the ferrule except for the last six inches of cable. Too much lubricant at this point may cause the lubricant to work into the speedometer head. INSTALLING CABLE During installation, if the cable sticks when inserted in the housing and will not go through, the housing is damaged inside or kinked. Be sure to check the housing from one end to the other. Straighten any sharp bends by relocating clamps or elbows. Replace housing if it is badly kinked or broken. Position the cable and housing so that they lead into the head as straight as possible. Check the new cable for kinks before installing it. Use wide, sweeping, gradual curves where the cable comes out of the transmission and connects to the head so the cable will not be damaged during installation. Arrange the housing so it does not lean against the engine because heat from the engine may dry out the lubricant. If inspection indicates that the cable and housing are in good condition, yet pointer action is erratic, check the speedometer head for possible binding. The speedometer drive pinion should also be checked. If the pinion is dry or its teeth are stripped, the speedometer may not register properly. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component Information > Technical Service Bulletins > Speedometer/Odometer - Inaccurate Readings Speedometer Head: Technical Service Bulletins Speedometer/Odometer - Inaccurate Readings SPEEDOMETER - MECHANICAL/ELECTRONIC - INACCURATE SPEED READINGS AND ODOMETER READINGS Article No. 89-2-7 FORD: 1989 AND PRIOR ALL CAR LINES LINCOLN-MERCURY: 1989 AND PRIOR ALL CAR LINES LIGHT TRUCK: 1989 AND PRIOR ALL TRUCK LINES ISSUE: The accuracy of speedometer/odometer readings may be influenced by several vehicle components or systems. The information in this TSB article is intended to assist technicians in speedometer/odometer concern diagnosis. ACTION: Use the following supplemental information below to assist in speedometer/odometer diagnostics. OPERATION A mechanical analog speedometer displays vehicle speed and the odometer displays total distance traveled. The speedometer/odometer assembly is cable driven by either a transmission or a transaxle. All speedometer/odometer assemblies, except for police vehicles are the same with respect to the speed accuracy tolerance used during calibration. The odometer gear ratio is fixed so that all are identical and have no error in the speedometer head. Electronic digital operation is similar. It could use a drive cable or a speed sensor to drive the speedometer/odometer. An electronic signal is sent from a speed sensor to the digital speedometer/ odometer assembly. The speed sensor is driven by a transmission or a transaxle, similar to a cable. Several areas of concern that may affect speedometer/ odometer readings are tires, axle gear ratio and speedometer/odometer drive and driven gears. TIRES Improper tire rolling radius and inflation pressure, temperature and size may contribute to inaccurate system readings. System accuracy testing should be performed after the tires are set at the correct pressure as shown on the safety compliance certification label. The tires should be warmed for a short period. Best results are obtained on smooth, dry pavement while driving at a constant speed within the posted speed limit. AXLE/TRANSAXLE RATIO The gear ratio of the rear axle or the final drive ratio of the transaxle must be known to select or check if the proper speedometer/odometer drive and driven gears are present. Various gear ratios are available, but usually are not a concern when dealing with speedometer/odometer concerns unless the gear ratio has been changed. WARNING: NEVER CORRECT SPEEDOMETER READINGS BY CHANGING GEARS UNLESS THE ODOMETER IS ALSO OFF. DRIVE/DRIVEN GEARS The speedometer/odometer drive gear is located inside the transmission, transaxle or transfer case and is not easily accessed for change. The driven gear rotates the speedometer cable. Rear wheel drive vehicles have several driven gears with various numbers of teeth available to correct input to the speedometer/odometer head. Front wheel drive vehicles generally do not offer different gears for correction. GENERAL DESCRIPTION The maximum allowable odometer system accuracy error is +/- 3.75% of the actual distance traveled. Ford Motor vehicles are well within those limits. The speed indication is biased high, except on police vehicles with certified calibration speedometers/ odometers. As a general rule, the indicated speed is equal to or greater than the actual speed. This is intended to protect the consumer against violating speed laws. Most customer concerns are related to speedometers reading too high at true speeds between 50 MPH and 65 MPH (80 - 105 Km/h). At that speed range, the worst case errors may indicate a speed that is 10% greater than true speed. The speedometer head is an instrument which processes information sent to it by the rotating speedometer cable. If the system components send the Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component Information > Technical Service Bulletins > Speedometer/Odometer - Inaccurate Readings > Page 6966 wrong number of revolution per mile to the speedometer head, an inaccurate speed reading and amount of distanced traveled will be displayed. Since there is no error in the fixed gear ratio of the speedometer head odometer, start by checking the accuracy of the odometer even if the customer concern indicates a speed accuracy problem. Odometer accuracy can be checked by using roads established at mile increments or a known local course. If roads with mile markers are used, a five mile stretch is recommended to allow for inaccuracies. If an error is greater than 3.75%, a change to the transmission drive/driven gear selection, tire size, or tire inflation may need attention. The odometer should be checked again to verify any corrective action. If the indicated speed error exceeds 10% between 50 MPH and 60 MPH (80 - 105 Km/h), replace the speedometer/odometer assembly. Vehicles with transfer cases that have fluctuating readings may be due to slippage of drive gears, parts not splined or loose yoke nuts. If the vehicle has speed control, the speed accuracy can be checked using the verified odometer vs. time. The formula is as follows: 3600 divided by TIME (seconds to cover one mile) = TRUE MPH (Km/h) EXAMPLES: 60 MPH (96 Km/h) requires 60 seconds to cover one mile 55 MPH (88 Km/h) requires 65 and 3/4 seconds to cover one mile 50 MPH (80 Km/h) requires 72 seconds to cover one mile ARTICLE SUPERSEDED: 84-14-6, date 7/3/84 WARRANTY STATUS: "INFORMATION ONLY" OASIS CODES: 2300, 2310, 2400, 2500 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tachometer > Component Information > Diagrams > Diagram Information and Instructions Tachometer: Diagram Information and Instructions Symbol Identification Wire Color Code Identification Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tachometer > Component Information > Diagrams > Diagram Information and Instructions > Page 6971 NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tachometer > Component Information > Diagrams > Diagram Information and Instructions > Page 6972 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tachometer > Component Information > Diagrams > Page 6973 Tachometer: Description and Operation The tachometer is an electrically operated instrument which indicates engine speed in revolutions per minute (rpm). It is mounted in the instrument cluster assembly. The tachometer on F-150-F-350 and Bronco vehicles can be used with either 6 cylinder or 8 cylinder engines. The tachometer terminals "B" (+12 volts), "C" (coil negative), and "G" (ground) are connected when used for 6 cylinder engines. A fourth terminal "8" (8 cyl. ground) is grounded through the wire harness for 8 cylinder engine operation. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tachometer > Component Information > Diagrams > Page 6974 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tachometer > Component Information > Diagrams > Page 6975 Tachometer: Service and Repair Removal 1. Disconnect the battery ground cable. 2. Remove the instrument cluster. 3. Remove the six screws attaching the mask and lens to the cluster backplate and remove the mask and lens. 4. Remove the four nuts attaching the tachometer to the cluster backplate and remove the tachometer. Installation 1. Position the tachometer to the cluster backplate and install the four attaching nuts. 2. Position the lens and mask to the cluster backplate and install the six attaching screws. Install the instrument cluster. Connect the battery ground cable and check the operation of the tachometer. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Gauge > Component Information > Testing and Inspection > Dash Gauge Test Temperature Gauge: Testing and Inspection Dash Gauge Test Gauge failures are often caused by defective wiring or grounds. The first step in locating trouble should be a thorough inspection of all wiring, terminals and printed circuits. If wiring is secured by clamps, check to see whether the insulation has been severed, thereby grounding the wire. In the case of a fuel gauge installation, rust may cause failure by corrosion at the ground connection of the tank unit. The Constant Voltage Regulator (CVR) type indicator is a bimetal-resistance type system consisting of an Instrument Voltage Regulator (IVR), an indicator gauge, and a variable resistance sending unit. Current to the system is applied to the gauge terminals by the IVR, which maintains an average-pulsating value of 5 volts. The indicator gauge consists of a pointer which is attached to a wire-wound bimetal strip. Current passing through the coil heats the bimetal strip, causing the pointer to move. As more current passes through the coil, heat increases, moving the pointer farther. The circuit is completed through a sending unit which contains a variable resistor. When resistance is high, less current is allowed to pass through the gauge, and the pointer moves very little. As resistance decreases due to changing conditions in system being monitored, more current passes through gauge coil, causing pointer to move farther. Do not apply battery voltage to system or ground output terminals of IVR, as damage to system components or wiring circuits may result. DASH GAUGE TEST 1. Disconnect battery ground cable and remove gauge from vehicle. 2. Connect ohmmeter between gauge terminals and read coil winding resistance. 3. An upward movement of ohmmeter needle from 10 ohms to 14 ohms is normal, as test current of ohmmeter causes a temperature rise in gauge coil windings. 4. If ohmmeter reads below 10 ohms or above 14 ohms, gauge is defective. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Gauge > Component Information > Testing and Inspection > Dash Gauge Test > Page 6980 Temperature Gauge: Testing and Inspection Electrical Temperature Gauges This temperature indicating system consists of a sending unit, located on the cylinder head, electrical temperature gauge and an instrument voltage regulator. As engine temperature increases or decreases, the resistance of the sending unit changes, in turn controlling current flow to the gauge. When engine temperature is low, the resistance of the sending unit is high, restricting current flow to the gauge, in turn indicating low engine temperature. As engine temperature increases, the resistance of the ending unit decreases, permitting an increased current flow to the gauge, resulting in an increased temperature reading. TROUBLESHOOTING A special tester is required to diagnose this type gauge. Follow instructions included with the tester. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Sensor (Gauge) > Component Information > Locations Temperature Sensor (Gauge): Locations LH Side Of V8-351/5. On Intake Manifold, Near Distributor Applicable to: 8L Engine Less EEC-IV Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Warning Lamp/Indicator, Engine Cooling > Component Information > Testing and Inspection Temperature Warning Lamp/Indicator: Testing and Inspection A bimetal temperature switch located in the cylinder head control the operation of a temperature indicator light with a red lens. If the engine cooling system is not functioning properly and coolant temperature exceeds a predetermined value, the warning light will illuminate. TROUBLESHOOTING If the red light is not lit when the engine is being cranked, check for a burned out bulb, an open in the light circuit, or a defective ignition switch. If the red light is lit when the engine is running, check the wiring between light and switch for a ground, defective temperature switch, or overheated cooling system. As a test circuit to check whether the red bulb is functioning properly, a wire which is connected to the ground terminal of the ignition switch is tapped into its circuit. When the ignition is in the ``Start'' (engine cranking) position, the ground terminal is grounded inside the switch and the red bulb will be lit. When the engine is started and the ignition switch is in the ``On'' position, the test circuit is opened and the bulb is then controlled by the temperature switch. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Volt Meter Gauge > Component Information > Testing and Inspection Volt Meter Gauge: Testing and Inspection The voltmeter is a gauge which measures the electrical flow from the battery to indicate whether the battery output is within tolerances. The voltmeter reading can range from 13.5---14.0 volts under normal operating conditions. If an undercharge or overcharge condition is indicated for an extended period, the battery and charging system should be checked. TROUBLESHOOTING To check voltmeter, turn key and headlights on with engine off. Pointer should move to 12.5 volts. If no needle movement is observed, check connections from battery to circuit breaker. If connections are tight and meter shows no movement, check wire continuity. If wire continuity is satisfactory, the meter is inoperative and must be replaced. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Locations Backup Lamp Switch: Locations Manual Transmission Wiring On Transmission Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions Brake Lamp: Diagram Information and Instructions Symbol Identification Wire Color Code Identification Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6999 NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7000 Fig. 24 Exterior Lamp (Turn, Stop & Hazard) Wiring Circuit. F150-350 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Locations Brake Light Switch: Locations Underneath LH Side Of I/P Top Of Brake Pedal Bracket Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 7004 Brake Light Switch: Service and Repair Fig. 6 Stop light switch replacement. Exc. 1980---83 E-100 w/manual brakes. Fig. 7 Stop light switch replacement. 1980---83 E-100 w/manual brakes 1. Disconnect battery ground cable. 2. Disconnect electrical connector from switch, Figs. 6 and 7. 3. Remove hairpin retainer, then slide stop light switch, pushrod, nylon washers and bushings away from pedal and remove the switch from vehicle. 4. Reverse procedure to install. Ensure stop light switch wires are of sufficient length to allow full travel of the brake pedal. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Lighting and Horns > Cargo Lamp > Component Information > Diagrams > Diagram Information and Instructions Cargo Lamp: Diagram Information and Instructions Symbol Identification Wire Color Code Identification Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Lighting and Horns > Cargo Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7009 NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Lighting and Horns > Cargo Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7010 Fig. 10 Cargo, Courtesy, Dome Lamps & Lamps-On Warning System Wiring Circuit. F150-350 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions Dome Lamp: Diagram Information and Instructions Symbol Identification Wire Color Code Identification Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7015 NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7016 Fig. 10 Cargo, Courtesy, Dome Lamps & Lamps-On Warning System Wiring Circuit. F150-350 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Diagrams > Diagram Information and Instructions Hazard Warning Switch: Diagram Information and Instructions Symbol Identification Wire Color Code Identification Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7022 NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7023 Fig. 24 Exterior Lamp (Turn, Stop & Hazard) Wiring Circuit. F150-350 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Control Module > Component Information > Diagrams > Diagram Information and Instructions Headlamp Control Module: Diagram Information and Instructions Symbol Identification Wire Color Code Identification Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7029 NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7030 Fig. 38 Headlamp Wiring Circuit Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Locations Headlamp Dimmer Switch: Locations On Floor Pan, At LH Side Of Cab Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions Headlamp Dimmer Switch: Diagram Information and Instructions Symbol Identification Wire Color Code Identification Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7036 NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7037 Fig. 38 Headlamp Wiring Circuit Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Service and Repair Headlamp Switch: Service and Repair Fig. 6 Light Switch F-100---350 & BRONCO 1. Disconnect battery ground cable. 2. Remove knobs from headlight switch, windshield wiper switch and fog light switch (if equipped). Use a suitable hook tool to release each knob lock tab. 3. Remove steering column shroud, then the cluster finish panel assembly, Fig. 5. 4. Remove switch attaching nut, Fig. 5. 5. Disconnect electrical connector from switch and remove switch from vehicle. 6. Reverse procedure to install. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Locations Horn Relay: Locations Horn Relay Location Under LH Side Of I/P. Under LH Side Of I/P, With Speed Control Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Locations > Page 7045 Underneath LH Side Of I/P Below LH Side Of I/P Horn Relay With Speed Control Bronco F-150 thru F-350, E-150 thru E-350 and Super F Series The horn relay is use on vehicles equipped with speed control and is located under the left side of the instrument panel, left of the steering column and is mounted on the outboard attaching screw of the speed control amplifier module. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Locations > Page 7046 Horn Relay: Testing and Inspection Fig. 3 Speed control wiring diagram. 1981---83 E-100-350 & 1984-87 E-150-350 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Locations > Page 7047 Fig. 4 Speed control wiring diagram. 1981 F-100-350 & Bronco Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Locations > Page 7048 Fig. 5 Speed control wiring diagram. 1982---83 F-100-350, 1984---87 F-150-350 & 1982---87 Bronco 1981-87 Models Exc. 1983-87 Ranger, 1984-87 Bronco II & 1986-87 Aerostar 1. Locate horn relay wire connector marked X and Y, Figs. 3, 4 and 5. 2. Using connector X, locate wire 460, then using a suitable voltmeter, check for battery voltage at male side of connector. 3. Using connector Y, locate wire 1, then using a suitable voltmeter, check for battery voltage at female side of connector. Depress horn, voltmeter should read zero and horn should sound. If battery voltage remains, circuit is open. Connectors should remain connected during testing. 4. Check horn relay by momentarily grounding circuit 1 to chassis. This bypasses horn switch and horn should sound. If horn does not sound, check for battery voltage at connector X wire 6 during relay operation. If voltage is present at circuit 6 during relay operation, an open circuit is indicated between horn and connector X. 5. If relay does not operate with battery voltage present at circuit 460 and circuit 1 is grounded, replace relay. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Marker Lamp Relay > Component Information > Locations Marker Lamp Relay: Locations LH Side Of Dash Panel Attached To Dash Panel, Below Junction Block Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram Information and Instructions Parking Lamp: Diagram Information and Instructions Symbol Identification Wire Color Code Identification Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7057 NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7058 Parking Lamp: Electrical Diagrams Fig. 22 Exterior Lamp (Body Markers, License, Parking & Trailer) Wiring Circuit (Part 1 of 2). F150-350 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7059 Fig. 22 Exterior Lamp (Body Markers, License, Parking & Trailer) Wiring Circuit (Part 2 of 2). Bronco & F150-350 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Headlamp Control Module > Component Information > Diagrams > Diagram Information and Instructions Headlamp Control Module: Diagram Information and Instructions Symbol Identification Wire Color Code Identification Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Headlamp Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7065 NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Headlamp Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7066 Fig. 38 Headlamp Wiring Circuit Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations Horn Relay: Locations Horn Relay Location Under LH Side Of I/P. Under LH Side Of I/P, With Speed Control Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 7070 Underneath LH Side Of I/P Below LH Side Of I/P Horn Relay With Speed Control Bronco F-150 thru F-350, E-150 thru E-350 and Super F Series The horn relay is use on vehicles equipped with speed control and is located under the left side of the instrument panel, left of the steering column and is mounted on the outboard attaching screw of the speed control amplifier module. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 7071 Horn Relay: Testing and Inspection Fig. 3 Speed control wiring diagram. 1981---83 E-100-350 & 1984-87 E-150-350 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 7072 Fig. 4 Speed control wiring diagram. 1981 F-100-350 & Bronco Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 7073 Fig. 5 Speed control wiring diagram. 1982---83 F-100-350, 1984---87 F-150-350 & 1982---87 Bronco 1981-87 Models Exc. 1983-87 Ranger, 1984-87 Bronco II & 1986-87 Aerostar 1. Locate horn relay wire connector marked X and Y, Figs. 3, 4 and 5. 2. Using connector X, locate wire 460, then using a suitable voltmeter, check for battery voltage at male side of connector. 3. Using connector Y, locate wire 1, then using a suitable voltmeter, check for battery voltage at female side of connector. Depress horn, voltmeter should read zero and horn should sound. If battery voltage remains, circuit is open. Connectors should remain connected during testing. 4. Check horn relay by momentarily grounding circuit 1 to chassis. This bypasses horn switch and horn should sound. If horn does not sound, check for battery voltage at connector X wire 6 during relay operation. If voltage is present at circuit 6 during relay operation, an open circuit is indicated between horn and connector X. 5. If relay does not operate with battery voltage present at circuit 460 and circuit 1 is grounded, replace relay. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Marker Lamp Relay > Component Information > Locations Marker Lamp Relay: Locations LH Side Of Dash Panel Attached To Dash Panel, Below Junction Block Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Locations Trailer Lighting Relay: Locations Attached To Dash Panel, Below Junction Block Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Trailer Lighting Module > Component Information > Locations Trailer Lighting Module: Locations Attached To Brake Pedal Assembly Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations Backup Lamp Switch: Locations Manual Transmission Wiring On Transmission Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations Brake Light Switch: Locations Underneath LH Side Of I/P Top Of Brake Pedal Bracket Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 7090 Brake Light Switch: Service and Repair Fig. 6 Stop light switch replacement. Exc. 1980---83 E-100 w/manual brakes. Fig. 7 Stop light switch replacement. 1980---83 E-100 w/manual brakes 1. Disconnect battery ground cable. 2. Disconnect electrical connector from switch, Figs. 6 and 7. 3. Remove hairpin retainer, then slide stop light switch, pushrod, nylon washers and bushings away from pedal and remove the switch from vehicle. 4. Reverse procedure to install. Ensure stop light switch wires are of sufficient length to allow full travel of the brake pedal. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Diagram Information and Instructions Hazard Warning Switch: Diagram Information and Instructions Symbol Identification Wire Color Code Identification Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7095 NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7096 Fig. 24 Exterior Lamp (Turn, Stop & Hazard) Wiring Circuit. F150-350 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Locations Headlamp Dimmer Switch: Locations On Floor Pan, At LH Side Of Cab Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions Headlamp Dimmer Switch: Diagram Information and Instructions Symbol Identification Wire Color Code Identification Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7102 NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7103 Fig. 38 Headlamp Wiring Circuit Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Service and Repair Headlamp Switch: Service and Repair Fig. 6 Light Switch F-100---350 & BRONCO 1. Disconnect battery ground cable. 2. Remove knobs from headlight switch, windshield wiper switch and fog light switch (if equipped). Use a suitable hook tool to release each knob lock tab. 3. Remove steering column shroud, then the cluster finish panel assembly, Fig. 5. 4. Remove switch attaching nut, Fig. 5. 5. Disconnect electrical connector from switch and remove switch from vehicle. 6. Reverse procedure to install. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Technical Service Bulletins > Customer Interest for Turn Signal Switch: > 862318 > Nov > 86 > Tilt Steering Column - Release Lever Feels Loose Turn Signal Switch: Customer Interest Tilt Steering Column - Release Lever Feels Loose Article No. 86-23-18 STEERING - TILT STEERING COLUMN - RELEASE LEVER FEELS LOOSE LIGHT TRUCK 1986 F-150/350, BRONCO, ECONOLINE Tilt release lever feels "limp" when attempting to adjust steering wheel. Tilt function is fully operable but lever has a loose feel during initial portion of the lever travel. Some vehicles built during June and July, 1986 have been found to have this condition because preload on the tilt lever is insufficient. This can be corrected by replacing the turn signal switch assembly. Refer to Volume A, Section 32-41 of the 1986 Light Truck Shop Manual on installation procedures. PART NUMBER PART NAME CLASS E5TZ-13341-B Turn Signal Switch B Assembly - F Series, Bronco E5TZ-13341-B Turn Signal Switch B Assembly - Econoline/4 Speed E5UZ-13341-D Turn Signal Switch B Assembly - Econoline/Automatic OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION: 13319A TIME: 0.7 Hr. DLR. CODING: Basic Part No. 13341 - Code: 33 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Turn Signal Switch: > 862318 > Nov > 86 > Tilt Steering Column - Release Lever Feels Loose Turn Signal Switch: All Technical Service Bulletins Tilt Steering Column - Release Lever Feels Loose Article No. 86-23-18 STEERING - TILT STEERING COLUMN - RELEASE LEVER FEELS LOOSE LIGHT TRUCK 1986 F-150/350, BRONCO, ECONOLINE Tilt release lever feels "limp" when attempting to adjust steering wheel. Tilt function is fully operable but lever has a loose feel during initial portion of the lever travel. Some vehicles built during June and July, 1986 have been found to have this condition because preload on the tilt lever is insufficient. This can be corrected by replacing the turn signal switch assembly. Refer to Volume A, Section 32-41 of the 1986 Light Truck Shop Manual on installation procedures. PART NUMBER PART NAME CLASS E5TZ-13341-B Turn Signal Switch B Assembly - F Series, Bronco E5TZ-13341-B Turn Signal Switch B Assembly - Econoline/4 Speed E5UZ-13341-D Turn Signal Switch B Assembly - Econoline/Automatic OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION: 13319A TIME: 0.7 Hr. DLR. CODING: Basic Part No. 13341 - Code: 33 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Technical Service Bulletins > Page 7120 Turn Signal Switch: Locations In Upper Part Of Steering Column Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Diagram Information and Instructions Turn Signal Switch: Diagram Information and Instructions Symbol Identification Wire Color Code Identification Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7123 NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7124 Fig. 24 Exterior Lamp (Turn, Stop & Hazard) Wiring Circuit. F150-350 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Page 7125 Turn Signal Switch: Service and Repair 1. Disconnect battery ground cable. 2. Remove horn switch, then the steering wheel. 3. Remove turn signal switch lever by unscrewing from steering column. 4. On 1981---87 F-100---350 and Bronco models, remove lower steering column shroud. 5. On 1981---87 E-100---350 models, remove upper and lower steering column shrouds. 6. On all models, disconnect electrical connector from turn signal switch and remove switch attaching screws. 7. On all models with tilt column and 1980 E-100---350, F-100---350 and Bronco with fixed column, remove wires and terminals from steering column electrical connector, after noting color code and location of each connector. Remove plastic cover sleeve, if equipped, from wiring harness, then lift switch assembly out through top of column. On 1981---87 E-100---350 models equipped with tilt column and automatic transmission, disconnect transmission selector indicator light electrical connector from turn signal switch harness prior to removing the switch. 8. On all models with fixed column, except 1980 E-100---350, F-100---350 and Bronco, remove switch assembly by lifting out of column while guiding connector plug through opening in shift socket. On 1981---87 E-100---350 models equipped with fixed column and automatic transmission, remove transmission selector indicator light assembly with turn signal switch. 9. Reverse procedure to install. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Lighting and Horns > Trailer Lighting Relay > Component Information > Locations Trailer Lighting Relay: Locations Attached To Dash Panel, Below Junction Block Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Lighting and Horns > Trailer Lighting Module > Component Information > Locations Trailer Lighting Module: Locations Attached To Brake Pedal Assembly Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Locations Turn Signal Flasher: Locations Rear Of Fuse Panel In Fuse Panel Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Diagrams > Diagram Information and Instructions Turn Signal Lamp: Diagram Information and Instructions Symbol Identification Wire Color Code Identification Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7140 NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 7141 Fig. 24 Exterior Lamp (Turn, Stop & Hazard) Wiring Circuit. F150-350 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Turn Signal Switch: > 862318 > Nov > 86 > Tilt Steering Column Release Lever Feels Loose Turn Signal Switch: All Technical Service Bulletins Tilt Steering Column - Release Lever Feels Loose Article No. 86-23-18 STEERING - TILT STEERING COLUMN - RELEASE LEVER FEELS LOOSE LIGHT TRUCK 1986 F-150/350, BRONCO, ECONOLINE Tilt release lever feels "limp" when attempting to adjust steering wheel. Tilt function is fully operable but lever has a loose feel during initial portion of the lever travel. Some vehicles built during June and July, 1986 have been found to have this condition because preload on the tilt lever is insufficient. This can be corrected by replacing the turn signal switch assembly. Refer to Volume A, Section 32-41 of the 1986 Light Truck Shop Manual on installation procedures. PART NUMBER PART NAME CLASS E5TZ-13341-B Turn Signal Switch B Assembly - F Series, Bronco E5TZ-13341-B Turn Signal Switch B Assembly - Econoline/4 Speed E5UZ-13341-D Turn Signal Switch B Assembly - Econoline/Automatic OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION: 13319A TIME: 0.7 Hr. DLR. CODING: Basic Part No. 13341 - Code: 33 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Technical Service Bulletins > Customer Interest for Turn Signal Switch: > 862318 > Nov > 86 > Tilt Steering Column - Release Lever Feels Loose Turn Signal Switch: Customer Interest Tilt Steering Column - Release Lever Feels Loose Article No. 86-23-18 STEERING - TILT STEERING COLUMN - RELEASE LEVER FEELS LOOSE LIGHT TRUCK 1986 F-150/350, BRONCO, ECONOLINE Tilt release lever feels "limp" when attempting to adjust steering wheel. Tilt function is fully operable but lever has a loose feel during initial portion of the lever travel. Some vehicles built during June and July, 1986 have been found to have this condition because preload on the tilt lever is insufficient. This can be corrected by replacing the turn signal switch assembly. Refer to Volume A, Section 32-41 of the 1986 Light Truck Shop Manual on installation procedures. PART NUMBER PART NAME CLASS E5TZ-13341-B Turn Signal Switch B Assembly - F Series, Bronco E5TZ-13341-B Turn Signal Switch B Assembly - Econoline/4 Speed E5UZ-13341-D Turn Signal Switch B Assembly - Econoline/Automatic OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION: 13319A TIME: 0.7 Hr. DLR. CODING: Basic Part No. 13341 - Code: 33 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Technical Service Bulletins > Page 7155 Turn Signal Switch: Locations In Upper Part Of Steering Column Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Diagrams > Diagram Information and Instructions Turn Signal Switch: Diagram Information and Instructions Symbol Identification Wire Color Code Identification Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7158 NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7159 Fig. 24 Exterior Lamp (Turn, Stop & Hazard) Wiring Circuit. F150-350 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Diagrams > Page 7160 Turn Signal Switch: Service and Repair 1. Disconnect battery ground cable. 2. Remove horn switch, then the steering wheel. 3. Remove turn signal switch lever by unscrewing from steering column. 4. On 1981---87 F-100---350 and Bronco models, remove lower steering column shroud. 5. On 1981---87 E-100---350 models, remove upper and lower steering column shrouds. 6. On all models, disconnect electrical connector from turn signal switch and remove switch attaching screws. 7. On all models with tilt column and 1980 E-100---350, F-100---350 and Bronco with fixed column, remove wires and terminals from steering column electrical connector, after noting color code and location of each connector. Remove plastic cover sleeve, if equipped, from wiring harness, then lift switch assembly out through top of column. On 1981---87 E-100---350 models equipped with tilt column and automatic transmission, disconnect transmission selector indicator light electrical connector from turn signal switch harness prior to removing the switch. 8. On all models with fixed column, except 1980 E-100---350, F-100---350 and Bronco, remove switch assembly by lifting out of column while guiding connector plug through opening in shift socket. On 1981---87 E-100---350 models equipped with fixed column and automatic transmission, remove transmission selector indicator light assembly with turn signal switch. 9. Reverse procedure to install. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions Heated Glass Element: Diagram Information and Instructions Symbol Identification Wire Color Code Identification Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 7166 NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 7167 Fig. 48 Rear Defogger & Power Tailgate Window Wiring Circuit. Bronco Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Circuit Breaker > Component Information > Locations Power Window Circuit Breaker: Locations Circuit Location Amps Power Door Locks.....................Fuse Panel................30 Power Windows........................Fuse Panel................20 Power Tailgate Window................Fuse Panel................25 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Component Information > Technical Service Bulletins > Customer Interest: > 88141 > Jul > 88 > Vent Windows - May Stick to Weatherstrip Window Glass: Customer Interest Vent Windows - May Stick to Weatherstrip GLASS - VENT WINDOWS - MANUAL - GLASS STICKS TO WEATHERSTRIP - VEHICLES BUILT BEFORE 4/04/88 Article No. 88-14-1 FORD: 1984-88 ALL CAR LINES LINCOLN-MERCURY: 1984-88 ALL CAR LINES MERKUR: 1985-88 ALL CAR LINES LIGHT TRUCK: 1984-88 ALL LIGHT TRUCK LINES MEDIUM/HEAVY TRUCK: 1984-88 ALL MEDIUM/HEAVY TRUCK LINES ISSUE: Manual vent windows that are not opened very often may stick to the vent window weatherstrip making them hard to open. In some cases, the high opening efforts may cause the weatherstrip to pull out of the vent division bar. ACTION: To correct this, apply "Krytox" oil to the vent window weatherstrip using the following service procedure. FIGURE 1 1. Open the vent window all the way. 2. From inside of vehicle, apply "Krytox" oil on the weatherstrip sealing lips of vent window, Figure 1. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Component Information > Technical Service Bulletins > Customer Interest: > 88141 > Jul > 88 > Vent Windows - May Stick to Weatherstrip > Page 7180 FIGURE 2 3. From outside of vehicle, apply "Krytox" oil on the weatherstrip sealing lips of vent window, Figure 2. 4. Close and open vent window to make sure window operates correctly. NOTE: CONTACT EXCEL INDUSTRIES, INC. TO ORDER "KRYTOX" OIL: (904) 286-8300 EXTENSION 305 REPRESENTATIVE: RACHEL FLYNN. OTHER APPLICABLE ARTICLES: Supersedes 87-11-2 WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION: 881401A TIME: 0.3 Hr. DLR. CODING: Basic Part No. 7022296 - Car 7021448 - Truck Condition Code: 41 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Component Information > Technical Service Bulletins > Customer Interest: > 8852 > Mar > 88 > Manual Vent Windows - Difficult to Open Window Glass: Customer Interest Manual Vent Windows - Difficult to Open GLASS - MANUAL VENT WINDOWS HARD TO OPEN Article No. 88-5-2 FORD: 1980-88 CROWN VICTORIA 1981-86 THUNDERBIRD 1981-87 ESCORT 1984-86 LTD LINCOLN-MERCURY: 1980-88 GRAND MARQUIS 1981-86 LYNX, COUGAR 1984-86 MARQUIS LIGHT TRUCK: 1980-88 E-SERIES, F-SERIES, BRONCO 1983-88 RANGER 1984-88 BRONCO II 1986-88 AEROSTAR ISSUE: Hard to open pivoting type vent windows may be caused by the glass sticking to the weatherstrip on the division bar. The weatherstrip is often pulled out of the division bar when this condition is present. FIGURE 1 ACTION: To correct this, apply a strip of clear pressure sensitive tape on the inside vertical edge of the vent window glass, Figure 1. PART NUMBER PART NAME CLASS E8AZ-19627-A Clear Pressure Sensitive B Tape OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION: 880502A - Both vent windows TIME: 0.3 Hr. DLR. CODING: Basic Part No. 7021402 Code: 41 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Component Information > Technical Service Bulletins > Customer Interest: > 87112 > Jun > 87 > Manual Vent Windows - Hard to Open Window Glass: Customer Interest Manual Vent Windows - Hard to Open Article No. GLASS - VENT WINDOWS - MANUAL 87-11-2 HARD TO OPEN FORD: 1984-87 ALL CAR LINES LINCOLN-MERCURY: 1984-87 ALL CAR LINES LIGHT TRUCK: 1984-87 ALL LIGHT TRUCK LINES Figure 2 - Article 87-11-2 ISSUE: Manual vent windows that are not opened very often may stick to the vent window weatherstrip which makes them hard to open. ACTION: To correct this, apply a thin coating of Silicone Lubricant (COAZ-19553-AA) to the vent window weatherstrip as shown in Figure 2. This lubricant can be applied during dealer prep and/or normal customer service visits. NOTE: DO NOT USE AEROSOL SPRAY CANS. PART NUMBER PART NAME CLASS COAZ-19553-AA Silicone Lubricant B OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual OPERATION: SP871102A - Both sides TIME: 0.3 Hr. DLR. CODING: Basic Part No. 7021448 Code: 41 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Window Glass: > 96221 > Oct > 96 > Windshield/Interior Glass - Fog/Film Window Glass: All Technical Service Bulletins Windshield/Interior Glass - Fog/Film Article No. 96-22-1 10/21/96 WINDSHIELD AND INTERIOR GLASS - FOG/FILM FORD: 1984-86 LTD 1984-88 EXP 1984-94 TEMPO 1984-97 CROWN VICTORIA, ESCORT, MUSTANG, THUNDERBIRD 1986-97 TAURUS 1988-93 FESTIVA 1989-97 PROBE 1994-97 ASPIRE 1995-97 CONTOUR LINCOLN-MERCURY: 1984-86 MARQUIS 1984-87 LN7, LYNX 1984-92 MARK VII 1984-94 TOPAZ 1984-97 CONTINENTAL, COUGAR, GRAND MARQUIS, TOWN CAR 1986-97 SABLE 1987-89 TRACER 1991-94 CAPRI 1991-97 TRACER 1993-97 MARK VIII 1995-97 MYSTIQUE MERKUR: 1985-89 XR4TI 1988-90 SCORPIO LIGHT TRUCK: 1984-97 F-150-350 SERIES 1986-90 BRONCO II 1986-96 BRONCO 1986-97 AEROSTAR, ECONOLINE, RANGER 1988-97 F SUPER DUTY 1991-97 EXPLORER 1993-97 VILLAGER 1995-97 WINDSTAR This TSB article is being republished in its entirety to update the model years. ISSUE: Customers with concerns of glass fogging (film) and with the chemicals that cause this fog can be advised that Ford Motor Company has extensively tested this material and found that it is not a health hazard. The film is caused by some of the chemicals used during the manufacture of the interior trim. ACTION: At the present time, there is no known field fix to prevent the window fogging, however, glass cleaner such as Ford Glass Cleaner (E4AZ-19C507-AA) has been found to be the best for film removal. PART NUMBER PART NAME E4AZ-19C507-AA Ford Glass cleaner Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Window Glass: > 96221 > Oct > 96 > Windshield/Interior Glass - Fog/Film > Page 7194 OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 86-13-6 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 102000, 107000 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Window Glass: > 93211 > Oct > 93 > Glass - Iridescence or Mottling In Tempered Glass Window Glass: All Technical Service Bulletins Glass - Iridescence or Mottling In Tempered Glass Article No. 93-21-1 10/13/93 GLASS - "IRIDESCENCE" OR "MOTTLING" IN TEMPERED GLASS FORD: 1984-94 CROWN VICTORIA, ESCORT, MUSTANG, TEMPO, THUNDERBIRD 1986-88 EXP 1986-94 TAURUS 1989-93 FESTIVA LINCOLN-MERCURY: 1984-86 CAPRI 1984-87 LYNX 1984-92 MARK VII 1984-94 COUGAR, GRAND MARQUIS, TOPAZ, TOWN CAR 1986-94 SABLE 1988-89 TRACER 1988-94 CONTINENTAL 1991-94 CAPRI, TRACER 1993-94 MARK VIII LIGHT TRUCK: 1984-90 BRONCO II 1984-94 ECONOLINE, F-150-350 SERIES, RANGER 1986-94 AEROSTAR 1991-94 EXPLORER 1993-94 VILLAGER ISSUE: Vehicles may exhibit iridescent spots or "mottling" in tempered glass under some lighting conditions. This condition is caused by the tempering process. ACTION: Explain to customers that "iridescence" or "mottling" of tempered glass is a normal condition and that glass replacement is neither warranted nor necessarily effective in resolving the condition. DESCRIPTION OF CONDITION The somewhat iridescent grayish or blueish and fairly geometric spots detected in side and rear window tempered glass are characteristic of tempered glass. The mottled appearance is noted only under certain conditions of lighting. The occurrence of mottling does not affect glass quality or durability and cannot be reduced by scouring the glass surface. The boldness of the mottled pattern in a given glass may vary, depending upon lighting conditions, but may appear intensified if viewed through polarized sunglasses. CAUSES OF CONDITION Atmospheric dust and other angular reflections can cause changes in the polarized properties of natural light. This polarization, combined with the light polarizing properties imparted to tempered glass by the forces of tension and compression (during the tempering process), cause the iridescent or mottled appearance. These are the same forces of compression and tension which make tempered glass so remarkably strong. Windshields, which are annealed rather than tempered, do not exhibit iridescence. OTHER APPLICABLE ARTICLES: 83-16-4 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 102000 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Window Glass: > 88141 > Jul > 88 > Vent Windows - May Stick to Weatherstrip Window Glass: All Technical Service Bulletins Vent Windows - May Stick to Weatherstrip GLASS - VENT WINDOWS - MANUAL - GLASS STICKS TO WEATHERSTRIP - VEHICLES BUILT BEFORE 4/04/88 Article No. 88-14-1 FORD: 1984-88 ALL CAR LINES LINCOLN-MERCURY: 1984-88 ALL CAR LINES MERKUR: 1985-88 ALL CAR LINES LIGHT TRUCK: 1984-88 ALL LIGHT TRUCK LINES MEDIUM/HEAVY TRUCK: 1984-88 ALL MEDIUM/HEAVY TRUCK LINES ISSUE: Manual vent windows that are not opened very often may stick to the vent window weatherstrip making them hard to open. In some cases, the high opening efforts may cause the weatherstrip to pull out of the vent division bar. ACTION: To correct this, apply "Krytox" oil to the vent window weatherstrip using the following service procedure. FIGURE 1 1. Open the vent window all the way. 2. From inside of vehicle, apply "Krytox" oil on the weatherstrip sealing lips of vent window, Figure 1. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Window Glass: > 88141 > Jul > 88 > Vent Windows - May Stick to Weatherstrip > Page 7203 FIGURE 2 3. From outside of vehicle, apply "Krytox" oil on the weatherstrip sealing lips of vent window, Figure 2. 4. Close and open vent window to make sure window operates correctly. NOTE: CONTACT EXCEL INDUSTRIES, INC. TO ORDER "KRYTOX" OIL: (904) 286-8300 EXTENSION 305 REPRESENTATIVE: RACHEL FLYNN. OTHER APPLICABLE ARTICLES: Supersedes 87-11-2 WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION: 881401A TIME: 0.3 Hr. DLR. CODING: Basic Part No. 7022296 - Car 7021448 - Truck Condition Code: 41 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Window Glass: > 8852 > Mar > 88 > Manual Vent Windows - Difficult to Open Window Glass: All Technical Service Bulletins Manual Vent Windows - Difficult to Open GLASS - MANUAL VENT WINDOWS HARD TO OPEN Article No. 88-5-2 FORD: 1980-88 CROWN VICTORIA 1981-86 THUNDERBIRD 1981-87 ESCORT 1984-86 LTD LINCOLN-MERCURY: 1980-88 GRAND MARQUIS 1981-86 LYNX, COUGAR 1984-86 MARQUIS LIGHT TRUCK: 1980-88 E-SERIES, F-SERIES, BRONCO 1983-88 RANGER 1984-88 BRONCO II 1986-88 AEROSTAR ISSUE: Hard to open pivoting type vent windows may be caused by the glass sticking to the weatherstrip on the division bar. The weatherstrip is often pulled out of the division bar when this condition is present. FIGURE 1 ACTION: To correct this, apply a strip of clear pressure sensitive tape on the inside vertical edge of the vent window glass, Figure 1. PART NUMBER PART NAME CLASS E8AZ-19627-A Clear Pressure Sensitive B Tape OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION: 880502A - Both vent windows TIME: 0.3 Hr. DLR. CODING: Basic Part No. 7021402 Code: 41 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Window Glass: > 87112 > Jun > 87 > Manual Vent Windows - Hard to Open Window Glass: All Technical Service Bulletins Manual Vent Windows - Hard to Open Article No. GLASS - VENT WINDOWS - MANUAL 87-11-2 HARD TO OPEN FORD: 1984-87 ALL CAR LINES LINCOLN-MERCURY: 1984-87 ALL CAR LINES LIGHT TRUCK: 1984-87 ALL LIGHT TRUCK LINES Figure 2 - Article 87-11-2 ISSUE: Manual vent windows that are not opened very often may stick to the vent window weatherstrip which makes them hard to open. ACTION: To correct this, apply a thin coating of Silicone Lubricant (COAZ-19553-AA) to the vent window weatherstrip as shown in Figure 2. This lubricant can be applied during dealer prep and/or normal customer service visits. NOTE: DO NOT USE AEROSOL SPRAY CANS. PART NUMBER PART NAME CLASS COAZ-19553-AA Silicone Lubricant B OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual OPERATION: SP871102A - Both sides TIME: 0.3 Hr. DLR. CODING: Basic Part No. 7021448 Code: 41 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Component Information > Technical Service Bulletins > All Other Service Bulletins for Window Glass: > 96221 > Oct > 96 > Windshield/Interior Glass - Fog/Film Window Glass: All Technical Service Bulletins Windshield/Interior Glass - Fog/Film Article No. 96-22-1 10/21/96 WINDSHIELD AND INTERIOR GLASS - FOG/FILM FORD: 1984-86 LTD 1984-88 EXP 1984-94 TEMPO 1984-97 CROWN VICTORIA, ESCORT, MUSTANG, THUNDERBIRD 1986-97 TAURUS 1988-93 FESTIVA 1989-97 PROBE 1994-97 ASPIRE 1995-97 CONTOUR LINCOLN-MERCURY: 1984-86 MARQUIS 1984-87 LN7, LYNX 1984-92 MARK VII 1984-94 TOPAZ 1984-97 CONTINENTAL, COUGAR, GRAND MARQUIS, TOWN CAR 1986-97 SABLE 1987-89 TRACER 1991-94 CAPRI 1991-97 TRACER 1993-97 MARK VIII 1995-97 MYSTIQUE MERKUR: 1985-89 XR4TI 1988-90 SCORPIO LIGHT TRUCK: 1984-97 F-150-350 SERIES 1986-90 BRONCO II 1986-96 BRONCO 1986-97 AEROSTAR, ECONOLINE, RANGER 1988-97 F SUPER DUTY 1991-97 EXPLORER 1993-97 VILLAGER 1995-97 WINDSTAR This TSB article is being republished in its entirety to update the model years. ISSUE: Customers with concerns of glass fogging (film) and with the chemicals that cause this fog can be advised that Ford Motor Company has extensively tested this material and found that it is not a health hazard. The film is caused by some of the chemicals used during the manufacture of the interior trim. ACTION: At the present time, there is no known field fix to prevent the window fogging, however, glass cleaner such as Ford Glass Cleaner (E4AZ-19C507-AA) has been found to be the best for film removal. PART NUMBER PART NAME E4AZ-19C507-AA Ford Glass cleaner Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Component Information > Technical Service Bulletins > All Other Service Bulletins for Window Glass: > 96221 > Oct > 96 > Windshield/Interior Glass - Fog/Film > Page 7217 OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 86-13-6 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 102000, 107000 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Component Information > Technical Service Bulletins > All Other Service Bulletins for Window Glass: > 93211 > Oct > 93 > Glass - Iridescence or Mottling In Tempered Glass Window Glass: All Technical Service Bulletins Glass - Iridescence or Mottling In Tempered Glass Article No. 93-21-1 10/13/93 GLASS - "IRIDESCENCE" OR "MOTTLING" IN TEMPERED GLASS FORD: 1984-94 CROWN VICTORIA, ESCORT, MUSTANG, TEMPO, THUNDERBIRD 1986-88 EXP 1986-94 TAURUS 1989-93 FESTIVA LINCOLN-MERCURY: 1984-86 CAPRI 1984-87 LYNX 1984-92 MARK VII 1984-94 COUGAR, GRAND MARQUIS, TOPAZ, TOWN CAR 1986-94 SABLE 1988-89 TRACER 1988-94 CONTINENTAL 1991-94 CAPRI, TRACER 1993-94 MARK VIII LIGHT TRUCK: 1984-90 BRONCO II 1984-94 ECONOLINE, F-150-350 SERIES, RANGER 1986-94 AEROSTAR 1991-94 EXPLORER 1993-94 VILLAGER ISSUE: Vehicles may exhibit iridescent spots or "mottling" in tempered glass under some lighting conditions. This condition is caused by the tempering process. ACTION: Explain to customers that "iridescence" or "mottling" of tempered glass is a normal condition and that glass replacement is neither warranted nor necessarily effective in resolving the condition. DESCRIPTION OF CONDITION The somewhat iridescent grayish or blueish and fairly geometric spots detected in side and rear window tempered glass are characteristic of tempered glass. The mottled appearance is noted only under certain conditions of lighting. The occurrence of mottling does not affect glass quality or durability and cannot be reduced by scouring the glass surface. The boldness of the mottled pattern in a given glass may vary, depending upon lighting conditions, but may appear intensified if viewed through polarized sunglasses. CAUSES OF CONDITION Atmospheric dust and other angular reflections can cause changes in the polarized properties of natural light. This polarization, combined with the light polarizing properties imparted to tempered glass by the forces of tension and compression (during the tempering process), cause the iridescent or mottled appearance. These are the same forces of compression and tension which make tempered glass so remarkably strong. Windshields, which are annealed rather than tempered, do not exhibit iridescence. OTHER APPLICABLE ARTICLES: 83-16-4 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 102000 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Windows and Glass > Windows > Window Seal > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Window Seal: > 88141 > Jul > 88 > Vent Windows - May Stick to Weatherstrip Window Seal: All Technical Service Bulletins Vent Windows - May Stick to Weatherstrip GLASS - VENT WINDOWS - MANUAL - GLASS STICKS TO WEATHERSTRIP - VEHICLES BUILT BEFORE 4/04/88 Article No. 88-14-1 FORD: 1984-88 ALL CAR LINES LINCOLN-MERCURY: 1984-88 ALL CAR LINES MERKUR: 1985-88 ALL CAR LINES LIGHT TRUCK: 1984-88 ALL LIGHT TRUCK LINES MEDIUM/HEAVY TRUCK: 1984-88 ALL MEDIUM/HEAVY TRUCK LINES ISSUE: Manual vent windows that are not opened very often may stick to the vent window weatherstrip making them hard to open. In some cases, the high opening efforts may cause the weatherstrip to pull out of the vent division bar. ACTION: To correct this, apply "Krytox" oil to the vent window weatherstrip using the following service procedure. FIGURE 1 1. Open the vent window all the way. 2. From inside of vehicle, apply "Krytox" oil on the weatherstrip sealing lips of vent window, Figure 1. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Windows and Glass > Windows > Window Seal > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Window Seal: > 88141 > Jul > 88 > Vent Windows - May Stick to Weatherstrip > Page 7230 FIGURE 2 3. From outside of vehicle, apply "Krytox" oil on the weatherstrip sealing lips of vent window, Figure 2. 4. Close and open vent window to make sure window operates correctly. NOTE: CONTACT EXCEL INDUSTRIES, INC. TO ORDER "KRYTOX" OIL: (904) 286-8300 EXTENSION 305 REPRESENTATIVE: RACHEL FLYNN. OTHER APPLICABLE ARTICLES: Supersedes 87-11-2 WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION: 881401A TIME: 0.3 Hr. DLR. CODING: Basic Part No. 7022296 - Car 7021448 - Truck Condition Code: 41 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Windows and Glass > Windows > Window Seal > Component Information > Technical Service Bulletins > Customer Interest for Window Seal: > 88141 > Jul > 88 > Vent Windows - May Stick to Weatherstrip Window Seal: Customer Interest Vent Windows - May Stick to Weatherstrip GLASS - VENT WINDOWS - MANUAL - GLASS STICKS TO WEATHERSTRIP - VEHICLES BUILT BEFORE 4/04/88 Article No. 88-14-1 FORD: 1984-88 ALL CAR LINES LINCOLN-MERCURY: 1984-88 ALL CAR LINES MERKUR: 1985-88 ALL CAR LINES LIGHT TRUCK: 1984-88 ALL LIGHT TRUCK LINES MEDIUM/HEAVY TRUCK: 1984-88 ALL MEDIUM/HEAVY TRUCK LINES ISSUE: Manual vent windows that are not opened very often may stick to the vent window weatherstrip making them hard to open. In some cases, the high opening efforts may cause the weatherstrip to pull out of the vent division bar. ACTION: To correct this, apply "Krytox" oil to the vent window weatherstrip using the following service procedure. FIGURE 1 1. Open the vent window all the way. 2. From inside of vehicle, apply "Krytox" oil on the weatherstrip sealing lips of vent window, Figure 1. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Windows and Glass > Windows > Window Seal > Component Information > Technical Service Bulletins > Customer Interest for Window Seal: > 88141 > Jul > 88 > Vent Windows - May Stick to Weatherstrip > Page 7236 FIGURE 2 3. From outside of vehicle, apply "Krytox" oil on the weatherstrip sealing lips of vent window, Figure 2. 4. Close and open vent window to make sure window operates correctly. NOTE: CONTACT EXCEL INDUSTRIES, INC. TO ORDER "KRYTOX" OIL: (904) 286-8300 EXTENSION 305 REPRESENTATIVE: RACHEL FLYNN. OTHER APPLICABLE ARTICLES: Supersedes 87-11-2 WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION: 881401A TIME: 0.3 Hr. DLR. CODING: Basic Part No. 7022296 - Car 7021448 - Truck Condition Code: 41 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Windows and Glass > Windows > Window Track > Component Information > Technical Service Bulletins > Customer Interest for Window Track: > 852416 > Dec > 85 > Door Glass Run Assembly - Drops Out of Channel Window Track: Customer Interest Door Glass Run Assembly - Drops Out of Channel Article No. 85-24-16 DOOR - GLASS RUN ASSEMBLY - DROPS OUT OF CHANNEL BUILT PRIOR TO DECEMBER 2, 1985 LIGHT TRUCK 1985-86 F SERIES, BRONCO The door glass run assembly may drop out of the door channel when the glass is rolled down. This is caused by manufacturing process variations to the door frame allowing inconsistent retention of the run assemblies. Figure 33 - DOOR GLASS RUN ASSEMBLY -DROPS OUT OF DOOR FRAME CHANNEL 1985-86 F SERIES AND BRONCO Dealers encountering customer complaints of dropping door glass run assemblies may add weatherstrip adhesive (Ford P & A No. C0AZ-19552-A) to the flat surface of the run assembly and reinstall it into the door frame. An alternate method of repair would be to apply a strip of double-backed adhesive tape (3M Part No. 06379 Scotch Mount Attachment Tape) 15 inches long by 1/2 inch wide to door frame channel. See Figure 33. PART NUMBER PART NAME CLASS C0AZ-19552-A Sealer AG OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION: SP21536A85 TIME: 0.3 Hr. DLR. CODING: Basic Part No. 7020124 - Code: 02 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Windows and Glass > Windows > Window Track > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Window Track: > 852416 > Dec > 85 > Door Glass Run Assembly - Drops Out of Channel Window Track: All Technical Service Bulletins Door Glass Run Assembly - Drops Out of Channel Article No. 85-24-16 DOOR - GLASS RUN ASSEMBLY - DROPS OUT OF CHANNEL BUILT PRIOR TO DECEMBER 2, 1985 LIGHT TRUCK 1985-86 F SERIES, BRONCO The door glass run assembly may drop out of the door channel when the glass is rolled down. This is caused by manufacturing process variations to the door frame allowing inconsistent retention of the run assemblies. Figure 33 - DOOR GLASS RUN ASSEMBLY -DROPS OUT OF DOOR FRAME CHANNEL 1985-86 F SERIES AND BRONCO Dealers encountering customer complaints of dropping door glass run assemblies may add weatherstrip adhesive (Ford P & A No. C0AZ-19552-A) to the flat surface of the run assembly and reinstall it into the door frame. An alternate method of repair would be to apply a strip of double-backed adhesive tape (3M Part No. 06379 Scotch Mount Attachment Tape) 15 inches long by 1/2 inch wide to door frame channel. See Figure 33. PART NUMBER PART NAME CLASS C0AZ-19552-A Sealer AG OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION: SP21536A85 TIME: 0.3 Hr. DLR. CODING: Basic Part No. 7020124 - Code: 02 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > Recalls: > NHTSA93E039000 > Nov > 93 > Recall 93E039000: Incorrect Glass Markings Windshield: Recalls Recall 93E039000: Incorrect Glass Markings THE WINDSHIELDS DO NOT MEET THE MARKING REQUIREMENTS OF FMVSS NO. 205, "GLAZING MATERIALS." THE WINDSHIELDS ARE NOT IDENTIFIED AS TO THE TYPE OF GLASS USED. HOWEVER, THE WINDSHIELDS COMPLY FULLY WITH THE PERFORMANCE REQUIREMENTS OF FMVSS NO. 205. SEE NOTE BELOW. SYSTEM: VISUAL SYSTEMS; GLASS; WINDSHIELD. VEHICLE DESCRIPTION: AFTERMARKET WINDSHIELDS FOR LIGHT DUTY TRUCKS. NOTE: THE MANUFACTURER'S PETITION WHICH REQUESTED THAT NHTSA DETERMINE THIS FMVSS NON-COMPLIANCE DOES NOT CREATE AN UNREASONABLE RISK TO MOTOR VEHICLE SAFETY HAS BEEN GRANTED. THEREFORE, THE MANUFACTURER IS NOT OBLIGATED TO CONDUCT AN OWNER NOTIFICATION AND REMEDY CAMPAIGN. 1980 FORD TRUCK BRONCO 1980 FORD TRUCK F SUPER DUTY 1980 FORD TRUCK F150 1980 FORD TRUCK F250 1980 FORD TRUCK F350 1980 FORD TRUCK F600 1980 FORD TRUCK F700 1980 FORD TRUCK F800 1981 FORD TRUCK BRONCO 1981 FORD TRUCK F SUPER DUTY 1981 FORD TRUCK F150 1981 FORD TRUCK F250 1981 FORD TRUCK F350 1981 FORD TRUCK F600 1981 FORD TRUCK F700 1981 FORD TRUCK F800 1982 FORD TRUCK BRONCO 1982 FORD TRUCK F SUPER DUTY 1982 FORD TRUCK F150 1982 FORD TRUCK F250 1982 FORD TRUCK F350 1982 FORD TRUCK F600 1982 FORD TRUCK F700 1982 FORD TRUCK F800 1983 FORD TRUCK BRONCO 1983 FORD TRUCK F SUPER DUTY 1983 FORD TRUCK F150 1983 FORD TRUCK F250 1983 FORD TRUCK F350 1983 FORD TRUCK F600 1983 FORD TRUCK F700 1983 FORD TRUCK F800 1984 FORD TRUCK BRONCO 1984 FORD TRUCK F SUPER DUTY 1984 FORD TRUCK F150 1984 FORD TRUCK F250 1984 FORD TRUCK F350 1984 FORD TRUCK F600 1984 FORD TRUCK F700 1984 FORD TRUCK F800 1985 FORD TRUCK BRONCO 1985 FORD TRUCK F SUPER DUTY 1985 FORD TRUCK F150 1985 FORD TRUCK F250 1985 FORD TRUCK F350 1985 FORD TRUCK F600 1985 FORD TRUCK F700 1985 FORD TRUCK F800 1986 FORD TRUCK BRONCO 1986 FORD TRUCK F SUPER DUTY Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > Recalls: > NHTSA93E039000 > Nov > 93 > Recall 93E039000: Incorrect Glass Markings > Page 7258 1986 FORD TRUCK F150 1986 FORD TRUCK F250 1986 FORD TRUCK F350 1986 FORD TRUCK F600 1986 FORD TRUCK F700 1986 FORD TRUCK F800 1987 FORD TRUCK BRONCO 1987 FORD TRUCK F SUPER DUTY 1987 FORD TRUCK F150 1987 FORD TRUCK F250 1987 FORD TRUCK F350 1987 FORD TRUCK F600 1987 FORD TRUCK F700 1987 FORD TRUCK F800 1988 FORD TRUCK BRONCO 1988 FORD TRUCK F SUPER DUTY 1988 FORD TRUCK F150 1988 FORD TRUCK F250 1988 FORD TRUCK F350 1988 FORD TRUCK F600 1988 FORD TRUCK F700 1988 FORD TRUCK F800 1989 FORD TRUCK BRONCO 1989 FORD TRUCK F SUPER DUTY 1989 FORD TRUCK F150 1989 FORD TRUCK F250 1989 FORD TRUCK F350 1989 FORD TRUCK F600 1989 FORD TRUCK F700 1989 FORD TRUCK F800 1990 FORD TRUCK BRONCO 1990 FORD TRUCK F SUPER DUTY 1990 FORD TRUCK F150 1990 FORD TRUCK F250 1990 FORD TRUCK F350 1990 FORD TRUCK F600 1990 FORD TRUCK F700 1990 FORD TRUCK F800 1991 FORD TRUCK BRONCO 1991 FORD TRUCK F SUPER DUTY 1991 FORD TRUCK F150 1991 FORD TRUCK F250 1991 FORD TRUCK F350 1991 FORD TRUCK F600 1991 FORD TRUCK F700 1991 FORD TRUCK F800 1992 FORD TRUCK BRONCO 1992 FORD TRUCK F SUPER DUTY 1992 FORD TRUCK F150 1992 FORD TRUCK F250 1992 FORD TRUCK F350 1992 FORD TRUCK F600 1992 FORD TRUCK F700 1992 FORD TRUCK F800 1993 FORD TRUCK BRONCO 1993 FORD TRUCK F SUPER DUTY 1993 FORD TRUCK F150 1993 FORD TRUCK F250 1993 FORD TRUCK F350 1993 FORD TRUCK F600 1993 FORD TRUCK F700 1993 FORD TRUCK F800 1994 FORD TRUCK BRONCO 1994 FORD TRUCK F SUPER DUTY 1994 FORD TRUCK F150 1994 FORD TRUCK F250 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > Recalls: > NHTSA93E039000 > Nov > 93 > Recall 93E039000: Incorrect Glass Markings > Page 7259 1994 FORD TRUCK F350 1994 FORD TRUCK F600 1994 FORD TRUCK F700 1994 FORD TRUCK F800 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Windshield: > 96221 > Oct > 96 > Windshield/Interior Glass - Fog/Film Windshield: All Technical Service Bulletins Windshield/Interior Glass - Fog/Film Article No. 96-22-1 10/21/96 WINDSHIELD AND INTERIOR GLASS - FOG/FILM FORD: 1984-86 LTD 1984-88 EXP 1984-94 TEMPO 1984-97 CROWN VICTORIA, ESCORT, MUSTANG, THUNDERBIRD 1986-97 TAURUS 1988-93 FESTIVA 1989-97 PROBE 1994-97 ASPIRE 1995-97 CONTOUR LINCOLN-MERCURY: 1984-86 MARQUIS 1984-87 LN7, LYNX 1984-92 MARK VII 1984-94 TOPAZ 1984-97 CONTINENTAL, COUGAR, GRAND MARQUIS, TOWN CAR 1986-97 SABLE 1987-89 TRACER 1991-94 CAPRI 1991-97 TRACER 1993-97 MARK VIII 1995-97 MYSTIQUE MERKUR: 1985-89 XR4TI 1988-90 SCORPIO LIGHT TRUCK: 1984-97 F-150-350 SERIES 1986-90 BRONCO II 1986-96 BRONCO 1986-97 AEROSTAR, ECONOLINE, RANGER 1988-97 F SUPER DUTY 1991-97 EXPLORER 1993-97 VILLAGER 1995-97 WINDSTAR This TSB article is being republished in its entirety to update the model years. ISSUE: Customers with concerns of glass fogging (film) and with the chemicals that cause this fog can be advised that Ford Motor Company has extensively tested this material and found that it is not a health hazard. The film is caused by some of the chemicals used during the manufacture of the interior trim. ACTION: At the present time, there is no known field fix to prevent the window fogging, however, glass cleaner such as Ford Glass Cleaner (E4AZ-19C507-AA) has been found to be the best for film removal. PART NUMBER PART NAME E4AZ-19C507-AA Ford Glass cleaner Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Windshield: > 96221 > Oct > 96 > Windshield/Interior Glass - Fog/Film > Page 7265 OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 86-13-6 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 102000, 107000 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Windshield: > NHTSA93E039000 > Nov > 93 > Recall 93E039000: Incorrect Glass Markings Windshield: All Technical Service Bulletins Recall 93E039000: Incorrect Glass Markings THE WINDSHIELDS DO NOT MEET THE MARKING REQUIREMENTS OF FMVSS NO. 205, "GLAZING MATERIALS." THE WINDSHIELDS ARE NOT IDENTIFIED AS TO THE TYPE OF GLASS USED. HOWEVER, THE WINDSHIELDS COMPLY FULLY WITH THE PERFORMANCE REQUIREMENTS OF FMVSS NO. 205. SEE NOTE BELOW. SYSTEM: VISUAL SYSTEMS; GLASS; WINDSHIELD. VEHICLE DESCRIPTION: AFTERMARKET WINDSHIELDS FOR LIGHT DUTY TRUCKS. NOTE: THE MANUFACTURER'S PETITION WHICH REQUESTED THAT NHTSA DETERMINE THIS FMVSS NON-COMPLIANCE DOES NOT CREATE AN UNREASONABLE RISK TO MOTOR VEHICLE SAFETY HAS BEEN GRANTED. THEREFORE, THE MANUFACTURER IS NOT OBLIGATED TO CONDUCT AN OWNER NOTIFICATION AND REMEDY CAMPAIGN. 1980 FORD TRUCK BRONCO 1980 FORD TRUCK F SUPER DUTY 1980 FORD TRUCK F150 1980 FORD TRUCK F250 1980 FORD TRUCK F350 1980 FORD TRUCK F600 1980 FORD TRUCK F700 1980 FORD TRUCK F800 1981 FORD TRUCK BRONCO 1981 FORD TRUCK F SUPER DUTY 1981 FORD TRUCK F150 1981 FORD TRUCK F250 1981 FORD TRUCK F350 1981 FORD TRUCK F600 1981 FORD TRUCK F700 1981 FORD TRUCK F800 1982 FORD TRUCK BRONCO 1982 FORD TRUCK F SUPER DUTY 1982 FORD TRUCK F150 1982 FORD TRUCK F250 1982 FORD TRUCK F350 1982 FORD TRUCK F600 1982 FORD TRUCK F700 1982 FORD TRUCK F800 1983 FORD TRUCK BRONCO 1983 FORD TRUCK F SUPER DUTY 1983 FORD TRUCK F150 1983 FORD TRUCK F250 1983 FORD TRUCK F350 1983 FORD TRUCK F600 1983 FORD TRUCK F700 1983 FORD TRUCK F800 1984 FORD TRUCK BRONCO 1984 FORD TRUCK F SUPER DUTY 1984 FORD TRUCK F150 1984 FORD TRUCK F250 1984 FORD TRUCK F350 1984 FORD TRUCK F600 1984 FORD TRUCK F700 1984 FORD TRUCK F800 1985 FORD TRUCK BRONCO 1985 FORD TRUCK F SUPER DUTY 1985 FORD TRUCK F150 1985 FORD TRUCK F250 1985 FORD TRUCK F350 1985 FORD TRUCK F600 1985 FORD TRUCK F700 1985 FORD TRUCK F800 1986 FORD TRUCK BRONCO 1986 FORD TRUCK F SUPER DUTY Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Windshield: > NHTSA93E039000 > Nov > 93 > Recall 93E039000: Incorrect Glass Markings > Page 7270 1986 FORD TRUCK F150 1986 FORD TRUCK F250 1986 FORD TRUCK F350 1986 FORD TRUCK F600 1986 FORD TRUCK F700 1986 FORD TRUCK F800 1987 FORD TRUCK BRONCO 1987 FORD TRUCK F SUPER DUTY 1987 FORD TRUCK F150 1987 FORD TRUCK F250 1987 FORD TRUCK F350 1987 FORD TRUCK F600 1987 FORD TRUCK F700 1987 FORD TRUCK F800 1988 FORD TRUCK BRONCO 1988 FORD TRUCK F SUPER DUTY 1988 FORD TRUCK F150 1988 FORD TRUCK F250 1988 FORD TRUCK F350 1988 FORD TRUCK F600 1988 FORD TRUCK F700 1988 FORD TRUCK F800 1989 FORD TRUCK BRONCO 1989 FORD TRUCK F SUPER DUTY 1989 FORD TRUCK F150 1989 FORD TRUCK F250 1989 FORD TRUCK F350 1989 FORD TRUCK F600 1989 FORD TRUCK F700 1989 FORD TRUCK F800 1990 FORD TRUCK BRONCO 1990 FORD TRUCK F SUPER DUTY 1990 FORD TRUCK F150 1990 FORD TRUCK F250 1990 FORD TRUCK F350 1990 FORD TRUCK F600 1990 FORD TRUCK F700 1990 FORD TRUCK F800 1991 FORD TRUCK BRONCO 1991 FORD TRUCK F SUPER DUTY 1991 FORD TRUCK F150 1991 FORD TRUCK F250 1991 FORD TRUCK F350 1991 FORD TRUCK F600 1991 FORD TRUCK F700 1991 FORD TRUCK F800 1992 FORD TRUCK BRONCO 1992 FORD TRUCK F SUPER DUTY 1992 FORD TRUCK F150 1992 FORD TRUCK F250 1992 FORD TRUCK F350 1992 FORD TRUCK F600 1992 FORD TRUCK F700 1992 FORD TRUCK F800 1993 FORD TRUCK BRONCO 1993 FORD TRUCK F SUPER DUTY 1993 FORD TRUCK F150 1993 FORD TRUCK F250 1993 FORD TRUCK F350 1993 FORD TRUCK F600 1993 FORD TRUCK F700 1993 FORD TRUCK F800 1994 FORD TRUCK BRONCO 1994 FORD TRUCK F SUPER DUTY 1994 FORD TRUCK F150 1994 FORD TRUCK F250 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Windshield: > NHTSA93E039000 > Nov > 93 > Recall 93E039000: Incorrect Glass Markings > Page 7271 1994 FORD TRUCK F350 1994 FORD TRUCK F600 1994 FORD TRUCK F700 1994 FORD TRUCK F800 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > All Other Service Bulletins for Windshield: > 96221 > Oct > 96 > Windshield/Interior Glass - Fog/Film Windshield: All Technical Service Bulletins Windshield/Interior Glass - Fog/Film Article No. 96-22-1 10/21/96 WINDSHIELD AND INTERIOR GLASS - FOG/FILM FORD: 1984-86 LTD 1984-88 EXP 1984-94 TEMPO 1984-97 CROWN VICTORIA, ESCORT, MUSTANG, THUNDERBIRD 1986-97 TAURUS 1988-93 FESTIVA 1989-97 PROBE 1994-97 ASPIRE 1995-97 CONTOUR LINCOLN-MERCURY: 1984-86 MARQUIS 1984-87 LN7, LYNX 1984-92 MARK VII 1984-94 TOPAZ 1984-97 CONTINENTAL, COUGAR, GRAND MARQUIS, TOWN CAR 1986-97 SABLE 1987-89 TRACER 1991-94 CAPRI 1991-97 TRACER 1993-97 MARK VIII 1995-97 MYSTIQUE MERKUR: 1985-89 XR4TI 1988-90 SCORPIO LIGHT TRUCK: 1984-97 F-150-350 SERIES 1986-90 BRONCO II 1986-96 BRONCO 1986-97 AEROSTAR, ECONOLINE, RANGER 1988-97 F SUPER DUTY 1991-97 EXPLORER 1993-97 VILLAGER 1995-97 WINDSTAR This TSB article is being republished in its entirety to update the model years. ISSUE: Customers with concerns of glass fogging (film) and with the chemicals that cause this fog can be advised that Ford Motor Company has extensively tested this material and found that it is not a health hazard. The film is caused by some of the chemicals used during the manufacture of the interior trim. ACTION: At the present time, there is no known field fix to prevent the window fogging, however, glass cleaner such as Ford Glass Cleaner (E4AZ-19C507-AA) has been found to be the best for film removal. PART NUMBER PART NAME E4AZ-19C507-AA Ford Glass cleaner Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > All Other Service Bulletins for Windshield: > 96221 > Oct > 96 > Windshield/Interior Glass - Fog/Film > Page 7277 OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 86-13-6 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 102000, 107000 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield Washer Relay > Component Information > Diagrams > Diagram Information and Instructions Windshield Washer Relay: Diagram Information and Instructions Symbol Identification Wire Color Code Identification Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield Washer Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7284 NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield Washer Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7285 Windshield Washer Relay: Electrical Diagrams Fig. 52 Windshield Wiper/Washer Wiring Circuit (L/Interval Wipers) Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield Washer Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7286 Fig. 53 Windshield Wiper/Washer Wiring Circuit (W/Interval Wipers) Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Locations Wiper Control Module: Locations Behind LH Corner Of I/P Under LH Side Of I/P Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams > Diagram Information and Instructions Wiper Relay: Diagram Information and Instructions Symbol Identification Wire Color Code Identification Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7294 NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7295 Wiper Relay: Electrical Diagrams Fig. 52 Windshield Wiper/Washer Wiring Circuit (L/Interval Wipers) Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7296 Fig. 53 Windshield Wiper/Washer Wiring Circuit (W/Interval Wipers) Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Diagram Information and Instructions Windshield Washer Switch: Diagram Information and Instructions Symbol Identification Wire Color Code Identification Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7302 NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7303 Windshield Washer Switch: Electrical Diagrams Fig. 52 Windshield Wiper/Washer Wiring Circuit (L/Interval Wipers) Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7304 Fig. 53 Windshield Wiper/Washer Wiring Circuit (W/Interval Wipers) Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Locations Wiper Switch: Locations Back View Of I/P On LH Side Of I/P Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Diagram Information and Instructions Wiper Switch: Diagram Information and Instructions Symbol Identification Wire Color Code Identification Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7310 NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7311 Wiper Switch: Electrical Diagrams Fig. 52 Windshield Wiper/Washer Wiring Circuit (L/Interval Wipers) Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7312 Fig. 53 Windshield Wiper/Washer Wiring Circuit (W/Interval Wipers) Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Page 7313 Wiper Switch: Testing and Inspection Fig. 4 Wiper Switch Continuity Test Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Page 7314 Fig. 5 Testing wiper switch continuity. 1980 Bronco & F-100---350 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Page 7315 Fig. 5 Wiper Switch Continuity Test 1. Check continuity between switch terminals, Figs. 4 through 6. 2. To detect marginal operation of switch, rotate or slide switch control knob while each reading is being taken. 3. If switch does not show continuity or if poor continuity exists at any switch position, replace switch. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Page 7316 Wiper Switch: Service and Repair F-100---350 & BRONCO 1. Disconnect battery ground cable. 2. Remove wiper switch knob, bezel nut and bezel. 3. Pull switch down from under instrument panel, then disconnect electrical connector and remove switch from vehicle. 4. Reverse procedure to install. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Motor > Component Information > Locations Windshield Washer Motor: Locations In Washer Reservoir Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Motor > Component Information > Diagrams > Diagram Information and Instructions Windshield Washer Motor: Diagram Information and Instructions Symbol Identification Wire Color Code Identification Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7322 NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7323 Windshield Washer Motor: Electrical Diagrams Fig. 52 Windshield Wiper/Washer Wiring Circuit (L/Interval Wipers) Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7324 Fig. 53 Windshield Wiper/Washer Wiring Circuit (W/Interval Wipers) Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Diagrams > Diagram Information and Instructions Windshield Washer Pump: Diagram Information and Instructions Symbol Identification Wire Color Code Identification Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Diagrams > Diagram Information and Instructions > Page 7329 NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Diagrams > Diagram Information and Instructions > Page 7330 Windshield Washer Pump: Electrical Diagrams Fig. 52 Windshield Wiper/Washer Wiring Circuit (L/Interval Wipers) Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Diagrams > Diagram Information and Instructions > Page 7331 Fig. 53 Windshield Wiper/Washer Wiring Circuit (W/Interval Wipers) Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Relay > Component Information > Diagrams > Diagram Information and Instructions Windshield Washer Relay: Diagram Information and Instructions Symbol Identification Wire Color Code Identification Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7336 NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7337 Windshield Washer Relay: Electrical Diagrams Fig. 52 Windshield Wiper/Washer Wiring Circuit (L/Interval Wipers) Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7338 Fig. 53 Windshield Wiper/Washer Wiring Circuit (W/Interval Wipers) Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Diagram Information and Instructions Windshield Washer Switch: Diagram Information and Instructions Symbol Identification Wire Color Code Identification Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7343 NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7344 Windshield Washer Switch: Electrical Diagrams Fig. 52 Windshield Wiper/Washer Wiring Circuit (L/Interval Wipers) Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7345 Fig. 53 Windshield Wiper/Washer Wiring Circuit (W/Interval Wipers) Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Technical Service Bulletins > Customer Interest for Wiper Arm: > 87530 > Mar > 87 > Windshield Wipers - Blades Skip and Leave Unwiped Areas Wiper Arm: Customer Interest Windshield Wipers - Blades Skip and Leave Unwiped Areas WINDSHIELD WIPERS - BLADES SKIP AND LEAVE Article No. UNWIPED AREAS 87-5-30 LIGHT TRUCK 1986 F-150/350, BRONCO ISSUE: Windshield wiper blades that skip and leave unwiped areas on the windshield when the vehicle is driven at or above 35 mph/56 km/h may be caused by the wiper arm assembly. The latch component on the wiper arm assembly may restrict downward pressure of the arm on the windshield. ACTION: To correct this, install two (2) new wiper arm assemblies (E4TZ-17526-C) using the following service procedure. 1. Switch the wiper arm and blade assemblies from right to left. 2. Road test the vehicle at speeds above 35 mph/56 km/h with the windshield wipers turned on. Use windshield washer spray if required. 3. If the condition still exists, replace both wiper arm assemblies. DO NOT replace the wiper blade(s). Refer to the 1986 Light Truck Shop Manual, Volume A, Section 35-60 for the removal and installation of the wiper arm assemblies. PART NUMBER PART NAME CLASS E4TZ-17526-C Wiper Arm Assembly - A 2 Required OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual OPERATION: SP870530A - Steps 1-2 TIME: 0.4 Hr. OPERATION: SP870530B - Steps 1-3 TIME: 0.5 Hr. DLR. CODING: Basic Part No. 17526 - Code: 02 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiper Arm: > 87530 > Mar > 87 > Windshield Wipers - Blades Skip and Leave Unwiped Areas Wiper Arm: All Technical Service Bulletins Windshield Wipers - Blades Skip and Leave Unwiped Areas WINDSHIELD WIPERS - BLADES SKIP AND LEAVE Article No. UNWIPED AREAS 87-5-30 LIGHT TRUCK 1986 F-150/350, BRONCO ISSUE: Windshield wiper blades that skip and leave unwiped areas on the windshield when the vehicle is driven at or above 35 mph/56 km/h may be caused by the wiper arm assembly. The latch component on the wiper arm assembly may restrict downward pressure of the arm on the windshield. ACTION: To correct this, install two (2) new wiper arm assemblies (E4TZ-17526-C) using the following service procedure. 1. Switch the wiper arm and blade assemblies from right to left. 2. Road test the vehicle at speeds above 35 mph/56 km/h with the windshield wipers turned on. Use windshield washer spray if required. 3. If the condition still exists, replace both wiper arm assemblies. DO NOT replace the wiper blade(s). Refer to the 1986 Light Truck Shop Manual, Volume A, Section 35-60 for the removal and installation of the wiper arm assemblies. PART NUMBER PART NAME CLASS E4TZ-17526-C Wiper Arm Assembly - A 2 Required OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual OPERATION: SP870530A - Steps 1-2 TIME: 0.4 Hr. OPERATION: SP870530B - Steps 1-3 TIME: 0.5 Hr. DLR. CODING: Basic Part No. 17526 - Code: 02 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Locations Wiper Control Module: Locations Behind LH Corner Of I/P Under LH Side Of I/P Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Gear Box > Component Information > Service and Repair Wiper Gear Box: Service and Repair 1. Disconnect battery ground cable. 2. Remove both wiper arm and blade assemblies. 3. Remove cowl grille attaching screws and raise the grille slightly. 4. Disconnect windshield washer fluid hose, then remove cowl grille. 5. Remove clip securing right and left linkage and the retaining clip from wiper motor arm. 6. Remove 3 pivot body-to-cowl panel attaching screws, then the arm and pivot shaft assembly. 7. Reverse procedure to install. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram Information and Instructions Wiper Motor: Diagram Information and Instructions Symbol Identification Wire Color Code Identification Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7369 NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7370 Wiper Motor: Electrical Diagrams Fig. 52 Windshield Wiper/Washer Wiring Circuit (L/Interval Wipers) Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7371 Fig. 53 Windshield Wiper/Washer Wiring Circuit (W/Interval Wipers) Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Page 7372 Wiper Motor: Testing and Inspection Fig. 1 Testing wiper motor current draw. 1980---87 Bronco & F-100---350 Series Bronco & F100---350 1. Disconnect wiper motor linkage and electrical connector. 2. Connect multimeter to wiper motor, Fig. 1, connecting positive lead of tester first to low speed connection, then to high speed connections at connector plug. Current draw should not exceed 3 amps. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Page 7373 Wiper Motor: Service and Repair F-100---350 & BRONCO 1. Disconnect battery ground cable. 2. Remove both wiper arm and blade assemblies. 3. Remove cowl grille attaching screws and raise the grille slightly. 4. Disconnect washer nozzle hose, then remove cowl grille assembly. 5. Remove wiper linkage clip from motor output arm. 6. Disconnect wiper motor electrical connector. 7. Remove wiper motor attaching screws and the wiper motor. 8. Reverse procedure to install. Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Wiper and Washer Systems > Interval Governor <--> [Wiper Motor Timer] > Component Information > Diagrams > Diagram Information and Instructions Interval Governor: Diagram Information and Instructions Symbol Identification Wire Color Code Identification Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Wiper and Washer Systems > Interval Governor <--> [Wiper Motor Timer] > Component Information > Diagrams > Diagram Information and Instructions > Page 7378 NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Wiper and Washer Systems > Interval Governor <--> [Wiper Motor Timer] > Component Information > Diagrams > Diagram Information and Instructions > Page 7379 Interval Governor: Electrical Diagrams Fig. 52 Windshield Wiper/Washer Wiring Circuit (L/Interval Wipers) Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Wiper and Washer Systems > Interval Governor <--> [Wiper Motor Timer] > Component Information > Diagrams > Diagram Information and Instructions > Page 7380 Fig. 53 Windshield Wiper/Washer Wiring Circuit (W/Interval Wipers) Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams > Diagram Information and Instructions Wiper Relay: Diagram Information and Instructions Symbol Identification Wire Color Code Identification Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7385 NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7386 Wiper Relay: Electrical Diagrams Fig. 52 Windshield Wiper/Washer Wiring Circuit (L/Interval Wipers) Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7387 Fig. 53 Windshield Wiper/Washer Wiring Circuit (W/Interval Wipers) Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Locations Wiper Switch: Locations Back View Of I/P On LH Side Of I/P Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Diagram Information and Instructions Wiper Switch: Diagram Information and Instructions Symbol Identification Wire Color Code Identification Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7393 NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7394 Wiper Switch: Electrical Diagrams Fig. 52 Windshield Wiper/Washer Wiring Circuit (L/Interval Wipers) Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7395 Fig. 53 Windshield Wiper/Washer Wiring Circuit (W/Interval Wipers) Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Page 7396 Wiper Switch: Testing and Inspection Fig. 4 Wiper Switch Continuity Test Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Page 7397 Fig. 5 Testing wiper switch continuity. 1980 Bronco & F-100---350 Ford F 150 2wd Pickup Workshop Manual (V8-351 5.8L (1986)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Page 7398 Fig. 5 Wiper Switch Continuity Test 1. Check continuity between switch terminals, Figs. 4 through 6. 2. To detect marginal operation of switch, rotate or slide switch control knob while each reading is being taken. 3. If switch does not show continuity or if poor continuity exists at any switch position, replace switch.